test G FORD MUSTANG 2003 Workshop Manual

DIAGNOSIS AND TESTING
Seats
Refer to Wiring Diagrams Cell
120 , Power Seats for schematic and connector information.
Refer to Wiring Diagrams Cell 122 , Power Lumbar Seats for schematic and connector information.
Inspection and Verification 1. Verify the customer concern by operating the system.
2. Visually inspect for obvious signs of mechanical or electrical damage.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. If the concern is not visually evident, verify the symptom. GO to Symptom Chart .
Symptom Chart
Refer to the Wiring Diagram manual for the connector numbers cited in the pinpoint tests. SECTION 501-
10: Seating 2003 Mustang Workshop Manual Special Tool(s)
73 III Automotive Meter
105-
R0057
Visual Inspection Chart Mechanical Electrical
z
Front seat track.
z Seat at limit(s) of travel. z
Battery junction box (BJB) Fuse Power Seat (25A).
z Loose, corroded or damaged connectors.
z Seat regulator control switch.
z Lumbar seat control switch.
z Lumbar motor.
z Bolster and lumbar control switches (cobra)
SYMPTOM CHART Condition
Possible Sources Action
z The power seat is
inoperative z
BJB Fuse Power Seat
(25A).
z Seat regulator control
switch.
z Circuitry. z
Go To Pinpoint Test
A . Klj . 1 ba
152003 Mustang Workshop Manual
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Pinpoint Tests
PINPOINT TEST A: THE POWER SEAT IS INOPERATIVE z
Seat track.
z The power seat does not
move vertically — front z
Seat regulator control
switch.
z Seat track.
z Circuitry. z
Go To Pinpoint Test
B .
z The power seat does not
move vertically — rear z
Seat regulator control
switch.
z Seat track.
z Circuitry. z
Go To Pinpoint Test
C .
z The power seat does not
move horizontally z
Seat regulator control
switch.
z Seat track.
z Circuitry. z
Go To Pinpoint Test
D .
z The power lumbar is
inoperative z
Lumbar motor.
z Lumbar seat control
switch.
z Circuitry. z
Go To Pinpoint Test
E .
z The power bolster/lumbar is
inoperative (Cobra only) z
Bolster/lumbar pump
and solenoid module.
z Bolster/lumbar seat
control switches.
z Circuitry. z
Go To Pinpoint Test
F .
Test Step Result / Action to Take
A1 CHECK CIRCUIT 566 (DG)
z
Disconnect: Seat Regulator Control Switch C360.
z Measure the voltage between seat regulator control
switch C360- 2, Circuit 566 (DG), harness side and
ground.
z Is the voltage greater than 10 volts? Yes
GO to
A2 .
No
REPAIR the circuit. TEST the
system for normal operation. A2 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
z
Measure the resistance between seat regulator control
switch C360- 4, Circuit 1205 (BK), harness side and
ground. Yes
GO to
A3 .
No
REPAIR the circuit. TEST the
system for normal operation. Klj . 2 ba
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PINPOINT TEST B: THE POWER SEAT DOES NOT MOVE
VERTICALLY —
FRONT z
Is the resistance less than 5 ohms? A3 CHECK THE SEAT REGULATOR CONTROL SWITCH
z
Carry out the seat regulator control switch component
test. Refer to Wiring Diagrams.
z Did the seat regulator control switch pass? Yes
CHECK for obstructed or binding
seat track. If no obstructions are
found, INSTALL a new seat
track. REFER to
Seat Track .
TEST the system for normal
operation.
No
INSTALL a new seat regulator
control switch. REFER to
Switch — Seat Regulator Control .
TEST the system for normal
operation. Test Step Result / Action to
Take B1 CHECK THE MOTOR SUPPLY CIRCUITS
z
Disconnect: Front Height Motor C382.
z NOTE: Make sure all connectors are connected on the seat.
z Measure the resistance between front height motor C382, Circuit
979 (RD/LB), harness side and ground and between front height
motor C382, Circuit 990 (YE/LB), harness side and ground.
z Are the resistances less than 5 ohms? Yes
GO to
B3 .
No
GO to B2 .
B2 CHECK CIRCUIT 979 (RD/LB) AND 990 (YE/LB) FOR AN OPEN
z
Disconnect: Seat Regulator Control Switch C360.
z Measure the resistance between front height motor C382, Circuit
979 (RD/LB), harness side and seat regulator control switch C360- 7, Yes
INSTALL a new
seat regulator Klj . 3 ba
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Circuit 979 (RD/LB), harness side; then between front height motor
C382, Circuit 990 (YE/LB), harness side and seat regulator control
switch C360-
5, Circuit 990 (YE/LB), harness side.
z Is the resistance less than 5 ohms? control switch.
REFER to
Switch —
Seat Regulator
Control . TEST the
system for normal
operation.
No
REPAIR the circuit.
TEST the system
for normal
operation. B3 CHECK CIRCUIT 979 (RD/LB) AND 990 (YE/LB) FOR A SHORT TO
GROUND z
Measure the resistance between front height motor C382, Circuit
979 (RD/LB), harness side and ground and between front height
motor C382, Circuit 990 (YE/LB), harness side and ground.
z Are the resistances greater than 10,000 ohms? Yes
GO to
B4 .
No
REPAIR the circuit.
TEST the system
for normal
operation. B4 CHECK THE UP POSITION INPUT
z
Connect: Seat Regulator Control Switch C360.
z Measure the voltage between front height motor C382, Circuit 979
(RD/LB), harness side and ground.
z Actuate the seat regulator control switch to the front UP position.
z Is the voltage greater than 10 volts? Yes
GO to
B5 .
No
INSTALL a new
seat regulator
control switch.
REFER to Switch —
Seat Regulator
Control . TEST the
system for normal
operation. B5 CHECK THE DOWN POSITION INPUT
z
Measure the voltage between front height motor C382, Circuit 990
(YE/LB), harness side and ground. Yes
INSTALL a new
seat track. REFER
to
Seat Track .
TEST the system
for normal
operation. Klj . 4 ba
152003 Mustang Workshop Manual
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PINPOINT TEST C: THE POWER SEAT DOES NOT MOVE
VERTICALLY —
REAR z
Actuate the seat regulator control switch to the front DOWN position.
z Is the voltage greater than 10 volts? No
INSTALL a new
seat regulator
control switch.
REFER to
Switch —
Seat Regulator
Control . TEST the
system for normal
operation. Test Step Result / Action to
Take C1 CHECK THE MOTOR SUPPLY CIRCUITS
z
Disconnect: Rear Height Motor C363.
z NOTE: Make sure all connectors are connected on the seat.
z Measure the resistance between rear height motor C363, Circuit 983
(RD/LG), harness side and ground and between rear height motor
C363, Circuit 982 (YE/LG), harness side and ground.
z Are the resistances less than 5 ohms? Yes
GO to
C3 .
No
GO to C2 .
C2 CHECK CIRCUIT 983 (RD/LG) AND 982 (YE/LG) FOR AN OPEN
z
Disconnect: Seat Regulator Control Switch C360.
z Measure the resistance between rear height motor C363, Circuit 983
(RD/LG), harness side and seat regulator control switch C360- 1,
Circuit 983 (RD/LG), harness side; then between rear height motor
C363, Circuit 982 (YE/LG), harness side and seat regulator control
switch C360- 6, Circuit 982 (YE/LG), harness side. Yes
INSTALL a new
seat regulator
control switch.
REFER to
Switch —
Seat Regulator
Control . TEST the
system for normal
operation.
No
REPAIR the circuit.
TEST the system
for normal
operation. Klj . 5 ba
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PINPOINT TEST D: THE POWER SEAT DOES NOT MOVE
HORIZONTALLY z
Is the resistance less than 5 ohms? C3 CHECK CIRCUIT 983 (RD/LG) AND 982 (YE/LG) FOR A SHORT TO
GROUND z
Measure the resistance between rear height motor C363, Circuit 983
(RD/LG), harness side and ground; and between rear height motor
C363, Circuit 982 (YE/LG), harness side and ground.
z Are the resistances greater than 10,000 ohms? Yes
GO to
C4 .
No
REPAIR the circuit.
TEST the system
for normal
operation. C4 CHECK THE UP POSITION INPUT
z
Connect: Seat Regulator Control Switch C360.
z Measure the voltage between rear height motor C363, Circuit 983
(RD/LG), harness side and ground.
z Actuate the seat regulator control switch to the rear UP position.
z Is the voltage greater than 10 volts? Yes
GO to
C5 .
No
INSTALL a new
seat regulator
control switch.
REFER to Switch —
Seat Regulator
Control . TEST the
system for normal
operation. C5 CHECK THE DOWN POSITION INPUT
z
Measure the voltage between rear height motor C363, Circuit 982
(YE/LG), harness side and ground.
z Actuate the seat regulator control switch to the rear DOWN position.
z Is the voltage greater than 10 volts? Yes
INSTALL a new
seat track. REFER
to
Seat Track .
TEST the system
for normal
operation.
No
INSTALL a new
seat regulator
control switch.
REFER to Switch —
Seat Regulator
Control . TEST the
system for normal
operation. Klj . 6 ba
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Test Step Result / Action to
Take D1 CHECK THE MOTOR SUPPLY CIRCUITS
z
Disconnect: Horizontal Motor C362.
z NOTE: Make sure all connectors are connected on the seat.
z Measure the resistance between horizontal motor C362, Circuit 981
(RD/WH), harness side and ground; and between horizontal motor
C362, Circuit 980 (YE/WH), harness side and ground.
z Are the resistances less than 5 ohms? Yes
GO to
D3 .
No
GO to D2 .
D2 CHECK CIRCUIT 981 (RD/WH) AND 980 (YE/WH) FOR AN OPEN
z
Disconnect: Seat Regulator Control Switch C360.
z Measure the resistance between horizontal motor C362, Circuit 981
(RD/WH), harness side and seat regulator control switch C360- 3,
Circuit 981 (RD/WH), harness side; then between horizontal motor
C362, Circuit 980 (YE/WH), harness side and seat regulator control
switch C360- 8, Circuit 980 (YE/WH), harness side.
z Is the resistance less than 5 ohms? Yes
INSTALL a new
seat regulator
control switch.
REFER to
Switch —
Seat Regulator
Control . TEST the
system for normal
operation.
No
REPAIR the circuit.
TEST the system
for normal
operation. D3 CHECK CIRCUIT 981 (RD/WH) AND 980 (YE/WH) FOR A SHORT
TO GROUND z
Measure the resistance between horizontal motor C362, Circuit 981
(RD/WH), harness side and ground; and between horizontal motor
C362, Circuit 980 (YE/WH), harness side and ground.
z Are the resistances greater than 10,000 ohms? Yes
GO to
D4 .
No
REPAIR the circuit.
TEST the system
for normal
operation. Klj . 7 ba
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PINPOINT TEST E: THE POWER LUMBAR IS INOPERATIVE D4 CHECK THE REARWARD POSITION INPUT
z
Connect: Seat Regulator Control Switch C360.
z Measure the voltage between horizontal motor C362, Circuit 981
(RD/WH), harness side and ground.
z Actuate the seat regulator control switch to the REARWARD
position.
z Is the voltage greater than 10 volts? Yes
GO to
D5 .
No
INSTALL a new
seat regulator
control switch.
REFER to Switch —
Seat Regulator
Control . TEST the
system for normal
operation. D5 CHECK THE FORWARD POSITION INPUT
z
Measure the voltage between horizontal motor C362, Circuit 980
(YE/WH), harness side and ground.
z Actuate the seat regulator control switch to the FORWARD position.
z Is the voltage greater than 10 volts? Yes
INSTALL a new
seat track. REFER
to Seat Track
.
TEST the system
for normal
operation.
No
INSTALL a new
seat regulator
control switch.
REFER to Switch —
Seat Regulator
Control . TEST the
system for normal
operation. Test Step Result / Action to Take
E1 CHECK THE LUMBAR COMPRESSOR OPERATION
z
Actuate the lumbar seat control switch to the inflate position.
z Did the lumbar compressor motor run? Yes
GO to
E6 .
No
GO to E2 .
E2 CHECK CIRCUIT 566 (DG)
z
Disconnect: Lumbar Seat Control Switch C361.
z Measure the voltage between lumbar seat control switch
C361, Circuit 566 (DG), harness side and ground. Yes
GO to
E3 .
No
REPAIR the circuit. TEST
the system for normal
operation. Klj . 8 ba
152003 Mustang Workshop Manual
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z
Is the voltage greater than 10 volts? E3 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
z
Disconnect: Lumbar Motor C366.
z Measure the resistance between lumbar motor C366, Circuit
1205 (BK), harness side and ground.
z Is the resistance less than 5 ohms? Yes
GO to
E4 .
No
REPAIR the circuit. TEST
the system for normal
operation. E4 CHECK THE POWER SUPPLY TO THE LUMBAR MOTOR
z
Connect: Lumbar Seat Control Switch C361.
z Measure the voltage between lumbar motor C366, Circuit 51
(BK/WH), harness side and ground.
z Actuate the lumbar seat control switch the inflate position.
z Is the voltage greater than 10 volts? Yes
INSTALL a new lumbar
motor. REFER to
Lumbar Motor . TEST the system
for normal operation.
No
GO to E5 .
E5 CHECK CIRCUIT 51 (BK/WH) FOR AN OPEN
z
Disconnect: Lumbar Seat Control Switch C361.
z Measure the resistance between lumbar seat control switch
C361, Circuit 51 (BK/WH), harness side and lumbar motor
C366, Circuit 51 (BK/WH), harness side. Yes
INSTALL a new lumbar
seat control switch.
REFER to
Lumbar Control Switch . TEST the system
for normal operation.
No
REPAIR the circuit. TEST
the system for normal
operation. Klj . 9 ba
152003 Mustang Workshop Manual
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z
Is the resistance less than 5 ohms? E6 CHECK THE LUMBAR ADJUSTING SYSTEM
z
Actuate the lumbar seat control switch to the inflate position
while observing the seat backrest lumbar adjusting pad.
z Did the seat backrest lumbar adjusting pad inflate? Yes
GO to
E10 .
No
GO to E7 .
E7 CHECK THE SEAT BACKREST LUMBAR ADJUSTING PAD
z
Visually inspect the seat backrest lumbar adjusting pad.
z Is the seat backrest lumbar adjusting pad damaged? Yes
INSTALL a new seat
backrest lumbar adjusting
pad. REFER to
Lumbar Assembly . TEST the
system for normal
operation.
No
GO to E8 .
E8 CHECK AIR FLOW FROM LUMBAR COMPRESSOR
z
Disconnect the seat backrest lumbar adjusting hose from the
lumbar motor.
z Actuate the lumbar seat control switch to the inflate position
while feeling for air at the motor connection.
z Is air felt at the lumbar motor hose connection? Yes
GO to
E9 .
No
INSTALL a new lumbar
motor. REFER to Lumbar Motor . TEST the system
for normal operation. E9 CHECK THE AIR FLOW FROM THE LUMBAR SEAT
CONTROL SWITCH z
Reconnect the hose to the lumbar motor.
z Disconnect the seat backrest lumbar adjusting hose at the
lumbar seat control switch.
z Actuate the lumbar seat control switch to the inflate position.
z Is air felt at the seat backrest lumbar adjusting hose? Yes
GO to
E10 .
No
INSTALL a new seat
backrest lumbar adjusting
hose. TEST the system
for normal operation. E10 CHECK THE SYSTEM FOR LEAKS
z
Reconnect the hose at the lumbar seat control switch.
z Disconnect the seat backrest lumbar adjusting hose at the
seat backrest lumbar adjusting pad.
z Install an in- line pressure gauge on the hose.
z Actuate the lumbar seat control switch to the inflate position
until the gauge reads 34.47 kPa (5 psi). The system should
hold pressure for three hours.
z After three hours, is the pressure reading 32.41 kPa (4.7 Yes
The system is operating
correctly. TEST the
system for normal
operation.
No
GO to
E11 . Klj . 10 ba
152003 Mustang Workshop Manual
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