KAMPANJE AZG : Skifte setevarmeelement

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1 KAMPANJE AZG : Skifte setevarmeelement Berørte modeller: Swift AZG produsert i Ungarn fra til Totalt 43 biler Eierne kontaktes pr. brev fra Teknisk avdeling. NB! Ikke alle bilene har eiere, sjekk derfor alltid om bilen er omfattet av kampanjen vha. "Kampanjesøk" på Forhandlerweb. Ved tvil tar dere kontakt med teknisk avdeling. Problem/symptomer: Varmeelement kan løsne i liming, og legge seg i folder. Dette kan føre til overoppheting, og videre brent setetrekk. Tiltak: Skifte setevarmeelement. OBS: Setevarmeelement skal skiftes på alle berørte biler! Les nøye gjennom arbeidsbeskrivelsen før jobben gjøres. Delebehov: Sett med begge varmeelement: RX0 I tilfeller der det er brent hull i setetrekk, bestilles dette i hht vedlagte beskrivelse. Det er estimert maksimalt 0,5% av bilene med brente setetrekk, så ingen skal bestilles opp før det er konstatert at det er brent, og teknisk avdeling er kontaktet. Tilleggsinformasjon: Velg "Kampanjesøk" på "Dashbord" (den siden du kommer til ved innlogging) og legg inn registreringsnummer eller VIN. Om bilen er omfattet av kampanjen vises dette på skjermen. Kampanjesøk kan også gjøres før innlogging på Forhandlerweb. Liste med chassisnummer over berørte biler legges IKKE ved dette skriv. Bruk Forhandlerweb! Ved reklamasjon: Legg inn chassisnummer/registreringsnummer under "Teknisk" / "Opprett Reklamasjon" på Forhandlerweb og trykk på "Søk". Trykk på "Velg" når bil kommer opp under "Søkeresultat" Du får nå valget mellom å opprette en blank reklamasjon eller en forhåndssøknad eller en kampanje. Merk av for kampanje AZG-6 "Skifte setevarmeelement", fyll ut datoer, arbeidsordrenummer og kilometerstand og lagre. Rapporten fylles automatisk ut med arbeid og deler. Legg inn beskrivelser. IKKE endre andre felt!! Trykk så på "Send reklamasjon" nederst på siden. Rapport ferdig. Se også eget skriv angående kampanjesøk og innlegging av kampanjer som finnes på samme sted som dette skriv på RSA Ekstranett. Kampanje AZG Dato: Revisjon A

2 SWIFT (AZG4 / AZG43D) and SWIFT SPORT (AZG46) Replacement Procedure for Front Seat Cushion Heater This procedure describes SWIFT (5-door model) as an example. The figures and pictures may vary depending on model and specification. Therefore, perform the operation while comparing this procedure with the entry vehicle.

3 Workflow. Confirmation of Affected Vehicle Page -. Confirmation of VIN Page -. Confirmation of vehicle with seat cushion heater Page. Preparation Page 3 -. Necessary tools Page 3 -. Replacement parts Page 4-3. Front Seat Components Page 6 3. Replacement Procedure for Front Seat Cushion Heater Page Removal of front seat assembly Page Removal of front seat cushion heater Page Check of the removed seat cushion heater, cushion trim, cushion pad and/or seat belt reminder sensor (passenger seat) Page 5 Cushion trim, cushion pad and/or seat belt reminder sensor is damaged. Cushion trim, cushion pad and seat belt reminder sensor are not damaged Replacement of seat cushion trim cushion pad and/or seat belt reminder sensor (passenger seat) Page Installation of front seat cushion heater Page Installation of front seat assembly Page Setting after replacement Page Final check Page 30

4 . Confirmation of Affected Vehicle -. Confirmation of VIN Check the Vehicle Identification Number (VIN) to see if the vehicle is affected on or not. VIN Location The cowl side outer member VIN Affected Vehicle MODEL MODEL TYPE VIN SWIFT SWIFT SPORT AZG4 AZG43D AZG46 TSMNZA7S to TSMNZA7S TSMNZAAS to TSMNZAAS00547 TSMNZC7S to TSMNZC7S TSMNZCAS to TSMNZCAS00534 TSMNZD7S to TSMNZD7S TSMNZDAS to TSMNZDAS TSMNZC0S00004 to TSMNZC0S00549 TSMNZC9S to TSMNZC9S00633 TSMNZA3S to TSMNZA3S TSMNZC3S to TSMNZC3S Confirmation of vehicle with seat cushion heater As for the vehicle with seat cushion heater, seat heater switches () are installed on the center console box as shown in figure. Check that the seat heater switch is equipped.

5 . Preparation -. Necessary tools No. Tool name No. Tool name Box-end wrench (0 mm) 8 Nipper Ratchet handle (9.5 sq) 9 Long nose pliers ( pcs) 3 Extension bar (9.5 sq) 0 Hog ring pliers 4 Torx Socket (E0, 9.5 sq) Permanent marker 5 Socket (4 mm, 9.5 sq) Craft knife 6 Phillips screwdriver (medium) 3 Torque wrench (9.5 sq, 0 45 N m) 7 Flat-bladed screwdriver (small) 4 Heating gun 3

6 -. Replacement parts a) Necessary replacement parts Part Number Part Name Q ty Remarks RX0 HEATER SET,FR CUSH SEAT CUSHION HEATER ( pcs) Back side Thermostat CLAMP A ( pcs) CLAMP B (5 pcs) Trim ring ( pcs) The number of trim ring depends on the vehicle specifications and replacement parts. b) Additional replacement parts (if necessary) If replacement of seat cushion trim, cushion pad and/or seat belt reminder sensor (passenger seat) is required, choose correct replacement parts referring to the table below. Seat belt reminder sensor of passenger seat is fixed with the double-faced tape to cushion pad. Therefore, seat belt reminder sensor that is removed once cannot reuse. If replacement of seat belt reminder sensor or cushion pad is required, replace new seat belt remainder sensor together with new cushion pad. <SWIFT> Driver side: Cushion pad Cushion trim Remarks L L0-HVG Type L0-AUS L0-A5K L0-AUS L0-BR L0-AUS L0-BR L0-CQ Type 3 (GL, GLX) (BLACK/GRAY) Type 3 (GL SPECIAL) (BLACK/WHITE/GRAY) Type 4 (GA, GL, GLX) (BLACK/GRAY) Type 4 (GL, GLX) (BLACK/PURPLE/GRAY) Type 5 (GL, GLX) (BLACK/GRAY) Type 5 (GL, GLX) (BLACK/PURPLE/GRAY) Type 5 (GL LIMITED) 4

7 Passenger side: Cushion assembly Cushion pad Cushion trim Seat belt reminder sensor Remarks LD3-HVG L00-HVG Type, 3door LD3-HVG L00-HVG Type, 5door LD3-AUS L00-AUS Type 3, 3door LD3-A5K L L00-A5K L00 Type 3, 3door GL special LD3-AUS L00-AUS Type 3, 5door LD3-A5K LD3-AUS LD3-AUS LD3-AUS LD3-BR LD3-CQ L00-A5K L00-AUS L00-AUS L00-AUS L00-BR L00-CQ Type 3, 5door GL special Type 4 and 5, 3door GL,GLX Type 4, 5door GA Type 4 and 5, 5door GL,GLX Type 4 and 5, 5door GL,GLX Type 5, 5door GL limited <SWIFT SPORT> Driver side: Cushion pad Cushion trim Remarks L00 Passenger side: Cushion assembly L0-JRR Type, 3door L0-AUM Type 3 to 5 Cushion pad Cushion trim Seat belt reminder sensor Remarks LD-JRR L00-JRR Type, 3door LD-AUM L L00-AUM L00 Type 3 to 5, 3door LB-AUM L00-AUM Type 3 to 5, 5door 5

8 -3. Front Seat Components The figure shows driver seat of 5-door model as an example.. Seat cushion heater 5. Cushion pad. Clamp A 6. Cushion trim 3. Clamp B 39 N m (4.0 kgf-m, 9.0 lbf-ft) 4. Trim ring 3 N m (.3 kgf-m, 7.0 lbf-ft) 6

9 3. Replacement Procedure for Front Seat Cushion Heater WARNING: Air bag is still capable of deploy due to back-up power circuit (capacitor) for a certain period of time even after turning ignition OFF. Before disconnecting the side air bag harness, wait for 90 seconds or more after turning ignition switch OFF and disconnecting negative cable at the battery. The side air bag harness is part of floor harness and seat harness. For easy identification, the connector-side of each air bag harness wire is covered with a yellow protection tube and each connector is yellow in color. Handle the air bag harness wires and connectors very carefully. The following procedure shows the driver seat of 5-door model as an example. For the passenger side of 5-door model and other models, this procedure is also applicable. 3-. Removal of front seat assembly ) Record the audio setting. ) Set ignition OFF, and then disconnect negative cable at the battery and wait for 90 seconds or more. 3) Slide the seat to the rear end position. Record the original seat position before work so that the seat can be re-installed to its original position. 4) Release connector lock () and disconnect side air bag connector () from floor harness. 5) Disconnect seat cushion heater and seat belt buckle switch connector (3). 3 6) Remove front seat mounting bolts. Front side 7) Dismount front seat assembly from the vehicle. NOTICE: Seat frame may hit and damage the B-pillar trim or front door trim while dismounting the seat assembly. Protect the B-pillar trim and front door trim with vinyl tape or the like before dismounting the seat assembly. Rear side 7

10 3-. Removal of front seat cushion heater When removing seat cushion trim from seat assembly, take care not to damage and/or soil it. Because it may be reused. ) Remove the headrest. ) If the seat is equipped with seat lifter mechanism, perform the following steps. a) Set the seat at the highest position operating the lifter lever. b) Remove the lifter lever cover (). c) Remove screws, and then remove the lifter lever (). 3) Remove the reclining knob () in numerical order ( ). 4) Remove the reclining outside cover screws. Outside Backside 5) Remove the reclining outside cover () in numerical order ( ). Outside Backside 8

11 6) Remove the reclining inside cover screws. Backside Inside 7) Remove the reclining inside cover () in numerical order ( ). Backside Inside 8) Turn over the seat assembly. 9) Disconnect clamp A () from bracket. 0) Disconnect the side airbag connector (), seat heater connector (3) and seat belt buckle connector (4) from seat adjuster. 3 4 ) Remove seat cushion trim from hook (). 9

12 ) Remove the harness from seat trim hole. 3) Remove the cushion trim from cushion panel by the following steps. NOTICE: If the seat trim is pulled forcibly, bracket of cushion panel may be damaged. Therefore, observe the following steps. a) Sliding the cushion trim to the right, unhook the plastic part () of the trim from left side bracket () as shown in figure [A]. b) Sliding the cushion trim to the left, unhook the plastic part (3) of the trim from right side bracket (4) as shown in figure [B]. [A] C [B] 4 C C C 3 4) Disconnect heater harness connector () using flat-bladed screwdriver. 0

13 5) Remove harness and clamp B () from cushion panel. 6) Remove harness and clamp B () from cushion frame. 7) Disconnect seat belt buckle switch connector (). 8) Disconnect clamp B () from cushion frame. 9) Pass the seat belt buckle switch connector () through spiral spring hole ().

14 0) For 3-door passenger seat, mark the walk-in cable holding position (). Then, disconnect walk-in cable () from seat back frame. ) Remove seat buckle bolts and nuts. Inside Outside ) Remove seat back assembly from seat cushion. Pass the side airbag harness () and seat back heater harness () through the slit (3) of seat cushion trim as shown in figure. 3 3) Unhook the plastic part () of the cushion trim outer side from the seat frame hook ().

15 4) Unhook the plastic part () of the cushion trim front side from the seat frame hook (). CAUTION: When removing the cushion trim, you may be injured by the edge of seat cushion panel. Wear clean gloves when removing the cushion trim. 5) Peel off the cushion trim a little as shown in figure. 6) Remove the trim rings as shown in figure from cushion pad according to the following steps. SWIFT NOTICE: For passenger seat cushion trim (), as the passenger seat belt reminder sensor () is fitted under the seat cushion heater (3), the trim rings and long nose pliers may damage the seat belt reminder sensor. When removing the trim rings, take care not to damage the passenger seat belt reminder sensor. SWIFT SPORT 3 3

16 a) Set the trim ring so that the joint part of ring turns to the top as shown in figure. b) Unfasten the trim ring using long nose pliers. 7) Peel the cushion trim () as shown in figure. 8) Remove seat cushion heater slowly from cushion pad using the heating gun (). NOTICE: If the seat cushion heater fixed with the double-faced tape () is pulled forcibly, cushion pad may be damaged. When removing the seat cushion heater from cushion pad, remove it while warming the parts of double-faced tape using the heating gun. 4

17 3-3. Check of the removed seat cushion heater, cushion trim, cushion pad and/or seat belt reminder sensor (passenger seat) Check the removed seat cushion heater, cushion trim, cushion pad and/or seat belt remainder sensor (passenger seat) along the following workflow. If necessary, replace cushion trim, cushion pad and/or seat belt reminder sensor (passenger seat) with new one. Seat belt reminder sensor of passenger seat is fixed with the double-faced tape to cushion pad. Therefore, seat belt reminder sensor that is removed once cannot reuse. If replacement of seat belt reminder sensor or cushion pad is required, replace new seat belt remainder sensor together with new cushion pad. Is there any burn in the removed seat cushion heater? YES NO Is there any damage* for the cushion pad, the cushion trim and/or the seat belt reminder sensor (passenger seat) due to overheat of seat cushion heater? *: Hole, deformation and/or burn YES NO Replace the damaged parts with new one. Perform 3-4. Replacement of seat cushion trim, cushion pad and/or seat belt reminder sensor. Install the new seat cushion heater. Perform 3-5. Installation of front seat cushion heater. 5

18 3-4. Replacement of seat cushion trim, cushion pad and/or seat belt reminder sensor (passenger seat) ) Remove cushion trim from cushion pad as following steps. a) Remove the remaining trim rings () of seat cushion referring to step 6) of page 3. b) Unhook seat cushion trim from seat cushion frame inner hook. SWIFT Rear side SWIFT Sport Front side c) Remove seat cushion trim hook () in numerical order ( ). ) If necessary, replace cushion trim, cushion pad and/or seat belt reminder sensor (passenger seat) with new one. Seat belt reminder sensor of passenger seat is fixed with the double-faced tape to cushion pad. Therefore, seat belt reminder sensor that is removed once cannot reuse. If replacement of seat belt reminder sensor or cushion pad is required, replace new seat belt remainder sensor together with new cushion pad. 3) Set the cushion pad on the seat cushion frame. 4) If necessary for passenger seat, check the seat belt reminder sensor () with the matching points () of cushion pad as shown in figure. Peel off the double-faced tape protection sheet of seat belt reminder sensor, and then paste seat belt reminder sensor to cushion pad. 6

19 5) Install hook of seat cushion trim () to seat cushion frame () as shown in figure. 6) Install the plastic part of cushion trim to cushion frame inner hook. Rear side Front side 7) Install cushion trim to cushion pad by trim rings () according to the following steps. SWIFT SWIFT SPORT a) Fit the cushion trim () on groove () of cushion pad as shown in figure. b) Set new trim ring () to hog ring pliers as shown in figure. 7

20 c) Caulk the trim ring to the specified point. d) Set the joint part of trim ring to inside of cushion pad. OK Not OK - In case hog ring pliers are not available, use general pliers to fit the trim ring. Deforming the trim ring beforehand facilitates the caulking. - Caulk trim ring as shown in figure. OK Not OK (Not enough) Not OK (Too much) 8

21 3-5. Installation of front seat cushion heater NOTICE: When re-attaching the seat cushion heater, the adhered part of the seat cushion heater peel off and the seat heater circuit may be damaged. Do not re-attach the seat cushion heater. ) Prepare a paper pattern and cut it out as shown in figure. The cut out part () shows the vehicle front. For details of paper pattern to process the seat cushion, refer to the PDF data separately announced. ) Check the hole positions of paper pattern according to the following steps. a) Place the new seat cushion heater () with thermostat side facing upward. b) Put the paper pattern () on the new seat cushion heater as shown in figure. Align the lowest end (3) of the seat heater with that of the paper pattern under this condition. c) Check that the holes of the paper pattern are aligned with thermostat positions. If not aligned, consider the gap and modify the holes of the paper pattern. 3 3) If cushion pad is reused, make craters of cushion pad for thermostat of new seat cushion heater according to the following steps. If the cushion pad is replaced with new one, there are already craters in new cushion pad. Therefore, it is not necessary to perform this step. a) Aligning the rear end matching positions () of the cushion pad with the corners of the paper pattern, put the paper pattern on cushion pad. b) Draw markings of the hole positions on the cushion pad. 9

22 c) Cut the cushion pad to a depth of approximately 0mm along the marking using the craft knife. NOTICE: When cutting passenger seat cushion pad, take care not to damage the passenger seat belt reminder sensor. 0mm d) Cut the cushion pad as shown in figure. 4) Install the rear side of seat cushion heater to the cushion pad according to the following steps. a) Put the new seat cushion heater on cushion pad so that the thermostat () of new seat cushion heater fits the craters. b) Set the rear corners of seat cushion heater to the matching positions () of the cushion pad. c) Make the holes (3) of seat cushion heater fit the groove of cushion pad. d) Peel off the double-faced tape protection sheet (4) of seat cushion heater, and then paste the seat cushion heater to cushion pad

23 5) Push the seat cushion heater into groove of cushion pad as shown in figure [A]. Confirm that the wire of cushion pad is seen from the hole of seat cushion heater as shown in figure [B]. [B] [A] 6) Install the front side of seat cushion heater to the cushion pad according to the following steps. a) Before pasting the seat cushion heater to cushion pad, confirm the center position () and the front corner () of seat cushion heater as shown in figure. Allowance length a : 5 to 5 mm a a b) Lift the seat cushion heater once, and then peel off the double-faced tape protection sheet from seat cushion heater. c) Paste the seat cushion heater to the cushion pad slowly from center part to front part at the position confirmed in a) of this step.

24 7) Install the center of cushion trim () to cushion pad by trim rings according to the following steps. NOTICE: For passenger seat cushion trim (), as the passenger seat belt reminder sensor (3) is fitted under the seat cushion heater (4), the trim rings and hog ring pliers may damage the seat belt reminder sensor. When installing the trim rings, take care not to damage the passenger seat belt reminder sensor. SWIFT SWIFT SPORT 4 3 a) Fit the cushion trim on groove () of cushion pad. b) Set new trim ring () to hog ring pliers as shown in figure. c) Caulk the trim ring to the specified point.

25 d) Set the joint part of trim ring to inside of cushion pad. OK Not OK - In case hog ring pliers are not available, use general pliers to fit the trim ring. Deforming the trim ring beforehand facilitates the caulking. - Caulk trim ring as shown in figure. OK Not OK (Not enough) Not OK (Too much) 8) Install the side of cushion trim to cushion pad by trim rings () referring to the step 9) of page. SWIFT SWIFT SPORT 9) Turn over the seat cushion. 3

26 0) Hook the front plastic part () of the seat cushion trim on the seat cushion frame (). ) Turn over the seat cushion, and then hook the outside part of seat cushion trim to the seat cushion frame as shown in figure. ) Set seat back assembly to seat cushion temporarily, and then pass the side airbag harness () and seat back heater harness () through the slit (3) of seat cushion trim. 3 3) Install the seat back assembly to seat cushion, and then tighten the seat back bolts and nuts to the specified torque. Tightening torque Seat back bolt (a): 39 N m (4.0 kgf-m, 9.0 lbf-ft) Seat back nut (a): 39 N m (4.0 kgf-m, 9.0 lbf-ft) (a) (b) 4

27 4) For 3-door passenger seat, connect walk-in cable () to inside of seat back frame. Reconnect the walk-in cable () referring to marked position (). 5) With spiral ring () pulled outward, pass the seat belt buckle switch connector () through the hole of the spiral ring from outside. 6) Install the new clamp B () to the seat back frame and clamp the seat belt buckle switch harness (). Cut unnecessary part of the clamp. 7) Connect the seat belt buckle switch connector (). 8) Connect the seat cushion heater connector (). 5

28 9) Clamp side air bag, seat cushion heater and seat belt buckle harness to seat cushion frame pipe with new clamp B () as shown in figure. Cut unnecessary part of the clamp. 0) Clamp the side air bag, seat cushion heater and seat belt buckle harness with new clamp B (), and then install it to seat cushion frame as shown in figure. ) Hook the plastic part () of cushion trim on the seat cushion frame (3). 3 ) Pass the harness through the hold of seat back trim as shown in figure. 6

29 3) Install the seat cushion trim () to hook (). 4) Connect the side airbag connector (3), seat heater connector (4) and seat belt buckle connector (5) to bracket. 5) Clamp the side airbag, seat cushion heater and seat belt buckle harness with new clamp A (6) and install it to the seat rail bracket. Cut unnecessary part of the clamp ) Install the reclining inside cover () and tighten its screws. Inside Backside 7) Install the reclining outside cover () and tighten its screws. Outside Backside 7

30 8) Install the reclining knob (). 9) If removed, install the lifter lever () and then tighten its screws. 30) If removed, install the lifter lever cap (). 3) Install the headrest. 8

31 3-6. Installation of front seat assembly ) Mount front seat to the vehicle. NOTICE: Seat frame may hit and damage the B-pillar trim or front door trim while installation of the seat assembly. Protect the B-pillar trim and front door trim with vinyl tape or the like before installation of the seat assembly. ) Tighten the seat mounting bolts to specified torque. Front side Tightening torque Seat mounting bolt (a):3 N m (.3 kgf-m, 7.0 lbf-ft) (a) Rear side (a) 3) Connect seat cushion heater, seat belt buckle switch connector () and side air bag connector (). 4) Connect negative cable at the battery. 9

32 3-7. Setting after replacement ) Perform throttle control system calibration as follows. a) After connecting negative cable at the battery, set ignition ON for 60 sec. b) Set ignition OFF. ) Perform power window system initialization as follows. a) Disconnect P/W T and P/W fuses. b) Set ignition ON. c) Pull up driver side power window main switch and hold it for about 5 seconds. d) Reconnect P/W T and P/W fuses. e) Lower driver side front door glass fully. f) Pull up and hold driver switch in AUTO position until door glass is fully raised and continue holding it up for about seconds. : Auto UP : Manual UP 3: OFF 3) Recover the original audio setting recorded Final check Check the following items. - Seat slide, reclining, lifter and walk-in (3-door model) operations - Seat belt buckle switch operation - Seat heater operation. - "Air bag warning light operation Set ignition ON, and check that "Air bag warning light in the combination meter is turned off after turning on for 6sec. - Seat belt reminder operation Check the state of Passenger Seat Belt Reminder Light according to the following table. Ignition Switch Passenger Seat Passenger Seat belt Passenger Seat Belt Reminder Light ON Not occupied Unfastened OFF ON Occupied Unfastened Light up ON Occupied Fastened OFF If all checks are completed, recover the original seat position setting recorded. 30

33 User: 3444 Date: 3-Jul-6 Time: 6:4 Part: U03444-P6-HTR-RECAL-GAGE-6050