501-20A Safety Belt System	2013 - 2014 Fusion
Diagnosis and Testing	Procedure revision date: 11/1/2012

Safety Belt System

Symptom Chart(s)

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).

Preliminary Inspection

Before diagnosing or repairing the safety belt system, inspect the following items:

Safety belt webbing integrity (torn, frayed, cut or stretched)
Safety belt buckle and tongue assembly

Symptom Chart: Safety Belt System

Symptom Chart

Condition	Possible Sources	Actions
The safety belt warning indicator does not operate	Burned-out indicator Wiring, terminals or connectors IPC RCM	If the airbag warning indicator is illuminated, REFER to: Airbag Supplemental Restraint System (SRS) (501-20B Supplemental Restraint System, Diagnosis and Testing). If the airbag warning indicator is not illuminated, REFER to: Instrumentation, Message Center and Warning Chimes (413-01 Instrumentation, Message Center and Warning Chimes, Diagnosis and Testing).
The safety belt warning chime does not operate	Wiring, terminals or connectors Safety belt switch IPC RCM	If the airbag warning indicator is illuminated, REFER to: Airbag Supplemental Restraint System (SRS) (501-20B Supplemental Restraint System, Diagnosis and Testing). If the airbag warning indicator is not illuminated, REFER to: Instrumentation, Message Center and Warning Chimes (413-01 Instrumentation, Message Center and Warning Chimes, Diagnosis and Testing).
The safety belt retractor webbing does not extract or exhibits excessive pressure on the occupant during use	Safety belt retractor is in Automatic Locking Retractor (ALR) mode Safety belt retractor binding internally	CARRY OUT the appropriate functional test. REFER to Functional Test - Safety Belt Retractor, Functional Test - Safety Belt Retractor, Automatic Locking Retractor (ALR) Mode or Functional Test - Safety Belt Retractor, Road Test Inspection, as appropriate. INSTALL new components as directed.
The safety belt retractor webbing does not retract or has excessive slack during use	Twisted or incorrectly routed safety belt webbing Safety belt retractor binding internally	CORRECT the twisted safety belt webbing. REFER to: Safety Belt Twisted at the Safety Belt Guide (501-20A Safety Belt System, General Procedures). REFER to: Safety Belt Tongue Rotated On Belt (501-20A Safety Belt System, General Procedures). CARRY OUT the appropriate functional test. REFER to Functional Test - Safety Belt Retractor, Functional Test - Safety Belt Retractor, Automatic Locking Retractor (ALR) Mode or Functional Test - Safety Belt Retractor, Road Test Inspection, as appropriate.
	Safety belt retractor	INSTALL a new safety belt retractor. REFER to the appropriate procedure in this section.
The Belt-Minder® feature is inoperative	Belt-Minder® feature is deactivated Wiring, terminals or connectors	To activate the Belt-Minder® feature, REFER to the Seating and Safety Restraints section of the Owner's Literature or REFER to: Safety Belt Minder Deactivating/Activating (413-01 Instrumentation, Message Center and Warning Chimes, General Procedures). If the Belt-Minder® is activated, DIAGNOSE the inoperative Belt-Minder® feature. REFER to: Instrumentation, Message Center and Warning Chimes (413-01 Instrumentation, Message Center and Warning Chimes, Diagnosis and Testing).
The safety belt tongue is rotated on the safety belt webbing	Twisted or incorrectly routed safety belt webbing	REFER to: Safety Belt Tongue Rotated On Belt (501-20A Safety Belt System, General Procedures).
The safety belt webbing is twisted at the safety belt guide	Twisted or incorrectly routed safety belt webbing	REFER to: Safety Belt Twisted at the Safety Belt Guide (501-20A Safety Belt System, General Procedures).
The safety belt webbing is dirty or soiled	Dirty or soiled safety belt webbing	REFER to: Safety Belt Cleaning (501-20A Safety Belt System, General Procedures).

Functional Test - Safety Belt Buckle and Tongue

WARNING: All safety belt components must be inspected and corrected as part of any collision repair. Inspect all safety belt components as prescribed by Safety Belt Inspection and Repair After a Collision found in Section 501-20A General Procedures of this manual. Failure to follow this instruction may result in incorrect operation of the safety belt system and increase the risk of serious personal injury or death in a crash.

NOTE: Make sure the safety belt buckle and tongue assembly operate freely during the latching and unlatching function. Fasten the safety belt by inserting the tongue (male portion) into the buckle (female portion).

Verify the following during the latching sequence:

Tongue insertion does not require excessive effort.
A click is heard when the safety belt buckle latches the tongue.

Verify the system integrity by forcefully pulling on the safety belt webbing.

Unlatch the safety belt by fully pressing the safety belt buckle release button and allowing the safety belt to release and retract.

Verify the following during the unlatching process:

Pressing the push button does not require excessive effort.
The tongue can be removed easily from the buckle.

Repeat the above steps 3 times.

If the functional test reveals a concern(s), install a new safety belt buckle or safety belt retractor as required.

Functional Test - Safety Belt Retractor

NOTE: Make sure the safety belt retractor is freely operational for extraction and retraction of the safety belt webbing between full extension and in-vehicle stowed positions.

Extract and retract the safety belt between the full extension and stowed positions.

Verify the safety belt retractor operates without excessive effort or binding.

Install a new safety belt retractor if any concern is found or the complaint has been verified.

Functional Test - Safety Belt Retractor, Automatic Locking Retractor (ALR) Mode

Position the seat backrest fully upright (if adjustable).

Position the safety belt shoulder height adjuster (if equipped) in the full down or up position.

Fasten the safety belt.

Pull out the safety belt webbing until the Automatic Locking Retractor (ALR) feature is activated.

Allow the safety belt webbing to retract until it stops.

Pull on the safety belt webbing to make sure the safety belt retractor has remained in the Automatic Locking Retractor (ALR) mode. If the safety belt retractor is not locked, install a new safety belt retractor.

Unfasten the safety belt and allow the safety belt webbing to retract to its stowed position.

Pull out and retract the safety belt webbing to verify the safety belt retractor has converted automatically out of Automatic Locking Retractor (ALR) mode. If the safety belt retractor remains locked in the Automatic Locking Retractor (ALR) mode, install a new safety belt retractor.

Functional Test - Safety Belt Retractor, Road Test Inspection

NOTE: Make sure there is no excessive slack in the safety belt webbing across the torso during testing.

NOTE: Do not jerk on the safety belt webbing when carrying out this test.

Fasten the safety belts and proceed to a safe area.

Reach a speed of 24 km/h (14.9 mph).

WARNING: Apply maximum brake force only on dry concrete or equivalent hard surface, never on wet pavement or gravel. Failure to follow this instruction may result in serious personal injury.
Grasp the shoulder harness, lean forward and apply the brakes, making a maximum braking application without a skid.

The safety belts should lock up with minimum webbing extension.

If there is a lockup of all safety belt retractors being tested, the safety belt retractors are functioning correctly. If any safety belt retractor fails to lock up, install a new safety belt retractor(s).

Functional Test - Safety Belt Retractor, Automatic Locking Retractor (ALR) Mode, Inflatable Safety Belt

NOTE: The inflatable shoulder belt retractor is not an Automatic Locking Retractor (ALR). Only the lap belt retractor is an Automatic Locking Retractor (ALR).

Fasten the safety belt.

Pull out the lap belt webbing until the Automatic Locking Retractor (ALR) feature is activated.

Allow the safety belt webbing to retract until it stops.

Pull on the safety belt webbing to check that the safety belt lap belt retractor has remained in the Automatic Locking Retractor (ALR) mode. If the safety belt lap belt retractor is not locked, install a new safety belt lap belt retractor.

Unfasten the safety belt and allow the safety belt webbing to retract to its stowed position.

Pull out and retract the safety belt lap belt webbing to verify the safety belt lap belt retractor has converted automatically out of Automatic Locking Retractor (ALR) mode. If the safety belt lap belt retractor remains locked in the Automatic Locking Retractor (ALR) mode, install a new safety belt lap belt retractor.

Functional Test - Safety Belt Retractor, Road Test Inspection, Inflatable Safety Belt

NOTE: Make sure there is no excessive slack in the safety belt webbing across the torso during testing.

NOTE: Do not jerk on the safety belt webbing when carrying out this test.

Move the seat in front of the seating position being tested as far forward as is safely possible.

Fasten the safety belts and proceed to a safe area.

Reach a speed of 24 km/h (14.9 mph).

WARNING: Apply maximum brake force only on dry concrete or equivalent hard surface, never on wet pavement or gravel. Failure to follow this instruction may result in serious personal injury.
Grasp the shoulder harness, lean forward and apply the brakes, making a maximum braking application without a skid.

The inflatable safety belt shoulder harness should lock up with minimum webbing extension.

Safely bring the vehicle to a stop.

Pull about 152.4 mm (6 in) of inflatable safety belt lap belt webbing off of the lap. Hold the belt off of the lap.

Reach a speed of 24 km/h (14.9 mph).

WARNING: Apply maximum brake force only on dry concrete or equivalent hard surface, never on wet pavement or gravel. Failure to follow this instruction may result in serious personal injury.
While holding the inflatable safety belt lap belt, apply the brakes, making a maximum braking application without a skid.

The inflatable safety belt lap belt should lock up with minimum webbing extension.

If there is a lockup of all inflatable safety belt retractors being tested, the inflatable safety belt retractors are functioning correctly. If any inflatable safety belt retractor fails to lock up, install a new inflatable safety belt retractor(s).