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Test Z: Seat Belt Warning Chime Does Not Operate Properly

NOTE: Perform all voltage and resistance tests using a Digital Volt-Ohm Meter (DVOM) with a minimum 10-megohm input impedance, unless stated otherwise in test procedure. Use ohmmeter to isolate wiring harness shorts or opens.
  1. Turn ignition switch to LOCK position. Connect Worldwide Diagnostic System (WDS) tester or New Generation Star (NGS) tester to Data Link Connector (DLC). See Figure. DLC is located under instrument panel between steering column and the radio. See Figure. Turn ignition switch to RUN position. Monitor Generic Electronic Module (GEM) PIDs IGN_KEY, IGN_A, IGN_S and IGN_R while cycling ignition switch through all positions. If PIDs agree with ignition switch positions, go to next step. If PIDs do not agree with ignition switch positions, perform TEST V: KEY-IN-IGNITION WARNING CHIME DOES NOT OPERATE PROPERLY .
  2. Using WDS or NGS tester, monitor GEM PID D_SBELT while buckling and unbuckling driver's seat belt. If PIDs agree with seat belt positions, go to next step. If PIDs do not agree with seat belt positions, go to step  5.
  3. Using WDS or NGS tester, select GEM active command CHIME. Trigger active command CHIME on and off. If chime operates properly, go to next step. If chime does not operate properly, go to step  11.
  4. Cycle ignition switch from LOCK to RUN position while monitoring seat belt indicator in instrument cluster. Seat belt indicator should illuminate for approximately 3 seconds. If seat belt indicator operates properly, go to step  11. If seat belt indicator does not operate properly, perform TEST L: SAFETY BELT INDICATOR INOPERATIVE/DOES NOT OPERATE PROPERLY (CHIME OPERATES) .
  5. Using WDS or NGS tester, monitor GEM PID D_SBELT while buckling and unbuckling driver's seat belt. If PID indicates OUT with seat belt buckled, go to next step. If PID does not indicate OUT with seat belt buckled, go to step  8.
  6. Turn ignition switch to LOCK position. Disconnect driver's seat belt switch 2-pin harness connector C323. Turn ignition switch to RUN position. Using WDS or NGS tester, monitor GEM PID D_SBELT. If PID does not indicate IN, go to next step. If PID indicates IN, replace driver's seat belt switch. See SEAT BELT BUCKLE SWITCH  under REMOVAL & INSTALLATION. After repair, check system for normal operation.
  7. Turn ignition switch to LOCK position. Disconnect Generic Electronic Module (GEM) 12-pin harness connector C201d. See Figure. GEM is located behind left side of instrument panel, next to central junction box. See Figure. Measure resistance between ground and GEM harness connector C201d terminal No. 8 (Brown/Light Blue wire). If resistance is more than 10 k/ohms, go to step  11. If resistance is 10 k/ohms or less, repair short circuit in Brown/Light Blue wire between GEM and seat belt switch. For WARNING SYSTEMS circuit identification, see WIRING DIAGRAMS . After repair, test system for normal operation.
  8. Disconnect driver's seat belt switch 2-pin harness connector C323. See Fig 1. Connect a fused jumper wire between ground and driver's seat belt switch harness connector C323 terminal No. 1 (Brown/Light Blue wire). Using WDS or NGS tester, monitor GEM PID D_SBELT. If PID does not indicate OUT, go to next step. If PID indicates OUT, go to step  10.
  9. Turn ignition switch to LOCK position. Disconnect Generic Electronic Module (GEM) 12-pin harness connector C201d. See Figure. GEM is located behind left side of instrument panel, next to central junction box. See Figure. Measure resistance between driver's seat belt switch harness connector C315 terminal No. 1 and GEM harness connector C201d terminal No. 8 (Brown/Light Blue wire). See Figure. If resistance is 5 ohms or less, go to step  11. If resistance is more than 5 ohms, repair open circuit in Brown/Light Blue wire between GEM and driver's seat belt switch. For WARNING SYSTEMS circuit identification, see WIRING DIAGRAMS . After repair, test system for normal operation.
  10. Turn ignition switch to LOCK position. Measure resistance between ground and driver's seat belt switch harness connector C323 terminal No. (Black wire). If resistance is 5 ohms or less, replace driver's seat belt switch. See SEAT BELT BUCKLE SWITCH  under REMOVAL & INSTALLATION. If resistance is more than 5 ohms, repair open circuit in Black wire between driver's seat belt switch and ground point G400. Ground point G400 is located in left rear of vehicle. See Figure. For WARNING SYSTEMS circuit identification, see WIRING DIAGRAMS . After repair, test system for normal operation.
  11. Disconnect all GEM harness connectors. Inspect all GEM harness connectors for loose, damaged or corroded terminals. If terminals are damaged, repair or replace as necessary. If terminals are not damaged, reconnect all GEM harness connectors. Ensure GEM harness connectors are seated properly. If problem still exists, replace GEM. See GENERIC ELECTRONIC MODULE  under REMOVAL & INSTALLATION. After repair, clear DTCs, repeat self-test and check system for normal operation.
Fig 1: Identifying Safety Buckle Switch Connector Terminals
G00162079Courtesy of FORD MOTOR CO.
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