Ford Fusion: Supplemental Restraint System / Side Airbag. Removal and Installation

Removal

  WARNING: Front seat backrest trim covers installed on seats equipped with seat side airbags cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these instructions may result in the seat side airbag deploying incorrectly and increase the risk of serious personal injury or death in a crash.

NOTE: Removal steps in this procedure may contain installation details.

NOTE: LH seat shown, RH seat similar.

1. Remove the front seat.
   Refer to: Front Seat (501-10A Front Seats, Removal and Installation).
   

1. NOTE: Power seats shown, others similar.

   Detach the electrical connector retainers and position the wire harnesses aside.
   

1. Detach the backrest cover straps and position the backrest cover upward.
   

1. 1. Remove the pin-type retainers.
      
   2. Detach the hook-and-loop strips.
      
   3. Lift the backrest cover flap.
      

1. 
   Position the front seat backrest cover.
   
   1. Release the J-clip.
      
   2. Position the backrest cover from between the seat cushion and backrest cushion.
      

1. Remove the backrest cover insert.
   

1. 1. NOTICE: Use care when separating the backrest trim cover from the hook-and-loop strips or the hook-and-loop strips may be torn from the backrest foam.

      Release the hook-and-loop strips.
      
   2. Invert the backrest cover up to access the rear J-clips.
      

1. Remove the pin-type retainers from the deployment chute wrap and begin feeding it through the backrest foam.
   

1. Pull the deployment chute wrap out of the backrest foam.
   

1. Lift the backrest cover and release the J-clips from the lumbar wires and backrest frame.
   

1. Remove the side airbag nuts
   Torque: 58 lb.in (6.5 Nm)

1. 1. Disconnect the side airbag electrical connector.
      
   2. Remove the side airbag with deployment chute.
      

1. NOTE: Follow the unique instructions or graphic for this step in the installation.

   Remove the side airbag from the deployment chute.
   

Installation

1.   WARNING: Inspect the seat side airbag, airbag cavity, mounting surface and deployment chute for damage or the presence of foreign material. Remove all foreign material. Install a new side airbag if it is damaged. Install a new deployment chute if the deployment chute is damaged. Failure to follow these instructions may result in the seat side airbag deploying incorrectly and increase the risk of serious personal injury or death in a crash.

   To install, reverse the removal procedure.
   

1. Install the side airbag into the deployment chute.
   

1. Position the side air bag studs through the deployment chute holes.