Service Manual2005 KALOS SEAT BELTS

SECTION 8A

SEAT BELTS

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

SPECIFICATIONS

Fastener Tightening Specifications

Application	N·m	Lb-Ft	Lb-In
Seat Belt Anchor Bolt	38	28	-
Seat Belt Bracket Screws	10	-	89
Seat Belt Height Adjuster Bolts	23	17	-
Seat Belt Retractor Bolt	38	28	-

SCHEMATIC AND ROUTING DIAGRAMS

Driver Seat Belt Warning

DIAGNOSIS

Seat Belt Warning Lamp is Inoperative

Diagnostic Aids

The chime module is located above the I/P fuse block.

Seat Belt Warning Lamp Is Inoperative

Step	Action	Value(s)	Yes	No
1	Check fuse F4. Is fuse F4 blown?	-	Go to Step 2	Go to Step 3
2	Check for a short circuit and repair it, if necessary. Replace the fuse. Is the repair complete?	-	System OK	-
3	Turn the ignition ON. Use a multimeter to check the voltage at fuse F4. Does the voltmeter show the specified value?	11-14 v	Go to Step 5	Go to Step 4
4	Repair the open power supply circuit for fuse F4. Is the repair complete?	-	System OK	-
5	Disconnect the chime module connector. Turn the ignition ON. Check the voltage at terminal 8 of the chime module connector. Is the voltage equal to the specified value?	11-14 v	Go to Step 7	Go to Step 6
6	Repair the open circuit between fuse F4 and the chime module. Is the repair complete?	-	System OK	-
7	Make sure the seat belt is unfastened. With the chime module connector disconnected, use an ohmmeter to measure continuity between terminal 1 of the chime module and ground. Does the ohmmeter indicate the specified value?	≈ 0 Ω	Go to Step 13	Go to Step 8
8	Make sure the seat belt is unfastened. Disconnect the seat belt connector under the driver's seat. Use an ohmmeter to measure between the two terminals at the switch side of the connector. Does the ohmmeter indicate the specified value?	≈ 0 Ω	Go to Step 9	Go to Step 12
9	While the seat belt connector is disconnected, measure the continuity between the terminal for the BLK wire and ground. Does the ohmmeter indicate the specified value?	≈ 0 Ω	Go to Step 10	Go to Step 11
10	Repair the open circuit between the seat belt connector and ground. Is the repair complete?	-	System OK	-
11	Repair the open circuit between terminal 1 of the chime module and the seat belt switch. Is the repair complete?	-	System OK	-
12	Replace the seat belt switch. Is the repair complete?	-	System OK	-
13	With the chime module disconnected, use an ohmmeter to measure continuity between terminal 5 of the chime module and ground. Does the ohmmeter indicate the specified value?	≈ 0 Ω	Go to Step 15	Go to Step 14
14	Repair the open circuit between terminal 5 of the chime module and ground. Is the repair complete?	-	System OK	-
15	Check the seat belt warning lamp. Is the warning lamp OK?	-	Go to Step 17	Go to Step 16
16	Replace the seat belt warning lamp. Is the repair complete?	-	System OK	-
17	Replace the chime module. Is the repair complete?	-	System OK	-

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE

Three-Point Front Seat Belt

Removal Procedure

Remove the bolt and the seat belt anchor on the upper B-pillar.

Remove the lower B-pillar trim panel. Refer to Section 9G, InteriorTrim.
Remove the bolt and the seat belt anchor on the lower B-pillar.

Remove the bolt and the seat belt retractor.

Installation Procedure

Notice : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion.

Install the seat belt retractor with the bolt.

Tighten

Tighten the seat belt retractor bolt to 38 N•m (28 lb-ft).

Install the seat belt anchor to the upper B-pillar with the bolt.

Tighten

Tighten the seat belt anchor bolt to 38 N•m (28 lb-ft).

Install the lower B-pillar trim panel. Refer to Section 9G, InteriorTrim.
Install the seat belt anchor to the lower B-pillar with the bolt.

Tighten

Tighten the seat belt anchor bolt to 38 N•m (28 lb-ft).

Front Seat Belt Height Adjuster

Removal Procedure

Remove the upper B-pillar trim panel. Refer to Section 9G, InteriorTrim.
Remove the bolts and the seat belt height adjuster.

Installation Procedure

Note : Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion.

Install the seat belt height adjuster with the bolts.

Tighten

Tighten the seat belt height adjuster bolts to 23 N•m (17 lb-ft).

Install the upper B-pillar trim panel. Refer to Section 9G, InteriorTrim.

Three-Point Rear Outboard Seat Belt

(Hatchback Shown, Notchback Similar)

Removal Procedure

Open the luggage compartment.
For hatchback model, remove the luggage compartment wheelhouse trim panel. Refer to Section 9G, Interior Trim. For notchback model, remove the backshelf panel. Refer to Section 9G, Interior Trim.
Remove the bolt and the seat belt retractor in the luggage compartment.

Remove the bolt and the seat belt anchor on the C-pillar.

Pull the rear seat knob and fold the rear seat cushion.
Remove the seat belt with bolt.

Installation Procedure

Install the seat belt retractor in the luggage compartment with the bolt.

Tighten

Tighten the seat belt retractor bolt to 38 N•m (28 lb-ft).

Install the seat belt with bolt.

Tighten

Tighten the seat belt bolt to 38 N•m (28 lb-ft).

Install the seat belt anchor to the C-pillar with the bolt.

Tighten

Tighten the seat belt anchor bolt to 38 N•m (28 lb-ft).

For hatchback model, install the luggage compartment wheelhouse trim panel. Refer to Section 9G, Interior Trim. For notchback model, install the backshelf panel. Refer to Section 9G, Interior Trim.
Install the lrear seat cushion and unfold the seatback. Refer to Section 9H, Seats.

Three-Point Rear Center Seat Belt

Removal Procedure

Pull the rear seatknob and fold the rear seat cushion.
Remove the bolts and the seat belt anchors.

Remove the luggage compartment side panel(LH) and remove the bolt from the rear center seat belt retrector.

Installation Procedure

Install the seat belt anchors with the bolts.

Tighten

Tighten the seat belt anchor bolts to 38 N•m (28 lb-ft).

Install the rear center seat belt retrector with bolt.

Tighten

Tighten the rear center seat belt retrector bolt to 38 N•m (28 lb-ft).

Install the luggage compartment side panel and unfold the rear seat.

GENERAL DESCRIPTION AND SYSTEM OPERATION

Driver Seat Belt Warning

The driver's seat belt incorporates a seat belt reminder light in the instrument cluster to remind the driver if the seat belt is not fastened when the ignition is turned ON.

Three-Point ELR Front Seat Belt

The three-point emergency locking retractor (ELR) driver seat belt is always unlocked, allowing the passenger freedom of movement, except in emergencies (rapid deceleration, rapid acceleration, or hard cornering maneuvers).

Three-Point CLR Seat Belt

Three-point CLR seat belts are standard for the front seat passenger and the rear seat outboard passenger positions. The CLR seat belt has two operation modes. Normally, the seat belt operates in the ELR mode, which allows the passenger freedom of movement, except in emergency situations. However, when the belt is fully extended and released, the seat belt operates in the ALR (auto-locking) mode. The ALR mode does not allow movement and is designed to hold a child seat firmly to the seat.

Two-Point LAP Rear Center Seat Belt

The two-point lap rear center seat belt is a single continuous length of webbing. The webbing is routed from the anchor through a latch plate and into a single retractor.

Operational and Functional Checks

Caution :

Keep sharp objects and potentially damaging objects away from the seat belts.

Avoid bending or damaging any portion of the buckle or the latch plate.

Do not bleach or dye the belt webbing. Use only mild soap and water in order to clean the belts.

When installing the seat belt anchor bolts and the screws, start the bolts and the screws by hand in order to prevent crossthreading.

Do not attempt any repairs on the retractor mechanisms or the covers. Replace any defective assemblies with new assemblies.

Replace any belts that are cut or damaged in any way.

Inspect all seat belt anchor bolts and the screws in order to verify that they are secure.
Inspect the seat belt buckle. The buckle must lock and unlock easily.
After inserting the latch into the buckle, tug sharply on the belt. The buckle must remain locked.
Fully extend the shoulder belt portion to make sure that there is no twisting or tears in the belt.
Let the shoulder belt retract fully. The belt should retract easily.