Mechanical System Troubleshooting for Stairmaster 4000PT Stepper

Sensor - Front Crash Removal
WARNING: Vehicle sensor orientation is critical for proper operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again.

1. Depower the system. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in this section.

1. Remove the radiator upper sight shield (8C291).

1. Remove the air bag sensor.
   1. Disconnect the air bag sensor electrical connector.
   1. Remove the three screws.
   1. Remove the air bag sensor.
   2. SECTION 501-20B: Supplemental Restraint System 2000 Town Car Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 06/10/2004 Sensor - Side Crash Removal
      WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed.
      WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment.
      WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
      NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
      NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
      NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again.
      NOTE: Left side is shown, right side is similar.
      NOTE: The side crash sensors are located under the carpet beneath the front seats.
      
      1. Position the seat to gain access to all fasteners.
      1. Depower the system. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in this section.
      1. Remove the front seat. For additional information, refer to Section 501-10 .
      1. Remove the safety belt anchor bolt cover.
      1. Remove the bolt and the safety belt anchor.
      1. Remove the front and rear door scuff plates.
      1. Remove the lower B-pillar trim panel.
      1. Remove the carpet to access the side crash sensor.
      1. Remove the side crash sensor.
         1. Remove the retaining bolts and position the side crash sensor in order to disconnect the electrical connector.
         1. Disconnect the electrical connector.
         1. Remove the side crash sensor and bracket.

Supplemental Restraint System (SRS) Depowering and Repowering

Depowering Procedure

WARNING: Always wear safety glasses when repairing an air bag supplemental

restraint system (SF3) vehicle and when handling an air bag module. This will reduce

the risk of injury in the event of an accidental deployment.

WARNING: Never probe the connectors on the airbag module. Doing so can result in

air bag deployment, which can result in personal injury.

WARNING: To reduce the risk of personal injury, do not use any memory saver

devices.

NOTE: Ifa seat equipped with a seat mounted side airbag and or a safety belt

pretensioner (if equipped) system is being serviced, the supplemental restraint system

(SES) must be depowered.

NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the

ignition switch is ON. This is normal operation and does not indicate a supplemental

restraint system (SRS) fault.

NOTE: The SRS must be fully operational and free of faults before releasing the vehicle

to the customer

1. Turn all vehicle accessories OFF.

2. Turn the ignition switch to OFF.

3. At the central junction box (Cm), located below the LH side of the instrument panel,

remove the cover and the restraints control module (RCM) fuse F223 (lOA) from

the CTh. For additional information, refer to the Wiring Diagram Manual.

4. Turn the ignition ON and visually monitor the air bag indicator for at least 30

seconds. The air bag indicator will remain lit continuously (no flashing) if the correct

ROsI fuse has been removed, If the air bag indicator does not remain lit

continuously, remove the correct RCM fuse before proceeding

5. Turn the ignition switch to OFF.

6. WARNING: To avoid accidental deployment and possible personal injury, the

backup power supply must be depleted before repairing or replacing any front or

side air bag supplemental restraint system (SRS) components and before set-ricing,

replacing, adjusting or striking components near the front or side air bag sensors,

such as doors, instrument panel, console, door latches, strikers, seats and hood

latches.

To deplete the backup power supply energy, disconnect the battery ground cable

and wait at least one minute. Be sure to disconnect auxiliary batteries and power

supplies (if equipped).

Disconnect the battery ground cable and wait at least one minute.

Repoweri.ng Procedure

1. WARNING: The restraint system diagnostic tool is for restraint system service

only. Remove from vehicle prior to road use. Failure to remove could result in

injury and possible violation of vehicle safety standards.

Make sure all restraint system diagnostic tool(s) that may have been installed during

the repair have been removed from the vehicle and all SRS components are

connected.

2. Turn the ignition switch from OFF to ON.

3. Install the ROsI fuse F2.23 (lOA) to the DB and install the cover.

4. WARNING: Be sure that nobody is in the vehicle and that there is nothing

blocking or set in front of any air bag module when the battery ground cable is

connected.

Connect the battery ground cable.

5. Prove out the supplemental restraint system (SRS) as follows:

Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to

ON and visually monitor the air bag indicator with the air bag modules installed. The

air bag indicator will light continuously for approximately six seconds and then turn

off. If an air bag supplemental restraint system (SF3) fault is present, the air bag

indicator will:

- failto light.

- remain lit continuously.

- flash.

The flashing might not occur until approximately 30 seconds after the ignition switch

has been turned from the OFF to the ON position. This is the time required for the

restraints control module (RCM) to complete the testing of the SRS. if the air bag

indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5

sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered

must be diagnosed and repaired.

Removal & Installation The ignition switch or warning switch can be replaced without removing the steering lock assembly. The ignition switch is on the back of the assembly and the warning switch on the side.

1. Disconnect the negative battery cable and insulate the terminal end.
   

CAUTION The air bag system must be disarmed before removing the steering wheel. Failure to do so may cause accidental deployment, property damage or personal injury.

1. Remove the steering wheel and the steering column upper and lower covers.
   
2. Remove the spiral cable assembly.
   

View of the steering lock and ignition switch assembly

1. Remove the combination switch from the steering column.
   
2. Remove steering column support nuts and lower the steering column.
   
3. Disconnect the ignition switch wiring and interlock cable (if equipped).
   
4. Remove the bolts that secure the steering lock and remove steering lock assembly.
   

To install:

1. Install the steering lock assembly and secure with new shear type bolts.
   
2. Connect the ignition switch wiring harness and the interlock cable.
   
3. Raise the steering column and secure with mounting nuts.
   
4. Install the spiral cable assembly.
   
5. Install the combination switch, steering column covers, and the steering wheel.
   
6. Connect the negative battery cable and enable the air bag system.
   

Seat Backrest — Front Printable View (404 KB) Disassembly
All vehicles
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury.
WARNING: Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced. Cleaning is permissible.
WARNING: To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer.

1. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS) Depowering and Repowering in the General Procedures portion of Section 501-20B.

1. Remove the head restraint.

1. Remove the head restraint guides.
   • Using a suitable screwdriver, depress the locking tang.