not sure i should even bother posting this given the ovewhelming interest. but maybe this will help some other poor soul... here we go:
pretensioner on a good seatbelt should measure closed circuit (close to zero ohms). the pretensioner is the orange connector. the seatbelt-not-attached warning is related to the brown connector. in other words there are two seperate circuits controlled by the seatbelt. on a bad seatbelt in which the pretensioner has been deployed, it will measure open circuit (close to infinate ohms). how to tell if you don't have an ohmeter? look down the black metal barrel at the end of the unit; if the securing end of the cable is not at the very bottom of the barrel then it's been deployed - and it's no good. you can also tell by looking at black plastic sheething covering the steel cable between the buckle and the main housing; if it looks crumpled, then the cable has been retracted and it no good.
seatbelt buckle replacement:
following instructions are for driver sidereplacement. set aside approximately 1.5-2 hrs and god bless you for your patience.
1) put seat in full back position and unbolt both front bolt connecting seat to floor (10mm)
2) using electrical seat switch, move seat all the way forward
3) unscrew plastic pieces covering rear seat floor bolts (philips screwdriver)
4) remove four rear seat floor bolts (10mm)
5) remove electrical harness from car to front of seat (6mm)
6) tip seat on side inside car (no need to remove) and block up with a small cardboard box underneath to level seat somewhat. balance it so that you can get at evereything underneath while sitting in the passanger seat.
7) pry thin metal retainer, and pull electrical connector forward, un-clipping from seat bracket
8) using small flathead screwdriver, release two clips holding brown and orange connectors from seatbelt assembly from the electrical connector backshel and push out.
9) unsrew seatbelt buckle assembly (large torx)
10) cut cable ties to remove seatbelt buckle assembly.
11) install new seatbelt assembly in reverse order - use a couple of new cable ties to prevent the two wires from cathing on anything below seat.
side note: the dashboard airbag light (associated with code 33 = driver side pretensioner failure) will reset itself without fiddling with any computers
Last edited by survey_sez; 08-11-2010 at 07:06 PM.