No , it acts normal , when somebody is in it and doesn't wear the seatbelt the alarm goes off etc. Just very strange how it seems to only be faulting when the front seat is occupied. Going to try driving it tomorrow with and without the front seat being used to see if it's just coincidental.

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Try disconnecting the front seat and see if the fault occurs then - car will throw up an airbag warning light and maybe some others but I think you'll still be able to drive it. That will prove out the front seat one way or another.

Is it the little black box under the seat ?

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Disconnected the occupancy sensor and fault still appeared. Moved into the back and everything was fine again. So I decided to pull on the seatbelt and within a few seconds the fault appeared. Let go of the seatbelt and kept driving with no problem. Pulled on the seatbelt again a few mins later and wiggled it about while it was tensioned and sure enough the fault came up almost immediately. Dropped the other half at tesco and while I was in the car park I decided to pull off a bit of the plastic covering by the seatbelt and had a rummage with a screwdriver and a torch. Then went to go home and the dash went mental saying power steering fault , engine fault etc then came up in limp mode. Drove it home and put my reader on it for it to say every system has a fault and they all had CAN bus fault. Now does anyone know of any wiring / connectors by the passenger seatbelt that could cause this ?

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Earthing point.

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Is that the 3 on the sill or is there one closer to the seatbelt ?

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Passenger side- E8 & E9 are just in front of the B pillar under the sill trim, E16 is directly below the B pillar.

Driver side- E11, E12 & E13 are in front of B pillar under sill trim.

Passenger side- E8 & E9 are just in front of the B pillar under the sill trim, E16 is directly below the B pillar.

Driver side- E11, E12 & E13 are in front of B pillar under sill trim.

Thanks I ll have a good look tonight.

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Ok , so I took the trim off and the first thing I notice is the cable the plugs into the connector that goes to the rear door is curled up and twisted into the seatbelt mechanism. Look closely and two wires had worn down so there was bare wire showing. Looked at the seatbelt mechanism and there is a small amount of build up / oxidisation with a couple of slight brown sections. Out to try it again tonight to see if this was the issue as all earths looked fine.

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That certainly looks like a likely candidate.

Most likely why the gem connector was burnt too.

Crossed circuits feeding back to another supply.

Hopefully that will be the end of your woes.

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The green connector has nothing to do with the seatbelt sensor. The brow connectors on the gem do however. Put electric al type around and see if the issue appears again. But the issues you have are just weird

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Maybe so, but the sensor wasn't causing ofuedd's problems, it was the loom on the passengers side fouling on the belt reel.

Any of the affected wires may have been shorting back to the green connector and therefore causing random power spikes throughout the car.

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Looks like you've finally gotten to the root cause of your problem - an intermittent earth fault like that could play havoc with the gem if it's overloading a circuit briefly or partially taking a feed down to ground.

Looks like the cable insulation is only just worn through so you can get away with taping it up then doing whatever's needed to secure the loom out of the way of the way so it can't get nibbled by the seatbelt retractor again?

All taped up and everything working perfect !!! Although had a scare with dash issues but completely different where dials went mad and car went into limp mode. Think I've cracked that though as I think the connector had a bit of dirt or something in it so cleaned it out with wd40 and all seems ok. :-)

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