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MODEL SELECTION INDEX
MY 2004 WK Series - Service Information
Section 1A7A Seat Assemblies (Build No L253068 Onwards)
1 General Information
1.1 Front Seat General Description
Seat Covers
Electric Seat Operation
Raise/Lower Movement
Fore/Aft Movement
Recline Movement
Four-way and Six-way Movement Control
Eight-way Movement Control
Memory Seat Position System
Priority Keys (Level 5 Vehicles Only)
Memory Buttons
Using the Exterior Mirrors
Active Head Restraints
1.2 Rear Seat General Description
Seat Covers
Surebond
Hook and loop
Conventional pull-down
2 Diagnostics – Front Seat, Level 1
2.1 Prerequisites
Safety Requirements
Equipment
Testing Procedures
2.2 Mechanical Diagnosis
Lumbar Support Inoperative
Introduction
Test Description
Diagnostic Table
Seat-back Recline Forward and/or Aft Function is Inoperative
Introduction
Test Description
Diagnostic Table
Four-way Seat Fore/Aft Movement Function is Inoperative or i
Introduction
Test Description
Diagnostic Table
2.3 Electrical Diagnosis – Four-way/Six-way Seat
Wiring Diagram – Four-way/Six-way Seat
Connector Chart – Four-way/Six-way Seat
Neither Seat Adjustment Switch Functions Operate
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
None of the Driver’s Seat Adjustment Switch Functions Operat
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Front/Rear of the Driver's Seat Does Not Raise and/or Lower
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Driver’s Seat Fore/Aft Movement Function is Inoperative or n
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
None of the Passenger's Seat Adjustment Switch Functions Ope
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Front/Rear of the Passenger's Seat Does Not Raise and/or Low
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
2.4 Four-way Seat Adjustment Switch Test
Test
2.5 Six-way Seat Adjustment Switch Test
Test
3 Diagnostics – Front Seat, Level 2, 3, 4 and 5
3.1 Prerequisites
Safety Requirements
Equipment
Testing Procedures
3.2 Mechanical Diagnosis
Lumbar Support Inoperative
Introduction
Test Description
Diagnostic Table
3.3 Electrical Diagnosis – Eight-way Seat, Non-memory, RHD
Wiring Diagram – Eight-way Seat, Non-memory, RHD
Connector Chart – Eight-way Seat, Non-memory, RHD
Neither Seat Adjustment Switch Functions Operate
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
None of the Driver’s Seat Adjustment Switch Functions Operat
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Front/Rear of the Driver’s Seat Does Not Raise and/or Lower
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Driver’s Seat Fore/Aft Movement Function is Inoperative or N
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Driver’s Seat-back Recline Forward and/or Aft Function is In
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
None of the Passenger’s Seat Adjustment Switch Functions Ope
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Front/Rear of the Passenger’s Seat Does Not Raise and/or Low
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Passenger’s Seat Fore/Aft Movement Function is Inoperative o
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Passenger’s Seat-back Recline Forward and/or Aft Function is
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
3.4 Electrical Diagnosis – Eight-way Seat, Non-memory, LHD
Wiring Diagram – Eight-way Seat, Non-memory, LHD
Connector Chart – Eight-way Seat, Non-memory, LHD
Neither Seat Adjustment Switch Functions Operate
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
None of the Driver’s Seat Adjustment Switch Functions Operat
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Front/Rear of the Driver’s Seat Does Not Raise and/or Lower
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Driver’s Seat Fore/Aft Movement Function is Inoperative or N
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Driver’s Seat-back Recline Forward and/or Aft Function is In
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
None of the Passenger’s Seat Adjustment Switch Functions Ope
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Front/Rear of the Passenger’s Seat Does Not Raise and/or Low
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Passenger’s Seat Fore/Aft Movement Function is Inoperative o
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Passenger’s Seat-back Recline Forward and/or Aft Function is
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
3.5 Eight-way Seat Adjustment Switch Test
Test
4 Diagnostics – Front Seat, Memory and Rear-view Mirror, Lev
4.1 Prerequisites
Safety Requirements
Equipment
Testing Procedures
4.2 System Self Diagnosis
Current DTCs
History DTCs
Clearing DTCs
4.3 Tech 2 Diagnostics
Test Modes
Mode F0: Diagnostic Trouble Codes
Mode F1: Diagnostic Data Display
Mode F2: Snapshot
Mode F3: Miscellaneous Tests
Mode F4: Additional Functions
4.4 Tech 2 Test Modes and Displays for Diagnosis
System Select Menu
Body Application Menu
System Identification
Application Menu
F0: Diagnostic Trouble Codes
F0: Read DTC Information
F1: Clear DTC Information
Diagnostic Trouble Codes
F1: Diagnostic Data Display
F0: Inputs and Outputs
F1: Memory
F2: System Identification
F2: Snapshot
F3: Miscellaneous Tests
F0: Chime
F1: LED
F2: Right Exterior Mirror
F3: Left Exterior Mirror
F4: Front Vertical Motor
F5: Rear Vertical Mirror
F6: Horizontal Motor
F7: Recline Motor
F4: Additional Functions
F0: Module Reset
4.5 Preliminary System Diagnosis
4.6 Diagnostic Tables
Introduction
4.7 Mechanical Diagnosis
Lumbar Support Inoperative
Introduction
Test Description
Diagnostic Table
4.8 Electrical Diagnosis – Memory Seat
Wiring Diagram – Memory Seat, RHD
Wiring Diagram – Memory Seat, LHD
Connector Chart – Memory Seat
Initial Check
Introduction
Test Description
Diagnostic Table
No Serial Data Communications to the Seat Memory Module
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Seat Adjustment Switch Inoperative – RHD
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Seat Adjustment Switch Inoperative – LHD
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Seat Front Lift Motor Inoperative – RHD
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Seat Front Lift Motor Inoperative – LHD
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Seat Rear Lift Motor Inoperative
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Seat Fore/Aft Movement Motor Inoperative
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Seat-back Recline Motor Inoperative
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Memory Position Switch Inoperative – RHD
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Memory Position Switch Inoperative – LHD
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Seat Front Lift Motor Hall-effect Sensor Check
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Seat Rear Lift Motor Hall-effect Sensor Check
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Seat Fore/Aft Movement Motor Hall-effect Sensor Check
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Seat-back Recline Motor Hall-effect Sensor Check
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Priority Key Feature Inoperative
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
DTC 1 – Front Vertical Up Switch Stuck – RHD
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
DTC 1 – Front Vertical Up Switch Stuck – LHD
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
DTC 2 – Front Vertical Down Switch Stuck – RHD
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
DTC 2 – Front Vertical Down Switch Stuck – LHD
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
DTC 3 – Rear Vertical Up Switch Stuck – RHD
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
DTC 3 – Rear Vertical Up Switch Stuck – LHD
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
DTC 4 – Rear Vertical Down Switch Stuck – RHD
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
DTC 4 – Rear Vertical Down Switch Stuck – LHD
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
DTC 5 – Horizontal Forward Switch Stuck
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
DTC 6 – Horizontal Back Switch Stuck
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
DTC 7 – Recline Up Switch Stuck
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
DTC 8 – Recline Down Switch Stuck
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
DTC 9 – Memory Button 1 Stuck
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
DTC 10 – Memory Button 2 Stuck
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
DTC 11 – Memory Button 3 Stuck
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
DTC 12 – Mirror DIP Button Stuck
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
DTC 13 – No Serial Data
DTC 14 – No Exterior Mirror Communications
DTC 20 – Front Vertical Position Sensor Fault
DTC 21 – Rear Vertical Position Sensor Fault
DTC 22 – Horizontal Position Sensor Fault
DTC 23 – Recline Position Sensor Fault
DTC 24 – System Voltage Out of Range
4.9 Memory Position Switch Test
Remove
Reinstall
Test
4.10 Electrical Diagnosis – Rear-view Mirrors
Wiring Diagram – Rear-view Mirrors, RHD
Wiring Diagram – Rear-view Mirrors, LHD
Connector Chart – Rear-view Mirrors
Initial Check
Introduction
Test Description
Diagnostic Table
Mirror Dip Function Check
Introduction
Test Description
Diagnostic Table
Mirror Heating Function Check
Introduction
Test Description
Diagnostic Table
No Serial Data from Exterior Rear-view Mirrors
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
No Serial Data – Right-hand Exterior Rear-view Mirror
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
No Serial Data – Left-hand Exterior Rear-view Mirror
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
Mirror Control Switch Inoperative
Introduction
Test Description
Diagnostic Table Notes
Diagnostic Table
5 Service Operations – Front Seat
5.1 Usage Chart
How To Use This Chart
Domestic
Gulf States
Front Seat Type 1
Front Seat Type 2
Front Seat Type 3
Front Seat Type 4
Front Seat Type 5
Front Seat Type 6
Front Seat Type 7
Front Seat Type 8
Front Seat Type 9
Front Seat Type 10
Front Seat Type 11
Front Seat Type 12
Front Seat Type 13
Front Seat Type 14
Front Seat Type 3, 4, 13 & 14 Head Restraint Assembly
5.2 Fire Extinguisher Assembly
Remove
Reinstall
5.3 Front Seat Assembly
Remove
Reinstall
Seat Memory Calibration, Front Seat Type 3 and 13
5.4 Front Seat Outer Side Cover Assembly
Remove
Disassemble
Front Seat Adjustment Switch
Memory Position Switch Assembly
Reinstall
5.5 Front Seat Inner Side Cover
Remove
Reinstall
5.6 Front Seat-back Rear Cover Assembly
Remove
Disassemble
Reassemble
Reinstall
5.7 Front Seat Head Restraint Assembly
Front Seat Type 1, 2 & 5 to 12
Remove
Disassemble
Reassemble
Reinstall
Front Seat Type 3, 4, 13 & 14
Remove
Disassemble
Reassemble
Reinstall
5.8 Front Seat Head Restraint Sleeve
Front Seat Type 1, 2 & 5 to 12
Remove
Reinstall
Front Seat Type 3, 4, 13 & 14
Remove
Reinstall
5.9 Lumbar Support Knob Assembly
Remove
Reinstall
5.10 Front Seat-back Pad and Cover Assembly
Remove
Disassemble
Reassemble
Reinstall
5.11 Front Seat-back Frame Assembly
Remove
Disassemble
Side Impact Airbag Assembly
Front Seat Dummy Block Insert Assembly
Lumbar Support Assembly
Active Head Restraint Frame Assembly
Reinstall
5.12 Seat Cable Tray and Memory Module
Remove
Reinstall
5.13 Track and Height Adjust Assembly
Remove
Reinstall
5.14 Front Seat Cushion Pad and Cover Assembly
Remove
Disassemble
Reassemble
Reinstall
5.15 Front Seat Cushion Frame Assembly
Remove
Disassemble
Reassemble
Reinstall
5.16 Front Seat Lift Motor Assemblies
5.17 Front Seat Fore/Aft Movement Motor Assembly
5.18 Front Seat-back Recline Motor Assembly
5.19 Drive Motor Hall-effect Sensors
6 Service Operations – Rear Seat
6.1 Usage Chart
How To Use This Chart
Domestic
Gulf States
Rear Seat Type 1
Rear Seat Type 2
Rear Seat Type 3
Rear Seat Type 4
Rear Seat Type 5
Rear Seat Type 6
Rear Seat Type 7
Rear Seat Type 8
Rear Seat-back Centre Tray and Armrest Assembly without Comp
Rear Seat-back Centre Tray and Armrest Assembly with Compart
6.2 Rear Seat Cushion Assembly
Remove
Disassemble
Rear Seat Cushion Release Handle
Rear Seat Cushion Frame
Cushion Cover Assembly
Rear Seat Type 1 and 6
Rear Seat Type 2 and 7
Rear Seat Type 3
Rear Seat Type 4
Rear Seat Type 5
Rear Seat Type 8
Reinstall
6.3 Rear Seat-back Head Restraint Assembly Right-hand and Le
Remove
Except Rear Seat Type 8 Head Restraint
Rear Seat Type 8 Head Restraint
Reinstall
6.4 Rear Seat-back Assembly
Remove
Head Restraint Sleeve
Remove
Reinstall
Rear Seat-back Cover
Rear Seat Type 1 and 6
Rear Seat Type 2 and 7
Rear Seat Type 3 and 4
Rear Seat Type 5
Rear Seat Type 8
Reinstall
6.5 Rear Seat-back Centre Head Restraint Assembly
Remove
Disassemble
Reassemble
Reinstall
6.6 Rear Seat-back Centre Armrest Assembly
Remove
Disassemble Rear Seat Type 1 – 4
Rear Seat-back Centre Armrest Hinge
Rear Seat-back Centre Armrest Lid and Cover
Rear Seat-back Centre Armrest Deposit Box, Cover and Cup Hol
Reassemble
Disassemble Rear Seat Type 5 – 8
Reassemble
Reinstall
6.7 Rear Seat-back Centre Assembly
Remove
Disassemble
Pad Assembly, Cover and Head Restraint Sleeves
Rear Seat-back Centre Release Button
Rear Seat-back Centre Lock Actuator
Rear Seat-back Centre Hinge
Reinstall
6.8 Rear Seat-back Centre Lock Striker
Remove
Reinstall
7 Torque Wrench Specifications
Front Seat
Rear Seat