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MODEL SELECTION INDEX
MY 2004 WK Series - Service Information
Section 1A7 Seat Assemblies
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 Service Operations – Front Seat, Level 1 and 3
2.1 Front Seat Usage Chart
How To Use This Chart
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
2.2 Fire Extinguisher Assembly
Remove
Reinstall
2.3 Front Seat Assembly
Remove
Reinstall
2.4 Front Seat Outer Side Cover Assembly
Remove
Disassemble
Front Seat Adjustment Switch, Front Seat Type 1 and 2
Front Seat Adjustment Switch, Front Seat Type 3 – 6
Reinstall
2.5 Front Seat Inner Side Cover
Remove
Reinstall
2.6 Front Seat-back Rear Cover Assembly and Lumbar Support Knob Assembly
Disassemble
Lumbar Support Knob and Deflector Ring
Front Seat-back Map Pocket
Reinstall
2.7 Front Seat Head Restraint Assembly
Remove
Disassemble
Reassemble
Reinstall
2.8 Front Seat Head Restraint Sleeve
Remove
Reinstall
2.9 Front Seat-back Pad and Cover Assembly
Remove
Disassemble
Reassemble
Reinstall
2.10 Front Seat-back Frame Assembly
Remove
Disassemble
Lumbar Support and Adjuster Assembly
Side Impact Airbag Assembly
Front Seat Dummy Block Insert Assembly
Reinstall
2.11 Track and Height Adjust Assembly
Remove
Reinstall
2.12 Front Seat Cushion Pad and Cover Assembly
Remove
Disassemble
Reassemble
Reinstall
2.13 Front Seat Cushion Frame Assembly
Remove
Disassemble
Reassemble
Reinstall
2.14 Front Seat Lift Motor Assemblies
2.15 Front Seat Fore/Aft Movement Motor Assembly
2.16 Front Seat-back Recline Motor Assembly
3 Diagnostics – Front Seat, Level 1 and 3
3.1 Prerequisites
Safety Requirements
Equipment
Testing Procedures
3.2 Mechanical Diagnosis
Lumbar Support Inoperative
Introduction
Test Description
Four-way/Six-way Seat-back Recline Forward and/or Aft Function is Inoperative
Introduction
Test Description
Four-way Seat Fore/Aft Movement Function is Inoperative or is Not Smooth
Introduction
Test Description
3.3 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
None of the Driver’s Seat Adjustment Switch Functions Operate
Introduction
Test Description
Front/Rear of the Driver's Seat Does Not Raise and/or Lower
Introduction
Test Description
Driver’s Seat Fore/Aft Movement Function is Inoperative or not Smooth
Introduction
Test Description
None of the Passenger's Seat Adjustment Switch Functions Operate
Introduction
Test Description
Front/Rear of the Passenger's Seat Does Not Raise and/or Lower
Introduction
Test Description
3.4 Four-way Seat Adjustment Switch Test
Test
3.5 Six-way Seat Adjustment Switch Test
Test
3.6 Electrical Diagnosis – Eight-way Seat
Wiring Diagram – Eight-way Seat
Connector Chart – Eight-way Seat
Neither Seat Adjustment Switch Functions Operate
Introduction
Test Description
None of the Driver’s Seat Adjustment Switch Functions Operate
Introduction
Test Description
Front/Rear of the Driver’s Seat Does Not Raise and/or Lower
Introduction
Test Description
Driver’s Seat Fore/Aft Movement Function is Inoperative or Not Smooth
Introduction
Test Description
Driver’s Seat-back Recline Forward and/or Aft Function is Inoperative
Introduction
Test Description
None of the Passenger’s Seat Adjustment Switch Functions Operate
Introduction
Test Description
Front/Rear of the Passenger’s Seat Does Not Raise and/or Lower
Introduction
Test Description
Passenger’s Seat Fore/Aft Movement Function is Inoperative or Not Smooth
Introduction
Test Description
Passenger’s Seat-back Recline Forward and/or Aft Function is Inoperative
Introduction
Test Description
3.7 Eight-way Seat Adjustment Switch Test
Test
4 Service Operations – Front Seat, Level 2, 4 and 5
4.1 Front Seat Usage Chart
How To Use This Chart
Domestic
Gulf States
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 15
Front Seat Type 16
Front Seat Type 17
Front Seat Type 18
Front Seat Type 19
Front Seat Type 20
Front Seat Type 11 – 14 Head Restraint Assembly
4.2 Fire Extinguisher Assembly
Remove
Reinstall
4.3 Front Seat Assembly
Remove
Reinstall
Seat Memory Calibration, Front Seat Type 11 and 13
4.4 Front Seat Outer Side Cover Assembly
Remove
Disassemble
Front Seat Adjustment Switch
Memory Position Switch Assembly
Reinstall
4.5 Front Seat Inner Side Cover
Remove
Reinstall
4.6 Front Seat-back Rear Cover Assembly
Remove
Disassemble
Reassemble
Reinstall
4.7 Front Seat Head Restraint Assembly
Front Seat Type 7 – 10
Remove
Disassemble
Reassemble
Reinstall
Front Seat Type 11 – 14
Remove
Disassemble
Reassemble
Reinstall
4.8 Front Seat Head Restraint Sleeve
Front Seat Type 7 – 10
Remove
Reinstall
Front Seat Type 11 – 14
Remove
Reinstall
4.9 Lumbar Support Knob Assembly
Remove
Reinstall
4.10 Front Seat-back Pad and Cover Assembly
Remove
Disassemble
Reassemble
Reinstall
4.11 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
4.12 Seat Memory Module
Remove
Reinstall
4.13 Track and Height Adjust Assembly
Remove
Reinstall
4.14 Front Seat Cushion Pad and Cover Assembly
Remove
Disassemble
Reassemble
Reinstall
4.15 Front Seat Cushion Frame Assembly
Remove
Disassemble
Reassemble
Reinstall
4.16 Front Seat Lift Motor Assemblies
4.17 Front Seat Fore/Aft Movement Motor Assembly
4.18 Front Seat-back Recline Motor Assembly
4.19 Drive Motor Potentiometers
5 Diagnostics – Front Seat, Level 2, 4 and 5
5.1 Prerequisites
Safety Requirements
Equipment
Testing Procedures
5.2 Mechanical Diagnosis
Lumbar Support Inoperative
Introduction
Test Description
5.3 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
None of the Driver’s Seat Adjustment Switch Functions Operate
Introduction
Test Description
Front/Rear of the Driver’s Seat Does Not Raise and/or Lower
Introduction
Test Description
Driver’s Seat Fore/Aft Movement Function is Inoperative or Not Smooth
Introduction
Test Description
Driver’s Seat-back Recline Forward and/or Aft Function is Inoperative
Introduction
Test Description
None of the Passenger’s Seat Adjustment Switch Functions Operate
Introduction
Test Description
Front/Rear of the Passenger’s Seat Does Not Raise and/or Lower
Introduction
Test Description
Passenger’s Seat Fore/Aft Movement Function is Inoperative or Not Smooth
Introduction
Test Description
Passenger’s Seat-back Recline Forward and/or Aft Function is Inoperative
Introduction
Test Description
5.4 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
None of the Driver’s Seat Adjustment Switch Functions Operate
Introduction
Test Description
Front/Rear of the Driver’s Seat Does Not Raise and/or Lower
Introduction
Test Description
Driver’s Seat Fore/Aft Movement Function is Inoperative or Not Smooth
Introduction
Test Description
Driver’s Seat-back Recline Forward and/or Aft Function is Inoperative
Introduction
Test Description
None of the Passenger’s Seat Adjustment Switch Functions Operate
Introduction
Test Description
Front/Rear of the Passenger’s Seat Does Not Raise and/or Lower
Introduction
Test Description
Passenger’s Seat Fore/Aft Movement Function is Inoperative or Not Smooth
Introduction
Test Description
Passenger’s Seat-back Recline Forward and/or Aft Function is Inoperative
Introduction
Test Description
5.5 Eight-way Seat Adjustment Switch Test
Test
6 Diagnostics – Front Seat Memory and Rear View Mirror, Level 5
6.1 Prerequisites
Safety Requirements
Equipment
Testing Procedures
6.2 System Self Diagnosis
Current DTCs
History DTCs
Clearing DTCs
6.3 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
6.4 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
6.5 Preliminary System Diagnosis
6.6 Diagnostic Charts
Introduction
6.7 Mechanical Diagnosis
6.8 Electrical Diagnosis – Memory Seat
Wiring Diagram – RHD
Wiring Diagram – LHD
Connector Chart
Initial Check
Circuit Description
Test Description
No Serial Data Communications to the Seat Memory Module
Circuit Description
Test Description
Notes on the Diagnostic Chart
Seat Adjustment Switch Assembly Inoperative – RHD
Circuit Description
Test Description
Notes on the Diagnostic Chart
Seat Adjustment Switch Assembly Inoperative – LHD
Circuit Description
Test Description
Notes on the Diagnostic Chart
Seat Front Lift Motor Inoperative
Circuit Description
Test Description
Notes on the Diagnostic Chart
Seat Rear Lift Motor Inoperative
Circuit Description
Test Description
Notes on the Diagnostic Chart
Seat Fore / Aft Movement Motor Inoperative
Circuit Description
Test Description
Notes on the Diagnostic Chart
Front Seat-back Recline Motor Inoperative
Circuit Description
Test Description
Notes on the Diagnostic Chart
Memory Position Switch Inoperative – RHD
Circuit Description
Test Description
Notes on the Diagnostic Chart
Memory Position Switch Inoperative – LHD
Circuit Description
Test Description
Notes on the Diagnostic Chart
Seat Front Lift Motor Potentiometer Check – RHD
Circuit Description
Test Description
Notes on the Diagnostic Chart
Seat Front Lift Motor Potentiometer Check – LHD
Circuit Description
Test Description
Notes on the Diagnostic Chart
Seat Rear Lift Motor Potentiometer Check – RHD
Circuit Description
Test Description
Notes on the Diagnostic Chart
Seat Rear Lift Motor Potentiometer Check – LHD
Circuit Description
Test Description
Notes on the Diagnostic Chart
Seat Fore/Aft Movement Motor Potentiometer Check
Circuit Description
Test Description
Notes on the Diagnostic Chart
Seat-back Recline Motor Potentiometer Check
Circuit Description
Test Description
Notes on the Diagnostic Chart
Priority Key Feature Inoperative
Circuit Description
Test Description
Notes on the Diagnostic Chart
DTC 1 — Front Vertical Up Switch Stuck
Right-hand Drive
Left-hand Drive
DTC 2 — Front Vertical Down Switch Stuck
Right-hand Drive
Left-hand Drive
DTC 3 — Rear Vertical Up Switch Stuck
Right-hand Drive
Left-hand Drive
DTC 4 — Rear Vertical Down Switch Stuck
Right-hand Drive
Left-hand Drive
DTC 5 — Horizontal Forward Switch Stuck
Circuit Description
Test Description
Note on Diagnostic Chart
DTC 6 — Horizontal Back Switch Stuck
Circuit Description
Test Description
Note on Diagnostic Chart
DTC 7 — Recline Up Switch Stuck
Circuit Description
Test Description
Note on Diagnostic Chart
DTC 8 — Recline Down Switch Stuck
Circuit Description
Test Description
Note on Diagnostic Chart
DTC 9 — Memory Button 1 Stuck
Circuit Description
Test Description
Note on Diagnostic Chart
DTC 10 — Memory Button 2 Stuck
Circuit Description
Test Description
Note on Diagnostic Chart
DTC 11 — Memory Button 3 Stuck
Test Description
Note on Diagnostic Chart
DTC 12 — Mirror DIP Button Stuck
Test Description
Note on Diagnostic Chart
DTC 13 — No Serial Data
DTC 14 — No Exterior Mirror Communications
DTC 15 — Front Vertical Position Sensor Fault
DTC 16 — Rear Vertical Position Sensor Fault
DTC 17 — Horizontal Position Sensor Fault
DTC 18 — Recline Position Sensor Fault
DTC 19 — ECU Malfunction
6.9 Memory Position Switch Test
Remove
Reinstall
Test
6.10 Electrical Diagnosis – Rear-view Mirrors
Wiring Diagram – RHD
Wiring Diagram – LHD
Connector Chart
Initial Check
Circuit Description
Test Description
Notes on the Diagnostic Chart
Mirror Dip Function Check
Circuit Description
Test Description
Notes on the Diagnostic Chart
Mirror Heating Function Check
Circuit Description
Test Description
Notes on the Diagnostic Chart
No Serial Data from Exterior Rear-view Mirrors
Circuit Description
Test Description
Notes on the Diagnostic Chart
No Serial Data – Right-hand Exterior Rear-view Mirror
Circuit Description
Test Description
Notes on the Diagnostic Chart
No Serial Data – Left-hand Exterior Rear-view Mirror
Circuit Description.
Test Description
Notes on the Diagnostic Chart
Mirror Control Switch Inoperative
Circuit Description
Test Description
Notes on the Diagnostic Chart
7 Service Operations – Rear Seat
7.1 Rear Seat 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 Compartment
Rear Seat-back Centre Tray and Armrest Assembly with Compartment
7.2 Rear Seat Cushion Assembly
Remove
Disassemble
Rear Seat Cushion Release Handle
Rear Seat Cushion Frame
Cushion Cover Assembly
Rear Seat Type 1
Rear Seat Type 2 and 5
Rear Seat Type 3 and 6
Rear Seat Type 4
Rear Seat Type 7
Rear Seat Type 8
Reinstall
7.3 Rear Seat-back Head Restraint Assembly Right and Left-hand Side
Remove
Except Rear Seat Type 4 Head Restraint
Rear Seat Type 4 Head Restraint
Reinstall
7.4 Rear Seat-back Assembly
Remove
Head Restraint Sleeve
Remove
Reinstall
Rear Seat-back Cover
Rear Seat Type1
Rear Seat Type 2 and 5
Rear Seat Type 3 and 6
Rear Seat Type 4
Rear Seat Type 7 and 8
Reinstall
7.5 Rear Seat-back Centre Head Restraint Assembly
Remove
Disassemble
Reassemble
Reinstall
7.6 Rear Seat-back Centre Armrest Assembly
Remove
Disassemble Rear Seat Type 1 – 4
Reassemble
Disassemble Rear Seat Type 5 – 8
Rear Seat-back Centre Armrest Hinge
Rear Seat-back Centre Armrest Lid and Cover
Rear Seat-back Centre Armrest Deposit Box, Cover and Cup Holder
Reassemble
Reinstall
7.7 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
7.8 Rear Seat-back Centre Lock Striker
Remove
Reinstall
8 Torque Wrench Specifications
8.1 Front Seat
Level 1 and 3
Level 2, 4 and 5
8.2 Rear Seat