Interior - Front Seat Sagging
501-37DATE 07/00
XK8
MODEL
1997-99 MY
XK8 Range
VIN
001001-036465
Front Seat Cushion - Sagging - Modify Seat
Issue:
An improved front seat design has been introduced in production starting with VIN 036466. The improved frame has additional mounting points at the rear edge for two additional hooks that keep the flexible diaphragm ("Sisiara suspension") taut in the frame. These additional fasteners provide increased support for the diaphragm, to resist sagging of the diaphragm itself and of the foam base and cover which it supports. The length of the cushion is also expanded forwards, to provide increased comfort.
Action:
On a customer complaint basis only, either or both front seats of earlier vehicles may be modified to the later condition.
It is necessary to remove the front seats from the vehicle to allow the cushion trim to be removed. This will provide access to allow drilling of the seat frame. A new flexible diaphragm can then be installed, along with a modified heater pad, foam base and seat cover.
MODIFICATION PROCEDURE
1. With ignition on, adjust the seat fully rearwards. Remove the two front securing screws.
2. Adjust the seat fully forwards. Remove the two rear securing screws.
3. Turn the ignition off. Disconnect the multiplug remove the seat. Place the seat on a workbench.
4. Remove the retaining screws. Remove the plastic covers from the hinge areas on each side of the seal.
5. Release the switch pack and disconnect the multiplug. Remove the retaining screw and remove the switch pack housing. Turn the seat over for access.
6. Remove the retaining nut for the Seat Control Module, disconnect the multiplug, and remove the Seat Control Module.
7. Release the seat harness fir tree fasteners. Noting their locations, and remove all tie straps that retain the seat harness.
8. Disconnect the multiplugs leading to the seat cushion heater pad and the fore/aft motor. Driver's seat only: Disconnect the multiplug leading to the seat belt warning switch.
9. Disconnect the main harness multiplug from the tang on the frame.
10. Remove the four bolts that retain the seat runner to the seat frame. Remove the seat runner assembly (Illustration 1).
11. Remove the pivot screws for the seat squab to the seat cushion frame. Remove the squab assembly.
12. If equipped, remove and discard the foot protection cover from the rear lower face of the seat frame. Pull at the pouch to release the "Velcro" patch from around the tubular frame, then release the support strip from the rear cross rail.
13. Remove the spring-steel D-clips that retain the seat cover material on the frame, near each corner. (See Illustration 2).
14. Use a suitable tool, with a sharp-pointed tip, to release the plastic J-clip strips that retain the cushion cover to the frame (Illustration 3). Work around the frame until all portions of the strips are released.
15. Ease the seat cover material free and remove it from the frame, complete with the seat foam pad. Discard the cover, foam pad and heater assembly.
16. Carefully peel the self-adhesive foam block from the rear of the seat frame. (It will be reinstalled during reassembly - protect the adhesive face).
17. Remove the wire hooks that retain the flexible diaphragm (Illustration 4). Retain the hooks for reuse during reassembly. Discard the diaphragm.
18. Refer to Illustration 5. Mark off and center-punch the locations for 2 holes to be drilled at the positions indicated by the arrows 'A', through the front edge of the seat frame rear cross rail. Drill pilot holes, then enlarge each hole to 5.5 mm diameter. Clear off all burrs from drilling. Treat the exposed metal surfaces with paint.
19. Insert one nylon bush into each drilled hole.
20. Position the replacement flexible diaphragm unit and engage the hooks on the frame, including the two additional hooks at the rear into the two holes drilled at step 18 above.
21. Reinstall the adhesive foam block on the rear edge of the frame.
22. Align and adhere the replacement seat heater pad to the replacement cushion foam.
23. Position the cushion foam to the flexible diaphragm, ensuring that the heater unit cable is correctly located to the underside.
24. Install the switch pack housing on the frame and install the securing screw.
25. Fold up the side panels of the replacement seat cover, to allow alignment of the "Velcro" patches on the cover to the corresponding patches on the cushion foam.
This alignment is critical to the fit of the cover to the frame without unsightly bunching or pleating of the cover material as it is tensioned and clipped to the frame. It may be found necessary to return to this step, separate the "Velcro", realign the cover with the foam and repeat the fitting sequence, following a trial fit operation in steps 26-27 below.
26. Fold down the side panels of the cover, align the cover to the frame and start the installing of the J-clip strips.
27. At all four corners, gently tension and fold the cover material without bunching or pleats until the material can be clipped to the frame, then reinstall the D-spring clips in their original locations.
If the alignment of the cover is off center or the side panels can not be aligned without bunching or pleating (when compared to the other unmodified front seat, return to step 25 above, realign the cover to the foam, and repeat the process to achieve the necessary standard of neatness.
28. Complete the attachment of the J-clip and the D-spring clips once a neat fit of the seat cover has been attained.
29. Where applicable: fit the replacement foot protection cover. With the pouch open, fit the pouch around the frame, then close the pouch, aligning and pressing together the "Velcro" patches to secure the cover in place. Engage the support strip to the rear cross rail of the frame.
30. Reassemble and reconnect all remaining items in the reverse order of disassembly. Install and tighten new tie straps, at the locations noted during disassembly, to secure the electrical harness.
31. Reinstall the seat in the vehicle.
32. If necessary, repeat the above procedure for the opposite front seat from the same vehicle.
Torque wrench settings:
Bolts, seat runner to seat frame 22 - 28 Nm
Pivot bolts, seat squab to seat frame 7 - 10 Nm
Bolts, seat runner to vehicle floor 22 - 28 Nm
Parts Information:
Note that the Quantity required is shown per seat, not per vehicle.
Note:
The Foot Protection Cover is only used on seats equipped with power raise/lower mechanism. Specification varies according to Market. Not used on early production vehicles (VIN 001036 - 006500 approximately) and can NOT be retrofitted to early vehicles that do not have the additional tubular frame below the main rear cross rail, introduced at approximately VIN 006500. Examine vehicle for presence of existing foot protection cover(s). If one or both seat have the foot protection cover, place an order for the later design foot protection cover(s) as required for this rework.
Warranty Information