Page 994 of 1529

SCREENS
REPAIRS 76-4-5
6.From outside of vehicle, use a Kent knife and
carefully cut through sealant to release glass
from body. Any remaining sealant not
accessible with Kent knife can be severed
using cutting wire or knife.
CAUTION: Hold the cutting wire as close to
the glass as possible to prevent damage to
the body and surrounding trim.
7.Remove glass.
CAUTION: Lay glass on felt covered
supports and be careful not to damage the
obscuration band. Do not stand on edge as
this can cause chips which subsequently
develop into cracks.
Refit
1.Carefully remove sealant from body to leave a
smooth surface.
2.With assistance, fit glass without sealant to
body and apply masking tape to establish
reference marks as an alignment aid.
3.Remove glass and place aside.
4.Clean body and sealant face on glass with
solvent.
CAUTION: Do not touch cleaned or primed
surfaces with fingers.5.Apply etch primer to any bare metal on body.
6.Apply glass primer to sealant face on glass and
allow to cure.
7.Apply primer over etch primer on body.
8.Apply activator over old sealant on body.
9.Allow activator to cure.
10.Fit pre-cut nozzle to sealant cartridge, remove
lid, shake out crystals, and fit cartridge to
applicator gun. If necessary modify the nozzle
to achieve required bead section.
11.Apply a continuous bead of sealant to sealant
face on glass as shown.
12.Position glass to body and align to reference
tape.
13.Lightly press glass to ensure correct profile.
14.Secure glass with tape until sealer has cured.
15.Remove protective covers and tape.
16.If applicable, connect coaxial cable to terminal
on glass
17.Test sealer for leaks, apply additional sealer if
necessary. If water is used, allow sealer to dry
before testing. Spray water around glass and
check for leaks. Mark any area that leaks. Dry
glass and sealer then apply additional sealer.
CAUTION: A curing time of 6 hours is
desirable. During this time leave a window
open to ventilate the vehicle interior. If the
vehicle must be used before the curing time
has elapsed, do not drive at speed or slam
the doors with the windows closed.
Page 996 of 1529
SCREENS
REPAIRS 76-4-7
12.Position glass to body and align to reference
tape.
13.Lightly press glass to ensure correct profile.
14.Secure glass with tape until sealer has cured.
15.Remove protective covers and tape.
16.Test sealer for leaks, apply additional sealer if
necessary. If water is used, allow sealer to dry
before testing. Spray water around glass and
check for leaks. Mark any area that leaks. Dry
glass and sealer then apply additional sealer.
CAUTION: A curing time of 6 hours is
desirable. During this time leave a window
open to ventilate the vehicle interior. If the
vehicle must be used before the curing time
has elapsed, do not drive at speed or slam
the doors with the windows closed.
Page 1012 of 1529
SEATS
REPAIRS 76-5-15
REPAIRS
Seat - front
$% 78.10.43.99
Remove
1.Disconnect battery earth lead.
2.Remove 3 screws and 1 trim clip securing
lower trim casing to seat.
3.Remove lower trim casing.
4.Remove cap from front seat belt lower
anchorage bolt.
5.Remove front seat belt lower anchorage bolt. 6.Remove 4 Torx bolts and nut securing front
seat to floor.
7.Lean seat forward to gain access to multiplugs.
Page 1013 of 1529
SEATS
76-5-16 REPAIRS
8.Release pretensioner multiplug from seat
frame and disconnect.
9. Electrically operated seats: Disconnect 2
seat motor multiplugs.
10.Remove front seat.
Refit
1.Fit front seat in vehicle.
2. Electrically operated seats: Connect seat
motor multiplugs.
3.Connect pretensioner multiplug and secure to
seat frame.
4.Fit Torx bolts and nut securing front seat to floor
and tighten to 45 Nm (33 lbf.ft).
5.Fit front seat belt lower anchorage bolt to front
seat and tighten to 32 Nm (24 lbf.ft).
6.Fit cap to lower anchorage bolt.
7.Fit lower trim casing to seat and secure with
screws and trim clip.
8.Connect battery earth lead.
Seat - third row
$% 78.10.45
Remove
1.Manufacture a spring retainer bracket to the
dimensions given above.
2.Position third row seat in deployed position.
3.Remove the cup holder (where applicable).
Page 1014 of 1529

SEATS
REPAIRS 76-5-17
4.Remove saddle bracket cover from lower rear
quarter to allow access to third row seat
securing bolts and nuts.
5.Remove top 2 bolts securing seat to lower rear
quarter panel.
6.Position the locally manufactured retainer
bracket across the seat mounting. Ensure that
the lugs on the end of the retainer fit below the
seat mounting bar, then partially fold the seat
so that the retainer bracket is held in position.
7.Remove lower 2 nuts securing seat to lower
rear quarter panel. The action of the spring will
now hold the retainer bracket in place.
8.Remove seat.Refit
1.Ensuring that the retainer bracket is in position
on the spring, position third row seat to its
mounting studs.
2.Fit nuts securing third row seat to lower rear
quarter panel and tighten to 22 Nm (16 lbf.ft).
3.Remove the retainer bracket, fit bolts securing
third row seat to lower rear quarter panel and
tighten to 22 Nm (16 lbf.ft).
4.Fit saddle bracket cover to third row seat
securing bolts, fit the cup holder (where
applicable) and stow the seat.
Page 1015 of 1529
SEATS
76-5-18 REPAIRS
Seat - rear
$% 78.10.48.99
This procedure is applicable to both rear seats.
Remove
1.Carefully pull carpet away from the rear seat
base to gain access to mounting brackets.
2.Remove 2 Torx bolts securing front of mounting
brackets to floor.
3.Fold rear seats fully forward.
4.Remove the 2 Torx bolts securing rear of
mounting brackets to floor.
5.Remove rear seat. Refit
1.Position rear seat to floor in the fully folded
position. Fit Torx screws to rear of mounting
brackets and tighten to 45 Nm (33 lbf.ft).
2.Position rear seat in upright position. Fit Torx
bolts to front of mounting brackets and tighten
to 45 Nm (33 lbf.ft).
3.Position front carpet.
Page 1016 of 1529

SEATS
REPAIRS 76-5-19
Bolster assembly - rear armrest
$% 78.20.02
Remove
1.Raise rear seat centre headrest, release clips
securing headrest and remove.
2.Lower armrest and carefully release 2 upper
clips securing armrest bolster bars to seat
frame.
3.Release bolster bars from seat frame and raise
armrest to closed position.
4.Firmly grasp the armrest and bolster assembly,
using considerable force withdraw armrest
bolster assembly from seat frame pivots.
NOTE: During removal it is likely that one or
both armrest pivots will break.
5.Remove broken lower armrest pivots. NOTE:
Care must be used to ensure seat frame is not
distorted during pivot removal.Refit
1.Fit and secure new armrest bolster pivots to
seat frame.
2.Fit new armrest and bolster assembly to lower
pivots, align and push fully home to lock.
3.Position bolster armrest assembly vertically,
align bars, fit and secure bolster bars to upper
seat frame clips.
4.Check operation of armrest assembly.
5.Fit and secure rear seat centre headrest.
Page 1017 of 1529

SEATS
76-5-20 REPAIRS
Cover - cushion - front seat
$% 78.30.01/81
Remove
1.Remove front seat.
+ SEATS, REPAIRS, Seat - front.
2.Place seat on a suitable work bench.
3.Remove 2 screws securing outer edge trim
casing to seat frame.
4.Remove trim casing.
5.Release inner edge trim casing from seat
frame.
6.Remove trim casing.
7.Position seat upside down on table.
8.Release clip securing front edge of cushion
cover to seat frame.
9.Release clips securing side edges of cushion
cover to seat frame. 10.Release clip securing lower edge of squab
cover to seat frame.
11.Remove 2 end clips securing rear edge of
cushion cover to seat frame.
12.Release main central clip securing rear edge of
cushion cover to seat frame.
13. Models with seat heaters: Disconnect seat
heater multiplug.
14.Release bonded rear edge of cushion from
seat frame.
15.Remove seat cushion and cover assembly.
16.Release outer edges of cover from cushion to
gain access to hog rings.
17.Remove 12 hog rings securing cover to
cushion.
18.Remove cover.