Procedure C - For E65/E66 (7SERIES) Sport Seat Only

1. Removal of seat cover from foam backrest pad.

Completely disconnect the seat cover from all of the metal hooks on the back side of the metal seat frame. Once they are all unhooked, pull the bottom of the seat cover towards the front of the vehicle to provide more slack at the top. Then, while leaving the seat cover attached to the foam pad, lift the seat cover and foam pad together up and over the backrest frame. Once the seat cover and foam pad are removed from the backrest frame, separate the cover from the foam by pushing down to compress the foam and then flip the seat cover forwards, over the top of the foam backrest pad.





2. Fold the top portion of the seat cover (1) forwards, away from the foam backrest pad (2). Mark the following dimensions on the cloth material of the seat cover (1).
A1: approximately 70 mm (from the door side seam to level with the middle of the head restraint hole).
A2: approximately 150 mm (from the upper edge of the cotton fabric).
Note: passenger seat shown for this procedure.





3. Using a seam ripper (1) cut the cloth material open along the marking (dimension A2).





4. Turn the cloth material over to expose the padding.





5. Draw guide lines (1) on the door side approximately 20 mm in from the seams on the padding. Then, using a seam ripper, cut along the guide lines into the fleece padding.





6. Fold down the fleece padding (1).
Note: The fleece padding remains attached at the bottom.





7. Draw a guide line (1) from the center of the head restraint hole across to the door-side seam.

8. Below the guide line (1) made in step 7, draw a second guide line (2) approximately 10 mm below.
A3: approximately 10 mm.





9. Mark dimension A4 from the door-side seam to guide line (3).
A4: approximately 30 mm
Note: When marking the line for dimensions A3 and A5, it is important to make sure the line stays to the outside of the 11 metal strands. The 11 metal strands can be identified by the grayish area located behind the fleece material. Also~ it is important to note that the metal strands may not run at an exact 90 degree angle from the guide line (2).





10. Using a seam ripper, carefully cut open the backrest heating pad along the marking (dimension A4) to expose all 11 metal strands. Widen the cut if necessary.





11. Cut parallel incisions (at a distance of 10 mm) to the left and right of the metal strands. Only cut into the first ply of the heating pad.
A5: approx. 40 mm.
Note: When marking the line for dimensions A3 and A5, it is important to make sure the line stays to the outside of the 11 metal strands. The 11 metal strands can be identified by the grayish area located behind the fleece material. Also, it is important to note that the metal strands may not run at an exact 90 degree angle from the guide line (2).





12. Peel back the first ply of the heating pad to expose the metal strands (1).





13. Carefully pull up on each metal strand (1), using the blunt side of the seam ripper (2), to release them from the fabric threads. Start pulling up on the metal strands near the cut made for dimension A4. Continue until at least 30 mm of each of the metal strands has been released from the fabric threads.
Note:The metal strands remain attached to the fleece near the bottom fold of the first ply.
Be careful not to damage the metal strands when pulling them away from the threads. It may be necessary to cut some of the treads to release the metal strands.





14. Once the 11 metal strands are released from the material, fan out the strands to make them ready to splice with the wire from the repair kit.





15. Strip the wire (1) from the repair kit (copper-colored end) and fan out the strands. Join the copper strands to the 11 metal heating strands and twist them together.





16. Twist the wires together tightly to form one slender splice of both sets of wires.





17. Push the crimp from the kit over the twisted strands with the larger diameter first.





18. Crimp (1) using special tool (2) number 52 0 100. Cut off the protruding strands end of the sleeve.





19. Affix the small fleece adhesive strip (1) (60 mm x 40 mm), from the repair kit over the padding where the cut was made.





20. Using a hot glue gun, apply glue to small fleece adhesive strip (1) and affix crimped strands to the glue. To secure, press a hammer onto glue (2) for at least one minute.
Note: Do not use an excessive amount of glue and be sure to press firmly with the hammer. Failure to do so may result in a bump in the leather when the procedure is completed.





21. Fold up the first ply of the backrest heating pad (1) over the cutout. Affix another small fleece adhesive strip (2) from the kit over the cutout and the backrest heating ply.





22. Turn the fleece padding (1) up and affix using the large fleece adhesive strip (2) from the kit over the top of it. Route the blue wire loosely on the door side of the seat.

Note: It may be necessary to trim the large fleece adhesive strip.

23. Continue to procedure D: For All Seats.