Body (Interior and Exterior) GENERAL ‘SPECIFICATIONS SPECIAL TOOLS TROUBLESHOOTING EXTERIOR HOOD REPLACEMENT ADJUSTMENT TAIL GATE REPLACEMENT ADJUSTMENT FRONT 000R ‘COMPONENTS REMOVAL AND INSTALLATION REPLACEMENT ADJUSTMENT REAR DOOR ‘COMPONENTS REMOVAL AND INSTALLATION REPLACEMENT ADJUSTMENT BODY SIDE MOLDINGS REPLACEMENT SUN ROOF COMPONENTS ON-VEHICLE INSPECTION REPLACEMENT ADJUSTMENT MIRROR COMPONENTS LACEMENT, aD-2 BD-4 80-6 INTERIOR CONSOLE COMPONENTS REPLACEMENT CRASH PAD ‘COMPONENTS. REPLACEMENT NTERIOR TRIM REPLACEMENT WINDSHIELD GLASS. ‘COMPONENTS. REPLACEMENT QUARTER GLASS REPLACEMENT BUMPER FRONT BUMPER REPLACEMENT REAR BUMPER REPLACEMENT SEAT FRONT SEAT COMPONENTS. REPLACEMENT REAR SEAT ‘COMPONENTS REPLACEMENT REAR SEAT BELT ‘COMPONENTS. REPLACEMENT BD -58 BD 59 0-61 ‘BD -62 80-69 0-72 0-73 0-77 BD -80 0-82 20-83 BD -84 80-81 0-92 BD -99 BD-100BD -2 BODY (INTERIOR AND EXTERIOR) GENERAL SPECIFICATIONS | escuse HOOD + Type Rear hinged, front opening type FRONT DOOR + Construction + Regulator system + Locking system Front hinged, full door construction X-arm type Pincfork system REAR DOOR * Construction + Regulator system + Locking system Front hinged, full door construction X-arm type Pineork system TAILGATE + Type Inner hinged, Gas iter GLASS THICKNESS mm (in) + Windshield glass + Front window glass + Rear fixed glass + Rear window glass Laminated dlear, tinted 5 (0.20) 3.2 (0.13) 35 (0.15) 3.2 (0.13) ‘SEAT BELTS + Type 3 point type with E.L.R (Emergency locking retractor)GENERAL BD-3 TIGHTENING TORQUE toms Nm kgfem Wort Front and rear doors * Door hinge to body 34 ~ 42 340 ~ 420, + Door hinge to door 13-26 130 ~ 260, + Glass mounting bolt a~12 80 ~ 120 + Door latch mounting serew 7-11 70 ~ 110 + Outside handle mounting bolt 7-11 70 ~ 110 + Door striker mounting bolt 17-22 170 ~ 220, + Door checker to door mH 70 ~ 110 Tailgate * Tailgate hinge to body 7-9 70 ~ 90 5-65 + Tailgate hinge to trunk tid 7~9 70 ~ 90 5-65 + Tailgate latch mounting bolt r1 70 ~ 110 5-8 + Tailgate straker mounting bott 711 70 ~ 110 5-8 + Key oylinder mounting 1 7-14 70 ~ 110 5-8 Hood *+ Hood hinge to body 22-27 220 ~ 270 + Hood hinge to hood 22~27 220 ~ 270 + Hood latch to body 741 70 ~ 140 5~8.0 ‘Seat + Front seat to floor bolt and nut 44 ~ 66 440 ~ 460 33-47 + Rear seat back titing bracket 17 ~ 26 470 ~ 260 12-19 + Rear seat cushion mounting bolts 17-26 170 ~ 260 12-19 ‘Seat belt + Front seat belt buckle 450 ~ 550 33 ~ 40 + Front seat belt upper anchor 450 ~ 550 33 ~ 40 + Front seat belt retractor to center pillar 450 ~ 550 33 ~ 40 + Front seat belt height adjuster 450 ~ 550 33 ~ 40 + Rear seat belt anchor attaching bolt 450 ~ 550 33 ~ 40 + Rear seat belt retractor mounting bolt 450 ~ 550 33 ~ 40BD 4 BODY (INTERIOR AND EXTERIOR) SPECIAL TOOLS esuces Tool (Number and name) Mustration Use (09793-21000 oor hinge adjusting wrench ‘Adjustment, removal and installation of the door hinge (09800-27000 ‘Ornament remover Trim removal (09859-31000 Headliner clip remover ——— Removal of the headliner clips (09861-31100 Sealant cut-out tool ‘Guiting the sealant of the windshield (use with 09861-31200) (09861-31200 Sealant cutting blade ‘Guiting the sealant of the windshield (use with 09861-31700) (09861-31300 Sealant gun ‘Application of the sealant to the windshieldGENERAL BD-5 Tool (Number and name) lustration Use (09867-37400 Removal and installation of the windshield Glass holder (09861-31000 Removal of the windshield moulding Windshield moulding remover (09880-4F000 Hogring alip installer Ss eS Installation of the hogring clipBD -6 BODY (INTERIOR AND EXTERIOR) TROUBLESHOOTING | csrercos ‘Symptom Suspect Area Remedy (See page) Water leaks from sunroof Dirt accumulated in drain tube Clear dirt inside of drain Clogged drain tube Blow alr into drain to remove dirt Broken or dislocated drain tube, defective cor cracked clip (Check tube installation and flange contact Deteriorated roof lid weatherstrip Replace Excessive roof lid-to-body clearance and improperly fited weatherstrip “Adjust Wind noise around sunroof Loose or deformed deflector, gaps in body work Retighten adjust or replace ‘Sunroof id makes a noise When moved Foreign particles lodged in guide rail (Check drive cable and guide rails for foreign particles Loose guide rails and lid Retighten ‘Motor runs but sunroof does not move or moves only partially Foreign parlides lodged in guide rall (Check drive cable and guide rails for foreign particles Incorrect engagement of motor pinion with drive cable (Check for loose motor installation and damaged pinion Decrease in motors clutch slipping force Adjust Increased sunroof sliding resistance or interference of sunroof with drive cables, weatherstrip, etc. due to maladjustment of sunroof ‘Adjust or replace Noise in motor (ehiteh slipping noise from motor when sunroof is fully opened or closed is not an unusual noise.) Incorrect engagement of motor pinion with drive cable (Check pinion instalation and Fetighten motor ‘Worn out or damaged motor pinion bearing Replace motor assembly Worn out or deformed drive cable Replace Door glass fails to operate up and down Incorrect window glass installation ‘Adjust position (see page BD- 33) Damaged or faulty regulator arm or regulator Correct or replace (see page BD- 27) Door does not open or close completely Incorrect door installation ‘Adjust position (see page BD- 33) Defective door check assembly Correct or replace Door hinge requires grease ‘Apply grease Hood does not open or close completely Striker and latch not properly aligned ‘Adjust (see page BD- 12) Incorrectly installed hood ‘Adjust (see page BD- 12) Incorrect hood bumper height ‘Adjust (see page BD- 12) Water leak through windshield and rear window Defective seal Fill with sealant Defective flange CorrectGENERAL BD-7 ‘Symptom Suspect Area Remedy (See page) Wind noise around door Weatherstrip not holding firmly ‘Adjust fit or door (see page BD- 33) Improperly installed weatherstrip Repair or replace (see page 8D- 27) Improperly closed door Adjust (see page 8D- 33) Improperly fit door ‘Adjust (688 page 8D- 33) Improperly clearance between door glass and division channel ‘Adjust (see page BD- 33) Deformed door Repair or replaceBD -8 BODY (INTERIOR AND EXTERIOR) EXTERIOR = When removing the clips, use a clip remover. 1. Disconnect the windshield washer nozzle connecting HOOD tube (A). 2. After loosening the hood hinge (B) mounting bolts, REPLACEMENT | cxsazios remove the hood (C). HOOD REPLACEMENT 3. Installation Is the reverse of removal [Ginore [Cinore = When removing and installing the hood, an as- = Make sure the hood opens properly and locks sistant is necessary. securely + Take care not to damage the hood and body. + Adjust the hood alignment (See page BD- 12). > :Bot eatin, Cipla, 4 6xt.25mm, 22-27Nm (220-270 kgtem| Yerta.s oth)EXTERIOR HOOD INSULATOR REPLACEMENT 2. Remove the hood latch (A) mounting bolts. 41. Usinga clip remover, detach the lps, and remove the hood insulator (A). [Dore Take care not to scratch the hood panel. 2. Installation is the reverse of removal. (Winore 3. Disconnectthe hood latch cable (B) and release cable Replace any damaged clips © HOOD LATCH REPLACEMENT 4. Installation is the reverse of removal. 1. Remove the hood cover (A). Nore + Make sure the hood latch cable is connected properly + Make sure the hood locks securely.BD -10 BODY (INTERIOR AND EXTERIOR) HOOD RELEASE CABLE REPLACEMENT 1. Remove the following items: + Hood release handle (see page BD- 10) + Wheel guard (see page 8D- 45) 2. Using a clip remover, detach the clips from the body, then disconnect the hood latch cable (A) and release cable (8), [Gore Take care not to bend the cable AL 3, Installation is the reverse of removal [Gore + Moke sure the hood latch cable Is connected propery = Replace any demaged cps HOOD RELEASE HANDLE REPLACEMENT 1, Remove the screws, then remove the hood release handle (A). 2. Disconnect the hood latch cable (8) from the hood release handle. Take care not to bend the cable, 3 Instatation ste reverse of removal (Gore + Make sure the hood latch cable is connected property. = Make sure the hood opens property.EXTERIOR BD -11 HOOD SEAL WEATHERSTRIP REPLACEMENT 4. Detach the clips, then remove the hood weathersrip (A). Take care not to scratch the hood 2. Installation Is the reverse of removal [Dore Replace any damaged clips.BD -12 BODY (INTERIOR AND EXTERIOR) ADJUSTMENT exons ADJUST HOOD 41. After loosening the hood hinge (A) mounting bolt, ad- Just the hood (B) by moving it up oF down, oF right or left 2 3 ‘Adjust the hood height by turning the hood overslam bumpers (C). ‘After loosening the hood latch (D) mounting bolts, ad- just the hood latch by moving it up or down, or right or leftEXTERIOR TAIL GATE REPLACEMENT | essuco TAILGATE TRIM REPLACEMENT [Dore = When removing and installing the trunk tid, an assistant is necessary. + Wear gloves to protect hands from injury. Open the tailgate glass ‘After loosening the screws the remove the tailgate trim (A), Remove the upper trim(B) and side trim(C). Installation is the reverse of removal, (Ujnore Replace and damaged clips. > : Screw location, 4] E> : Clip feationBD -14 BODY (INTERIOR AND EXTERIOR) TAILGATE GLASS REPLACEMENT [Dore When prying with a flatsip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage. Take care not to scratch the surface the tailgate glass. Wear gloves to protect hands from injury. Remove the fallowing items. = Rear wiper assembly [A(See page BE- "Rear wiper* Tailgate liter (B(See page 8D- 18) High stop lamp [C(See page BE- "High stop tamo* After loosening the mounting bolts remove the tailgate glass (0). P :Bolt locaton, 2 oEXTERIOR TAILGATE LATCH REPLACEMENT ACTUATOR ASSEMBLY 1. Remove the tallgate trim (See page BD- 13) 1. Remove the tailgate trim (See page BD- 13) 2. Disconnect the outside handle rod (A) and actuator 2. Disconnect the outside handle rod (A), actuator rod rod (8). {B), glass latch rod (C), key cylinder rod (D) and con- nector. 3. Aller loosening the mounting bolt and nuts, then re- move the actuator assembly (E). 3. Loosen the latch mounting bolts and disconnect the connector (A). 4, Remove the tailgate latch (8). » :eatocatn.3 eae, 4. Instalation is the reverse of removal Daft cren| ee [rere Make sure the connector Is connected properly 4nd the connecting rod is connected property. + Make sure the tailgate opens properly and locks securely. 5. Installation is the reverse of removal [nore - Make sure the connector is connected properly and the connecting rd fs connected proper. «Make sure the faite opens properly and locks secure.BD -16 BODY (INTERIOR AND EXTERIOR) TAILGATE GLASS LATCH REPLACEMENT KEY HOLDER REPLACEMENT 4. Remove the tailgate trim (See page 8D: 13. 1. Remove the tailgate trim (See page BD: 13). 2. Disconnect the talgate glass latch rod (A). 2. Remove the taligate garnish (See page BD- 45) 3. AMler loosening the mounting boks, disconnect the 3 pisconnect the key rod (A) and connector. connector (B). 4. Remove the tailgate glass laten(C). 4, Remove the key holder (8) > ect iste sinian C= fren oe 5. Instaation isthe reverse of removal 5. Insallation isthe reverse of removal [Gore [Gnore Make sure the tailgate glass opens properly and locks Make sure the tailgate glass opens property and locks securely. securely.EXTERIOR BD-17 GLASS WEATHERSTRIP REPLACEMENT ‘TAILGATE WEATHERSTRIP REPLACEMENT 1. Afterdisconnecting the tailgate liter, removetheglass 1. weatherstrip (A). Remove the tailgate weatherstrip (A). 2, Installation is the reverse of removal. 2. Installation is the reverse of removalBD -18 BODY (INTERIOR AND EXTERIOR) OUTSIDE HANDLE REPLACEMENT 1. Remove the tailgate trim (See page BD- 13). 2. Disconnect the outside handle rod (A) and latch rod ©). 3. Loosen the inside handle (C) mounting bott. LIFTER REPLACEMENT 4. Using a screwdriver (A), lit up slightly the socket clips (8) of both ends on the liter (C), and then remove the liter from the bracket (D). 2. Push the socket ofthe lifer into the bracket for instal= lation, 4, Installation is the reverse of removal [Daore ‘Make sure the tailgate glass opens properly and locks securely,EXTERIOR BD -19 PULL HANDLE REPLACEMENT Push down the hook (A) on the upper part ofthe pull han= dle (B) by using the screwdriver or the remover.BD -20 BODY (INTERIOR AND EXTERIOR) FUEL FILLER DOOR RELEASE CABLE = Center pillar lower trim (see page 8D- 68). REPLACEMENT = Luggage trim, left side (see page BD- 70), 41. Remove the following items. 2. Disconnect the fuel fller door release cable from the - Front seat (See page BD- 84) + Rear seat (See page 8D- 92). + Front door scuff trim LH (See page BD- 69). + Rear door scuff trim LH (See page BD- 69), release handle (A). Fastener Locations > :Glip, 3 3, Remove the release cable (B) from the clip, and dis connect the fuel filler door catch (C), then remove the {uel filler door cable from the vehicle,EXTERIOR BD -21 FUEL FILL DOOR REPLACEMENT 1. Loosen the bolts, then remove the fuel filer door (A). > :Bot cation, 2 2. Installation is the reverse of removal [Dore ‘Make sure the fuel fil door opens properly and locks securely. 3. Check that the fuel fil door (A) fits flush against the body. If necessary, adjust it RELEASE HANDLE REPLACEMENT 1. Remove the front door scuff trim and center pillar lower trim (See page BD- 69), 2. Loosen the release handle (A), mounting bot Disconnect the release cable (B), then remove the release handle, > : Bol location, 3. Installation is the reverse of removal. (Gywore = Make sure the release cable is connected prop- erly = Make sure the fel filer doortrank id open prop- ony.BD -22 BODY (INTERIOR AND EXTERIOR) ADJUSTMENT swscsss ‘Adjust the tailgate fit by turing the tailgate over slam bumper (8) and side bumper (C) 41. Adjust the tailgate alignment. + Adjust the striker (0) by moving itup or down, or After loosening the tailgate hinge (A) mounting right or left bolt, adjust the tailgate by moving it up or down, or right or lef. 2. Tighten each bolt securely. 3, Make sure the trunk lid opers and locks securely.EXTERIOR BD -23 FRONT DOOR COMPONENTS | sssous: Door panel \ Door weather strip Door belt weather strip \ ‘Quadrant inner cover ax~ Il on \\} \ Door checker Door hingeBD -24 BODY (INTERIOR AND EXTERIOR) lass molding _—Key cylinder > (Outside handle assembly oor maduleEXTERIOR BD -25 REMOVAL AND INSTALLATION | cocossre: 3. Loosen the door trim (A) mounting screws. Release the lps that hold the door then romove he door FRONT DOOR TRIM ttm by pling upward. Dsconnes the power wie dow such connector (8), power mor connector C) [Dwore Sa door courtesy lamp connector (0) «Take care notte scratch the der tim and other ports Fanta Lsatens 2. Remove the inside handle cover (A), = Patton gloves to protec your hands. teiscome amssew, [D>:cin.5 1. remove thequetantnnercowr see pogeso-sn, > | Om | |i +) 4, Remove the door trim seal 5. Installation is the reverse of removal. NOTE sono = Make sure the connectors is plugged in properly ‘and each rod is connected securely, = Make sure the door locks and opens properly.BD -26 BODY (INTERIOR AND EXTERIOR) REPLACEMENT cosas REAR CHANNEL REPLACEMENT GLASS REPLACEMENT 1. Remove the door rim (see page BD- 25). [nore 2. Remove the glass (see page BD- 26). Put on gloves to protect your hands. 1. Remove the door trim (see page BD- 25). 2. Carefully move the glass (A) until you can see the bolts, then loosen them. Separate the glass from the glass run and carefully pull the glass out through the window slot (B). Ascamon Take care not to drop the glass and scratch the glass surface. > :Battlocation,2 OER] / 3. Installation is the reverse of removal + Roll the glass up and down to see if it moves freely without binding + Make sure that there is no clearance between the glass and glass run channel when the glass is closed + Adjustthe position of the glass as necessary (see page 8D- 32), 3, Loosen the rear channel mounting nuts. 4, After disconnecting the glass molding, remove the rear channel (A). 5. Installation is the reverse of removalEXTERIOR POWER WINDOW MOTOR REPLACEMENT DOOR MODULE REPLACEMENT 4. Remove the door trim (see page BD- 25). [Djnore 2. After disconnecting the connector (A), remove the Put on gloves to protect your hands, power window motor (B). 1. Remove the front door trim (See page BD- 25). 2. Remove the glass (see page BD- 26), 3. Disconnect the wiring harness (A). 3, Installation is the reverse of removal. [Gwore cw Roll the glass up and down to see it it moves freely without binding. 4. Disconnect the lock rod (A) and outside handle rod (8).BD -28 BODY (INTERIOR AND EXTERIOR) 5. Remove the door module (C). Fern e aw sscoms | 2 Nt 9 teh 25mm, ech 25m, oti sei Bape harem] ED slaren 6, Installation is the reverse or removal [Winore - Make sure the connectors is plugged in properly and each cable is connected securely. - Make sure the door locks and opens property. = Roll the glass and down to see if it moves freely without binding. OUTSIDE HANDLE REPLACEMENT [Gwore Puton gloves to protect your hands Remove the following parts. + Door trim (See page BD- 25). + Glass trim (See page BD- 26). + Rear channel (See page BD- 26) Disconnect the outside handle rod (A) and lock rod 8) ‘After removing the outside handle mouting bolt, re- move the outside handle base (C) and key cylinder.EXTERIOR BD -29 4, Afterremoving the key cylinder (A) and outside handle base (B), remove the outside handle lever (C), 5, Installation is the reverse of removal = Make sure the connector is plugged in properly and each rod Is connected securely. ~ Make sure the door locks and opens properly SPEAKER REPLACEMENT 1. Remove the door trim (See page BD- 25) 2. Disconnect the speaker connector (A), and remove the speaker (8), cow location 4 3. Installation is the reverse of removal.BD -30 INSIDE HANDLE REPLACEMENT DOOR BELT WEATHERSTRIP REPLACEMENT 1. Remove the front door trim (See page 8D- 25). 1. Remove the front door trim (See page BD- 25). 2. Loosen the inside handle (A) mounting screw. 2. Release the hooks (A), and then remove the door belt Push the inside handle forward to disconnect from the Weatherstrip (8), door module. Ss 3. Disconnect the lock cable and (A) inside handle con- rnect cable (8). 3. Installation is the reverse of removal 4, Installation is the reverse of removal [Gore Make sure the door lock end opene roped.EXTERIOR GLASS RUN CHANNEL REPLACEMENT DOOR WEATHERSTRIP REPLACEMENT 4, Remove the front door trim (See page BD- 25). 1. Release the clips then remove the door weatherstrip a). 2. Remove the glass (see page BD- 26). 3, Remove the glass un channel (A) from the lower part 2. Installation is the reverse of removal. 4, Installation Is the reverse of removal.BD -32 BODY (INTERIOR AND EXTERIOR) ADJUSTMENT | crocs GLASS ADJUSTMENT [Gore (Check the glass run channel for damage or deteriora- tion, and replace them if necessary. 41. Remove the following parts: + Quadrant cover (See page BD- 57) + Door trim (See page BD- 25) 2. Carefully move the glass (A) until you can see the glass mounting bolts (8), then loosen them. Push the glass (A) against the channel (C), then tighten the glass mounting bolts. Check that the glass moves smoothly. Raise the glass fully, and check for gaps. Check that the glass contacts the glass run channel evenly. Check for water leaks, Run water over the roof and ‘on the sealing area as shown, and nate these items: = Use a 12mm (1/2in,)diameter hose (A = Adjust the rate of water flow as shown (B). = Donot use a nozzle, = Hold the hose about 300mm (12in.) away from the door (C). 120m (047 in) 05 m(t8in)EXTERIOR BD -33, DOOR POSITION ADJUSTMENT 3. Check that the door and body edges are parallel [Dore Aor stating the door, check for @ fh wth the ts ten check for equa! gaps between the font rear and bottom, door edges and th bod heck thatthe dor and body edges are poral Bere asin replace the mounting Bote 1. Place the vehicle on a firm, level surface when adjust- ing the doors. 2. Adjust at the hinges(A): + Loosen the door mounting botts(8) slightly, and ‘move the door |N or OUT until it aligns flush with the body. + Loosen the hinge mounting bolts(C) slightly, ang move the door BACKWARD or FORWARD, UP or DOWN as necessary to equalize the gaps. + Place a shop towel(D) on the jack(E) to prevent damage to the door when adjusting the door. Sten jfis-26nm \ 10-19 Ib) S 24.5~30 bt) | | ” jep > | 4. Grease the pivot portions of the hinges indicated by the arrows. | (130-260 kgtom, 5. Check for water leaks (See page BD- 32)BD -34 BODY (INTERIOR AND EXTERIOR) DOOR STRIKER ADJUSTMENT Make sure the door latches securely without slamming it. If necessary, adjust the striker (A): The striker nuts are fixed, ‘The striker can be fine adjusted up or down, and in or out 1. Loosen the screws (B), then insert a shop towel be- tween the body and striker. 47-22Nm (170-220 kgem, 12-16 nt) 2. Lightly tighten the screws. 3, Wrap the striker with a shop towel, then adjust the striker by tapping it with a plastic hammer. Do not tap the striker too hard. 4, Loosen the screws and remove the shop towel. 5, Lightly tighten the screws, 6. Hold the outer handle out, and push the door against the body to be sure the striker allows a fush fit. Ifthe door latches propery, tighten the screws and recheck.EXTERIOR BD -35 REAR DOOR COMPONENTS ccxcme Door panel Stker Door batt weathersiip Door weatherstip oor belt weatherstrip / Retainer a Speaker Door hinge Door trim seal Door trimBD -36 BODY (INTERIOR AND EXTERIOR) Glass molding Outside handle assembly Power window motor | Inside hanete cable Insige nanceEXTERIOR BD -37 REMOVAL AND INSTALLATION REMOVE REAR DOOR TRIM [Wore + Take care not to scratch the door trim and other parts. = Put on gloves to protect your hands. 4. Remove the inside handle cover (A). 2. Loosen the door trim (A) mounting screws. Release the clips that hold the door trim, then remove the door trim by pulling it upward, Disconnect the power win= dow switch connector (8). Fastener Locations “> lo | i 3. Remove the door trim seal 4, Installation is the reverse of removal, make sure the connectors and courtesy ight bulb socket are plugged in propertyBD -38 BODY (INTERIOR AND EXTERIOR) REPLACEMENT | cc:sssw 3. Carefully move the glass (A) until you can see the bolts, then loosen them. Carefully pull the glass out GLASS AND QUARTER GLASS REPLACEMENT through the window slot (3) [Ginore cauTiON Put in gloves to protect your hands. Take care not to drop the glass and scratch the 4. Remove the door trim (See page BD- 37). glass surface. 2. _Alterdisconnecting the glass run (A) and weatherstrip (6), then remove the delta molding (C). Fastener Locations 4, Installation is the reverse of removal + Roll the glass up and down to see if it moves freely without binding + Make sure that there is no clearance between the glass and glass run channel when the glass 's closed = Adjust the postion of the glass as necessary (See page 8D- 43).EXTERIOR REAR CHANNEL REPLACEMENT 1. Remove the rear door trim (See page BD- 37). 2. Remove the glass (See page BD- 38). 3, After removing the rear channel mounting bolt and hut, remove the rear channel (A). Fastener Locations ON 4 ©) fe iron| D> eee ‘4, Installation Is the reverse of removal. POWER WINDOW MOTOR REPLACEMENT 1. Remove the rear door rim (See page BD- 37). 2. Disconnect the power window motor connector (A). 3. After loosening the mounting nut, remove the power ‘window motor (8). 4, Installation is the reverse of removal. Gore ‘Make sure that there is no clearance between the glass and glass run channel when the glass is closed. - Adjust the position of the glass as necessary (See page BD- 43)BD -40 REAR DOOR MODULE REPLACEMENT OUTSIDE HANDLE REPLACEMENT 1. Remove the door trim (See page BD- 37). [Gaore 2. Remove the glass (See page BD- 38). Put on gloves to protect your hands. 3, Remove the rear channel (See page BD- 38). 1. Remove the door trim (See page BD- 37). 4, Dsconnectt 2. Remove the glass (see page 8D- 38). power window motor connector (A), speaker connectar (B) and actulator connector (C). 3, Detach the harness clip. Remove the rear door module (see page BD- 40). 4, Remove the outside handle base (A). > Bot locations, 2 i Co) CH Fy 5, Remove the door module assembly (A). Tee a feiSomes /2ot 5. Remove the outside hand lever (A) and cover (8). DOP Prasom| Er | pe ratem| i i fi Mh ey 6. Installation is the reverse of removal 6, Installation is the reverse of removal [Gore ‘Make sure the door locks and opens properly. ‘Make sure the door locks and opens properly.EXTERIOR BD -41 REAR DOOR LATCH REPLACEMENT SPEAKER REPLACEMENT 1. Remove the rear door module (See page BD- 40). 1. Remove the rear door trim (See page BD- 37). 2. Remove the latch cover, then disconnect the lock ca- 2. After disconnecting the speaker connector (A), re- ble (A) and inside handle cable (B). move the speaker (B) 3, Remove the rear door latch (C). 3. Installation is the reverse of removal. ‘ 4, Installation Is the reverse or removalBD -42 INSIDE HANDLE REPLACEMENT DOOR BELT WEATHERSTRIP REPLACEMENT 1. Remove the front door trim (See page 80-37). 1. Remove the front door trim (See page BD- 37). 2. Loosen the inside handle (A) mounting screw. 2. Release the hooks (A), and then remove the door belt Push the inside handle forward to disconnect from the Weatherstrip (8), door module. Ss 3. Disconnect the lock cable (A) and inside handle can- rnect cable (8). 3. Installation is the reverse of removal 4, Installation is the reverse of removal. [Gore Make sure the door lock end opene roped.EXTERIOR BD -43, ADJUSTMENT | ésrsisca 6. Check for water. Run water over the roof and on the Seaing area as shown, and note these tems GLASS ADJUSTMENT rnlsea 12mm (tin) dameter hese (9) 1 Agjustine rat of water ow as shown (3). [Dnore 2 Donat use a nose + Hold the hose about 300mm(12in.) away from the door (C). Check the weatherstrips and glass run channel for damage or deterioration, and replace them if neces- sary. 4. Remove the door trim (See page BD- 37) 2. Carefully move the glass (A) until you can see the glass mounting bolts (8). then loosen them. DOOR POSITION AND STRIKER ADJUSTMENT ‘Adjust the door posttion and striker (See page BD- 34). 3. Push the glass against the center channel, then tighten the glass mounting bolts, 4, Check that the glass moves smoothly. 5. Raise the glass fully, and check for gaps. Cheok that the glass contacts the glass run channel evenly.BD 44 BODY (INTERIOR AND EXTERIOR) BODY SIDE MOLDINGS FRONT MUD GUARD AND WHEEL GUARD REPLACEMENT REPLACEMENT ae [Glaore ROOF RACK REPLACEMENT + When prying with a flat screwdriver, wrap it with protective tape, and apply protective tape [Winore around the related parts, to prevent damage + Puton gloves to protect your hands. When prying with a fatstip screwdriver, wrap it + Take care not to scratch the body surface. with protective tape, and apply protective tape around the related parts, o prevent damage. 4. Remove the mud guard (A). = Puton gloves fo protect your hands = Take care not to scratch the body surface. 2. Remove the wheel guard (8), 41. Remove the roof rack cover (A). Installation is the reverse of removal. Fastener Locations “= | | 2. Remove the roof rack (B). sone 3, Installation is the reverse of removalEXTERIOR BD -45 REAR MUD GUARD AND WHEEL GUARD TAILGATE GARNISH REPLACEMENT REPLACEMENT [Wore + When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage. 3. Remove the tailgate garnish (A). + Put on gloves to protect your hands. + Take care not to scratch the body surface. 1. Remove the tailgate trim (See page BD- 13). 2. Remove the key cylinder (See page SD: 16). Installation is the reverse of removal 4. Remove the mud guard (A). 2. Remove the wheel guard (8) Nutocations, 11 ‘x1.omm 04-0.8kgtim Installation is the reverse of removal RADIATOR GRILLE REPLACEMENT 4. Open the hood. 2. Remove the radiator grille (A) 3. _ Installation is the reverse of removal. fe “Nut locatons, 8 6x1.25mm 04-0.8kgtmBD 46 BODY (INTERIOR AND EXTERIOR) SIDE GARNISH AND SIDE SILL REPLACEMENT [Ginore = Wrap the blado of a putty knife or flat tp serew= driver with protective tape to prevent damage to the door. = Be careful not to pry too far or you may bend the garnish, = Puton gloves to protect your hands. 1 Prepare to remove the garnish from inside the vehicle. + Remove screws fraim the front and rear door panel (See page BD- 25, 37). Remove the clips and screws and gently pry the side garnish (A) or side sill (8) away from the door while removing the adhesive tape, Fastener Locations pe :Screw [E> Clip ‘Installation point 3, Installation is the reverse of removal Replace any damaged alips achesive tape.BD 48 BODY (INTERIOR AND EXTERIOR) ON-VEHICLE INSPECTION. sason 4, The roof panel (A) should be even with the glass (8) weatherstrip (C), to within the standard value "E” all INSPECT SUNROOF GLASS ALIGNMENT the way around. ifnot, make the following adjustment. 41. Start the engine and check the operating time of the “Standard value "© sunroof (A) Front edge: 0 ~ 1.4mm Rear edge: 1.0 ~ 7.4mm (Operating time: Approx. 5 secs. 5. If the position is not as specified, lightly loosen the 2. Check for abnormal noise or binding during operation. Glass ecusting screw (A) to adjust te Glass height, 3, With the suntoof fully closed, check for water leakage, and tighten it Tightening torque: 2 ~ 4Nm (20 ~ 40kgf-cm, 1.5 ~ 2.9 Ibfft)EXTERIOR BD ~49 6. Check for overtap between the sunroof weatherstrip (A) and the roof panel (B). Standard value: 1.1mm aT REPLACEMENT [Chnore Put on gloves to protect your hands. GLASS REPLACEMENT 1. Close the glass fully and slide the sunshade all the way back, 2. Remove both decoration covers (A).BD -50 BODY (INTERIOR AND EXTERIOR) 3. Remove the glass (A) by iting it up. [Gaore Do not damage the roof panel. 4, Installation is the reverse of removal, and adjust the glass height alignment. Check for water leaks. Do not use high-pressure water. MOTOR AND CONTROLLER REPLACEMENT Remove the over head console (See page BD- 71). Disconnect the motor connector (A), remove the screws and then remove the motor (B). Installation is the reverse of removal.EXTERIOR DEFLECTOR REPLACEMENT 4. Open the glass fully. 2. Disconnect the deflector link (A) from the frame (8), and then remove the deflector (C). 3, Installation Is the reverse of removalBD -52 BODY (INTERIOR AND EXTERIOR) SUNROOF ASSEMBLY REPLACEMENT 3. After loosening the mounting bolts and nuts, remove the sunroof assembly (8). 1. Remove the follows parts. + Frontand rear door scuff trim (See page BD- 69). {Front cotter andrea par in Grote (See page BD- 69) Take care not fo scratch the Interior trims and other + Headlining (See page 8D- 71), parts. ~ Sunroof glass (See page BD: 49) 4, Installation isthe revers of removal 2. Disconnect the drain tubes (A).EXTERIOR SUNSHADE AND DRIP RAIL REPLACEMENT GUIDE ASSEMBLY REPLACEMENT 1. Remove the sunroof assembly (See page 8D- 52). 1. Remove the sunroof assembly (See page BD- 2). 2. Remove the drip nk (A) and sunshade stopper (8). 2. Remove a quide assembly (A) after lowering a guide 3, Remove the sunshade (C) and atip rail (0). thoroughly by pushing a slide (B) to rear. 4. Installation i the reverse of removal 3. Remove the guide (A) and slide (8).BD -54 BODY (INTERIOR AND EXTERIOR) 4. Installation is the reverse of removal ADJUSTMENT cvs 3\ caution HOW To INITIALIZE MOTOR + Make sure to align the slide with the center of 1. Check that the glass has been installed. "A" and "B". = Finished height adjustment. + Make sure to initalize the motor. 2. Push the up switch. (Keeping on pushing the switch) = The slide moved 5mm forward after 15 seconds. ‘ter moving the side 3. After moving the slide Smm forward, turn OFF the ‘switch and push the UP switch (Keeping on pushing the switch with continuous operation) = Ifthe operation above is normal condition, the sunroof once and closes. 4, When the sunroof Is closed completely, turn OFF the UP switch inialize the motor completely.EXTERIOR BD -55 WHEN TO INITIALIZE THE MOTOR 41. First operation the vehicle after manufacture it. 2. Initial value is erased or damaged because of short power electric discharge during operation 3. After using the manual handle, OPERATING THE SUNROOF EMERGENCY HANDLE 4. Use the sunroof emergency handle to close and open the sunroof manually forthe following ease only: = To close the sunroof before driving a vehicle Ina rainy day of on the highway ifthe sunroof cannot be closed due to failure of the sunroof motor or controller. 2. Operating method = Remove the overhead console, = Push the emergency handle up into the hexago- nal drive (A) ofthe sunroof motor. You must push hard enough to disengage the motor clutch; oth- erwise the emergency handle wil slip due to in- ‘complete fit in the motor. + Carefully turn the emergency handle clockwise to dose the sunroof, + After closing the sunroof, wiggle the handle back and forth as you remove the tool from the motor, to ensure the motor dutch reengages. + -A'Smm hex socket may be used in place of the emergency handle, witha "Speeder”lype handle. &\ caurion Do not use power tools to operate the sunroof. Damage to the components may occur.BD -56 BODY (INTERIOR AND EXTERIOR) MIRROR COMPONENTS «: [Outside rearview mirror] [Inside rearview mirror] HousingEXTERIOR BD -57 REPLACEMENT | c2orasco INSIDE REAR VIEW MIRROR REPLACEMENT OUTSIDE REAR VIEW MIRROR REPLACEMENT 1. Push the inside rear view mirror base (A) down to remove the inside rear view mirror assembly (B). [Dnore 2. Installation ste reverse of removal + When prying with a fiat-tip screwatriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage. + Put on gloves to protect your hands. 4. Remove the quadrant inner cover (A), then disconnect the connector (B). ECM MIRROR REPLACEMENT 4. Remove the cover and connector (A). 2. Push the ECM mirror base down to remove the ECM. mirror assembly (B). 2. After disconnecting the connector(A),removethe out. 3 _ Installation is the reverse of removal side rear view miror (B) T N,2 ok 3, Installation is the reverse of removalBD -58 BODY (INTERIOR AND EXTERIOR) INTERIOR CONSOLE COMPONENTS | exrc:ne:INTERIOR BD -59 REPLACEMENT | scsos: ARMREST REPLACEMENT FLOOR CONSOLE REPLACEMENT 4. Remove the end cover. [nore 2. After loosening the armrest mounting screw, remove the armrest (A). + When prying with a fiat-tip screwatriver, wrap it with protective tape, and apply protective tape 3. installation is the reverse of removal around the related parts, to prevent damage. + Put on gloves to protect your hands. 4. Remove the end cover (A). nes 2. Loosen the console mounting bolts and nuts. 3, After disconnecting the seat warmer connector (A), remove the console assembly (B). Fastener Locations eet Oo» OER Ben] Om Oden : 4) | ‘4, Installation is the reverse of removalBD -60 POP-UP UNIT REPLACEMENT FRONT CONSOLE REPLACEMENT 1. Loosen the armrest cover (A) mounting screws. [Gjnore ~ When prying with a flat-tip screwdriver, wrap it Scow locations, with protective tape, and apply protective tape around the related parts, to prevent damage. + Put on gloves to protect your hands. = Take care not to scratch the trim and other parts. 1. Remove the crash pad center lower cover (See page BD- 66). 2. Remove the front console upper cover (A) and discon- nect the connector (B). 2. 3. After loosening the mounting screw, remove the front console (A). 3. Installation is the reverse of removal 4, Installation is the reverse of removalINTERIOR BD -61 CRASH PAD COMPONENTS | srewcco Main crash pac Avent Sue assebly | luster facia pane! Air vent Soe box upr cover Center facia pane! Asntray Glove box Side arbag Heater control unitBD 62 BODY (INTERIOR AND EXTERIOR) REPLACEMENT CLUSTER FACIA PANEL REPLACEMENT [Dore + When prying with a screwdriver, wrap it with pro- tective tape, and apply protective tape around the related parts, to prevent damage. + Take care not to scratch the crash pad and re- lated parts. 1. Tilt the steering column down. 2. Remove the screws, and detach the clips. 3. After disconnecting the trip sensor connector (A), re- move the cluster facia panel (8). Fastener Locations 4, Installation Is the reverse or removal [Gore + Make sure the connector is plugged in properly. + Replace any damage clips. CENTER FACIA PANEL REPLACEMENT 1. Remove the front console cover (See page 8D- 58) 2. Remove the setew, and detach the clips 3. Disconnect the following items to remove the center facia panel (A). = Hazard warning lamp connector (B), - Rear defroster connector (D) - Windshield deicer connector (C). + Front fog lamp connector (E), Fastonor Locations = 4, Installation is the reverse of removal [Ghaore ‘Make sure the connector is plugged in propertyINTERIOR BD -63, LOWER CRASH PAD PANEL REPLACEMENT HEATER CONTROL UNIT REPLACEMENT [nore 1. Remove the ausio assembly (See page BD- 64), Take care not to scratch the crashpad and related —2._Loosen the screws. parts. 4 3, Remove the heater control unit (A) Disconnect the hood release cable from the hood re- lease handle (See page 8D- 10). Remove the screws, bolts and clip. Disconnect the self-diagnosis connector (A), then re- move the lower crash pad panel (B). Fastoner Locations 4, Installation is the reverse of removal (Ghnore Make sure the connector is plugged in properly. Installation is the reverse of removal.BD -64 BODY (INTERIOR AND EXTERIOR) ‘AUDIO ASSEMBLY REPLACEMENT GLOVE BOX REPLACEMENT 1. Remove the center facia panel (See page BD-62). 1. Disconnect the air damper wire (A) and guide (B) from the glove box (C). 2. Loosen the screws. 3. Disconnect the audio connector (A) and antenna ca- ble (B), then remove the audio assembly (C). 4, Installation is the reverse of removal. [Gore Moke sure the connectors plugged in propery.INTERIOR BD -65 2. Disconnect the pin (A), then remove the glove box (C). CLUSTER REPLACEMENT 1. Remove the cluster facia panel (See page BD- 62). 2. Loosen the screws. \I & 3. Disconnect the cluster connector (A), then remove the \ chster (8). 3, Installation is the reverse of removal. 4, Installation is the reverse of removal. [Ghnore Moke sure the connectors plugged i propery,BD 66 BODY (INTERIOR AND EXTERIOR) AIR VENT REPLACEMENT 1. Wrap a flattip screwdriver with protective tape, and apply protective tape around the related parts to pre- vent damage. Take care not to scratch the crash pad and related parts, 2. Remove the air vent (A) by detaching the clip. ip eatons 3. Reinstall the hook portions of the vent first, then push the clip portions into place securely, COVER REPLACEMENT [Gore * When prying witha screwdriver, wrap with ro- {ecive tape, and apply protective ape rain the related parts o proven damage ‘+ Take care not to scratch the crash pad, body and aiher related parts, + Paton gloves to protect your hands Remove the crash pad side cover (A), frout consolz side cover (B), Crash pad side cover Front cons Front console side cover, RH 1Dscip.1 |2b-cip,3INTERIOR BD -67 CRASH PAD REMOVAL AND INSTALLATION SRS components are located in this area. Review the ‘SRS component locations, precautions, and procedures in the SRS section before performing repairs or service (see page RT- “Airbag’) [Dore * Wen png with 8 srewciver wrap wth po tective tape, and apply protective tape around the rolated pats to prevent damage « An ease fe ep when removing end b- Stating tne crash pd «Take care otto soath the crash pad, body and diner related parts + Paton gloves te protect your hands 4. Make sure you have the antitheft code for the radio, then write down the frequencies for the radio's preset buttons. 2. Disconnect the negative cable from the battery 3. Remove the following items. + Front seat, both sides (See page BD- 84), = Front console (See page BD- 58). + Crash pad side trim, both sides (Gee page 8D- 66) = Front pillar trim, both sides (See page BD- 68). = Clutster tacia panel (See page BD- 62). + Lower orash pad panel (See page 8D- 63). = Heater control unt (See page BD- 63). = Clutster (See page BD- 65). + Aude (See page BD- 63) = Glove box (See page BD- 64). ~ Steering wheel (See page ST- "Steering whee!BD 68 BODY (INTERIOR AND EXTERIOR) 4. Disconnect the passenger's air bag connector (A). Loosen the bolts and nut, then remove the crash pad ©). Fastoner Locations > : Bot 19 6x1.25mm 07-141 kgtim 6<1.25mm 0.7=1.1 kgtim Carefully remove the crash pad through the front door + Make sure the connectors are plugged in prop- erly, and the antenna lead is connected properly. opening = Entorthe antktneft code forthe rao then enter 6. Instaltion sth reverse of removal. the customer's radio station preset [nore Make sure the crash pad fs onto the guide pins comecth + Before tightening the bolts, make sure the crash pad wire harnesses are not pinched.INTERIOR BD -69 INTERIOR TRIM - Take care not to bend or scratch the trim and panels. REPLACEMENT | enrice: 2. Installation is the reverse of removal FLOOR AND SIDE AREA o Ujnore 1. Remove the trims Replace any damage cis. = Apply iquld thread fock tothe front seat bell up- (Wnore per anchor bolt befor installation. = Puton gloves to protect your hands. + Gafore instaing the anchor bolts mate sure + When prying with a flat-tip screwdriver, wrap it there are no twists or kinks in the belts. with protective tape to prevent damage Fastener Locations te scew [1 :cip | 2c: clip Op [a> Front pilar tim Le 4 “ a s UA [Center pilar upper tim aw S 2 ‘ 7 4 . 2 Geinter pillar a“ lowertrm 2 2 E aN 2 — Rear pila tim 1 Cow side tim Fe Door step ————— Rear lowor scuff imBD -70 BODY (INTERIOR AND EXTERIOR) TRUNK AREA = Take care not to bend or scratch the trim and panels. 1. Remove the trims. 2. Installation is the reverse of removal, and replace any [Ginore damaged clips + Puton gloves to protect your hands. + When prying with a flat-tip screwdriver, wrap it with protective tape to prevent damage, »| Luggage floor tim 1p: Screu,2 [2m Bott Floor mat Seif covering tim Luggage floor front tim Luggage center tray “Transverse tmINTERIOR BD-71 ROOF AREA 1 Remove the trims. [Dnore * Puton gloves to protect your hans hen prying with » Naty sorewdrver, wrap i vith protective tape to prevent demage. Installation is the reverse of removal, wore Replace any damage clps. = Apply liquid thread fock fo the front seat belt up- per anchor bolt before installation. = Before installing the anchor bolts, make sure there are no twists or kinks in the belts, + Take care no to bend or scratch the trim and pan- als. Fastener Locations 1m Screw | 2m Screw | E>2Cp ‘Sunvisor Bracket ‘Overhead console lp Sunvisor A catg0 lamp 2 HeadliningBD -72 BODY (INTERIOR AND EXTERIOR) WINDSHIELD GLASS COMPONENTS | sxcss:er Wind shield molding Glass pad / Wind ehiele glassINTERIOR BD -73, REPLACEMENT senac 5. Cut out the sealant using the sealant cutting tool [a(09861-31100)) REMOVAL [Gnore + Put on gloves to protect your hands. + Use seat covers to avoid damaging any surfaces. 4. Remove the following items: + Inside rear view mirror (See page 8D- 57). ‘+ Sunvisors and holders, both sides, overhead console, Grab handles, both sides (See page 8D- 71) + Front pillar trim, both sides (see page BD- 68). + Windshiels wiper arms and cow! cover (See page BE- “Windshield wiper”) 2. Remove the molding (A) from the edge of the wind- shield (B). If necessary, cut the molaing with a utility kaif. 3. Remove the spacer (C), 6. Remove the winshield (A) carefully using the glass holder (8(09861-31 100}}, 4, Pull down the front portion of the headliner. Take care not to bend the headliner excessively, or you may crease or break it.BD -74 BODY (INTERIOR AND EXTERIOR) INSTALLTION 1. With a knife, scrape the old adhesive smooth to a thickness of about 2mm (0.08 in.) on the bonding surface around the entire windshield opening flange: + Donot scrape down to the painted surface of the body; damaged paint wil interfere with proper bonding + Remove the rubber dam and fasteners from the body, + Mask off surrounding surfaces before painting 2. Clean the body bonding surface with a sponge damp- ened in alcohol, After cleaning, keep oil, grease and water from getting on the clean surface. 3. Apply the glass primer (A) tothe side of the windshield glass edge and stick the both-sided adhesive tape (B) ‘on the inside of molding (C). 4, When attaching the molding, make tt in ine (D) with the windshield glass and attach the windshield glass pad (E)to the designated place. 5. Install the spacer (A) install the windshield glass (8) temperarily with making sure to position them on the center, and then place the alignment mark (C). 6. Remove the windshield = Never touch the primed surface with your hand. you do, the adhesive may not bond to the glass properly, causing a leak after the windshield (glass iS instalod, = Donot apply body primer to the glass. = Keep water, dust, and abrasive materials away from the primer. /,:Boply alas pier here, poco er — CSS SeeINTERIOR BD -75 &. With a sponge, apply a light coat of body primer to the original adhesive remaining around the windshield ‘opening flange. Letthe body primer dry for atleast 10 minutes: *+ Do not apply glass primer to the body, and be careful not to mixup glass and body primer sponges, + Never totich the primed surfaces with your hands, + Mask off the dashboard before painting the flange. 8. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking gun, and run a bead of sealant (A) arouna the edge of the windshield (8) between the fastener ‘and molding as shown. Apply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner,BD -76 BODY (INTERIOR AND EXTERIOR) 410. Use glass holder (A) to hold the windshield over the ‘opening, align it with the alignment marks (B) made in step 15, and set it down an the adhesive. Lightly push on the windshield unti ts edges are fully seated fon the adhesive all the way around, Do not open or close the doors until the adhesive is dry. 11. Scrape o wipe the excess adhesive off with a putty knife oF towel. To remove adhesive from a painted surface or the windshield, wipe with a soft shop towel ‘dampened with alcohol. 412. Letthe adhesive ary for atleast one hour, then spray water over the windshield and check for leaks, Make leaking areas, and let the windshield dry, then seal with sealant * Let the vehicle stand for at least four hours after Windshield installation, If the vehicle has to be used within the first four, it must be driven slowly. + Keep the windshield dry for the first hour after installation, 48. Reinstall all remaining removed parts. Install the rearview mirror after the adhesive has dried thor- oughly. Advise the customer not to do the following things for two the three days: + Slam the door with all the windows rolled up. + Twist the body excessively (such as when going inand out of driveways at an angle or driving over rough uneven roads).INTERIOR BD-77 QUARTER GLASS REPLACEMENT xn: REMOVAL 1 2 [Dore = Put on gloves fo protect your hands. + Take care not to body surface and other parts. Remove the following parts: = Rear seat assembly (See page BD- 92) + Rear door scuff trim (See page BD- 69). = Self covering trim (See page BD- 70) = Luggage side trim (See page 8D- 70) + Rear seat belt upper anchor bolt (See page 8D- 100) = Rear pillar rim (See page BD- 69). Loosen the quarter fixed glass (A) mounting nut Nt tone 4 Cut out the sealant using the sealant oulting tool fa(o801-31 1000) Remove the quarter fixed glass.BD -78 BODY (INTERIOR AND EXTERIOR) INSTALLATION 1. With a putty knife, sorape the old achesive smooth to a thickness of about 2mm (0.08 in.) on the bonding surface around the entire quarter fixed glass flange. + Donot scrape down to the painted surface of the body; damaged paint will interfere with proper bonding ‘+ Mask off surrounding surfaces before painting + Remove the fasteners from the body. 2. Clean the body bonding surface with a sponge damp- ened in alcohol. After cleaning, keep oil, grease and water from getting on the surface. 3, With a sponge, apply alight coat of glass primer along the edge of the quarter fixed glass as shown, then lightly wipe it off with gauze or cheesecloth: ‘+ Do not apply body primer to the quarter fixed glass, and do not get body and glass primer sponges mixed up. + Never touch the primed surfaces with your hands. Ifyou do, the adhesive may not bond to the quar- ter fixed glass properly, causing a leak after the quarter fixed glass in installed. + Keep water, dust, and abrasive materials away from the primed surface. Apply olass primer hare. 4 With a sponge, apply alight coat of body primer to the. original adhesive remaining around the flange. Let body primer dry for at least 10 minutes. * Do not apply glass primer to the body, and be careful not to mx up glass and body primer sponges. + Never touch the primed surfaces with your hands. Apply alas primer here. Pack adhesive into the cartridge without air pockets to ensure continuous delivery. Put the cartridge in a caulking gun, and run a bead of sealant (A) around ‘edge of the quarter fixed glass (8) as shown. Ap- ply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corINTERIOR BD -79 6 a Install the quarter fixed glass. Let the adhesive dry for atleast one hour, then spray water over the rear window and check forleaks, Mark the leaking areas, let the rear window dry, then seal with sealant, Let the vehicle stand for at least four hours after rear window installation. If the vehicle has to be used within the first four hours, it must be driven slowly Reinstall all remaining removed parts.BD -80 BODY (INTERIOR AND EXTERIOR) BUMPER = Puton gloves to protect your hands Tae ede not to bond of sora the cover and FRONT BUMPER Rents any damage clos REPLACEMENT | cirron (Gore Wren prying with a fatip screwdriver wap it vith protective tape, and epply protective tape trourd the rloted ports, o prevent damage Fastener Locations 1m sBot 4c: ip > | te 2m: Screw Bracket Front bumper coverBUMPER BD -81 Fastener Locations d= | O= | o> | ip Rivet Side mauntng ip» ce Side mounting clip Rivet FRT BUMPER UPR SIDE Fog lamp, Bumper cover Fog lamp cap Side meshBD -82 BODY (INTERIOR AND EXTERIOR) REAR BUMPER + When prying with a flat-tip screwdriver,wrap it wth protective tape, and appl protective tape around the related parts to prevent demage. + Paton gloves to protect your hands «Take core not bend oF saate the cover and [Gore other parts + Alter remove the rear combination lamp. + Replace any damage clips. REPLACEMENT | cnsscrss Faste 8 lele| s/o {| Rear bumper beam! 1 Locations Energy absorber | Bumper stepSEAT BD -83, SEAT FRONT SEAT COMPONENTS tosras Headrest va Headrest guide ‘Seat back pac Back panel ‘Seat back cover Reeleier cover Recliner cover Recliner leverBD -84 BODY (INTERIOR AND EXTERIOR) SEAT ASSEMBLY REPLACEMENT sicoos 5. Installation is the reverse of removal. 1. Remove te seat assembly mounting cover (A) A. caurion 2. ler loosening the seat assembly mounting bolt and SEAT MOUNTING BOLT INSTALLATION PROCE- nut remove the seat assembly (8). DURE: + Sot tho seat into tho most roarward position. Check then each slide 1s locked, and then Fastener Locations tighten the front mounting bolt temporarily. Pipote + Sot tho seat into the most forward position. @p zen Check thet each slide is locked, and then 4.4-6.6kgfm| tighten the rear mounting bolt completely. + Set the seat into the most rearward position. Check the front mounting bolt completely. + Check that tho seat oporates to and fro smoothly and the locking portion locks properly. RECLINER COVER,KNOB AND HEIGHT KNOB REPLACEMENT 1. Remove the height adjuster knob (A) and recliner lever (8), 2. Loosen the recliner mounting screw and clip, then re- move the recliner cover (C). Fastener Locations 3. Open the connector box (A). 4. Disconnect the connector (B), and remove the seat assembly,SEAT BD -85 SEAT BACK COVER REPLACEMENT 4. After disconnecting the scuff band (A),temove the ‘seat back parel (B). 2. Disconnect the protector (A) from the back frame, then open the zipper (6).BD -86 BODY (INTERIOR AND EXTERIOR) 3. Remove the headrest and headrest guide(A). 5. Installation is the reverse of removal. [haore To prvontwrnkies, make sur the matrali setahed evenly over tne cover (A) bere secur jing the hogring clips (B). = Raplece the hoghg cps with new ones using spo to) 4. Alter removing the hogring clips (A) on the front of eat back and remove the Seat back cover (B), serow ocatons, | 4. Remove the connectors (A).After loosening the ‘mounting bolts,remove the cushion (8)BD -88 BODY (INTERIOR AND EXTERIOR) 6. After removing the hogring clips (A) on the front of | SEAT BACK FRAME REPLACEMENT seat cushion and remove the seat cushion caver (B), 1, Remove the seat back panel (See page BD- 85), ity cauTion 2. Remove the headrest guide (See page BD- 86). When removing the hogring clip, remove the hogring clip while pressing the wire so as not to soparato the wire from the sponge Remove the seat back cover and pad from the frame. 4, Loosen the mounting bolts,then remove the seat back frame(A\. (Gore = Remove the side airbag for replacing side air bag installation seat + Bafore service, be fully aware of precautions and service procedure relevant to air bag (See page RT- "Airbag’) ‘0x1.25mm, 7. Installation is the reverse of removal = To prevent wrinkles, make sure the material is stretched evenly over the cover (A) before secur- Ing the hogring clips (B) = Replace the hogring clips with new ones using special too! (C). sosso00 5. Installation is the reverse of removal.SEAT BD -89 SEAT TRACK REPLACEMENT ‘SEAT BACK HEATER REPLACEMENT 1. After removing the seat back panel, disconnect the 1. Remove the seat back cover (See page BD- 85), protector and open the zipper. 2. Cut the heater (A) attached to the pad (B), as shown 2, Remove the seat back assembly (A) In the picture, 3. Take offthe paper from the the backside of the heater Bot cations, 4 assembly. 40xt.25mm, 45-5.5kgtm 4. Attch the heater to the main part of pad Install the seat back cover. 3, Remove the seat cushion (See page BD- 87). 4, Remove the recliner coverrecliner knob and height adjuster knob (See page SD- 85), 5, Remove the seat track (A) soos 6. Installation is the reverse of removalBD -90 BODY (INTERIOR AND EXTERIOR) ‘SEAT CUSHION HEATER REPLACEMENT 1. Remove the seat cushion cover (See page BD: 87). 2. Cut the heater (A) attached to the pad (B), as shown Inthe picture. 3, Take off the paper from the the backside of the heater assembly, 4, Attach the heater to the main part of pad 5, Install the seat cushion cover.SEAT BD -91 REAR SEAT COMPONENTS crszrsr Go T i T Fem oe Seat back cover Seat back frame Hinge cover / Seat back pane! Seat back pad Le ‘Seat eushion frameBD 92 BODY (INTERIOR AND EXTERIOR) REPLACEMENT | exsics: ‘SEAT ASSEMBLY REPLACEMENT 1. After removing the cushion frame hinge cover(A), loosen the mounting bolts.Fold the cushion (B). 2. Loosen the recliner hinge (C) mounting nut and bolt, then rear seat assembly (D), 3. Installation is the reverse of removal [Chaore SEAT MOUNTING BOLT AND NUT INSTALLATION PROCEDURE. reer temporary inte ordrfnutanboiton the tont of racine hinge station port «Aer empl ttn gto bolton he back of to rector fnge Instn part hen te bot onthe font of completly = Seting down te see cicon, tighten the mount ing bok ofthe coshon tame hinge « Ghoctfrectnng the Sea and fling setback operat amt Fastener Locations > :Bott 10 Nut, 2 40x 4.25mm, 40x 4.25mm, 44 ~ 66Nm ™ 44~66Nm (44-6.6Kgtm, (44 ~8.6Kgtm, 33 a7bt#) 33~47ibrf)SEAT BD -93, SEAT CUSHION COVER REPLACEMENT 1 ‘After loosening cushion frame hinge mounting bolts, fold the cushion (See page BD- 92). Remove the protector (A) and hogring clio (B), then remove the cushion (C) Pull out the hagring clips (A) on the front of seat cush- Ton, remove the seat cushion cover (8). Avcaurion When removing the hogring cllp, remove the hogrng lp wile pressing tre wire so az not fo ‘the wire tom the sponge Installation is the reverse of removal, (Chwore + To prevent wrinkles, make sure the materia is stretched evenly over the cover (A) before secur- ing the hogring clips (8). + Replace the hogring clips with new ones using ‘special too! (C).BD -94 BODY (INTERIOR AND EXTERIOR) SEAT BACK COVER REPLACEMENT 6. 1 2. 3, 4, ‘After folding the seat back,remave the shopping hook (A) from the back panel Remove the headrest. Remove the armrest (See page BD- 98). > : Sere locations, 4 Remove the back folding hinge cover (A). After loosening the mounting bolts,remove the cush- - fon @) > : Bot locations, 2 \\ ° @p _ IN 6. Remove the back panel (A),SEAT 7. Remove the recliner lever caver (A. 8. Remove the hogring clip (A) of the pad. 8. Remove the hogring clip (A) and headrest guide (B), 10. Disconnect the aplix (A) on the front of seat back, then remove the seat back assembly (C). remove the back cover (B). 11, Installation Is the reverse of removal. [Gore To prevent wrinkles, make sure the material is stretched evenly over the cover before securing the aplixBD 96 BODY (INTERIOR AND EXTERIOR) SEAT BACK FRAME AND RECLINER 4, Loosen the recliner (A) mounting bolt. REPLACEMENT After disconnecting the recliner cable (B), remove the ‘seat back frame (C). 1. Remove the seat cushion assembly (ee page BD- 97). 2. Remove the seat back cover (See page BD- 94), rt 25mm CB 1 arn| 3, Remove the recliner cover (A). > : crow locations 2 5, Installation is the reverse of removalSEAT Bl 7 SEAT CUSHION FRAME REPLACEMENT 3. Loosen the back folding cover (A). After loosening the mounting,remove the cushion frame (8). 1, Remove the seat cushion hinge mount bot (See page BD- 92). Remove the cushion assembly (A). 8x1.0mm 4, Installation Is the reverse of removalBD 98 BODY (INTERIOR AND EXTERIOR) ARMREST REPLACEMENT RECLINER LEVER REPLACEMENT 1. Squeeze out the gap between the seat back (A) and 1. Remove the seat back frame (See page BD- 96). the armrest (B) to open using a screweriver (C) and remove the bushing (0). ‘After removing the "E"ring (A) from the recliner mount ing pin,remove the recliner mounting pin (8). 2. Pushing the arm rest to the left, remove the arm rest. 3, Disconnect the recliner cable wire(C) and the BUSH(F).then remove the recliner lever (D). 4, Installation is the reverse of removal PeusH) 3, Remove the armrest cover(A). 4, Installation Is the reverse of removal.SEAT BD -99 SEAT BELT COMPONENTS | sxcoccu, Reor center seat bolt Rear seat belt retractor tear center seat bucdla™~ Front seat buckleBD -100 BODY (INTERIOR AND EXTERIOR) REPLACEMENT FRONT SEAT BELT REPLACEMENT B caution When installing the seat belt, make sure not to damage the pretensioner, 41. Remove the following items first. + Front seat assembly (See page BD- 84). + Frontand rear door scar trim (See page BD- 68). 2. After raise the lower anchor cover (A) loosen the lower anchor maunting bolt (8). > Bolt 63 4.25mm, 45~ SsNim (450 550kgfrem, 33 ~ 4016) Batt O= 3. Remove the center pillar lower trim (Gee page BD- 69). 4. Remove the upper anchor cover (A).then loosen the upper anchor (8). 5. After disconnecting the pretensioner connector lock pin,remove the connector (C). Loosen the mounting bolt.then remove the pretensioner (0). [STRUCTURE OF UPPER ANCHOR BOLT Batt Spacer 9 Busting AnchorSEAT BD -101 REAR SEAT BELT REPLACEMENT \ cauTION When installing the seat belt, make sure not to damage the retractor. 4. Remove the following items frst. + Rear seat assembly (See page BD- 92) - Frontand rear door scarf trim (See page 8D- 69) + Seff covering trim (See page BD- 70) + Luggage center trim (See page BD- 70) 2. Remove the lower anchor (A). 3. Remove the luggage side trim (8-See page BD- 70). STRUCTURE OF LOWER ANCHOR BOLT “anchot 4, Remove the upper anchor cover (A), then loosen the mounting bolt Remove the upper anchor (B). 5. After loosening the retractor (C) mounting bolt, re- move the rear seat belt (0), > 2 Boe, 6 1.25mm, 45~ 55Nm (450~ Ss0kgfrem, 33 ~ Ao1ben) STRUCTURE OF UPPER ANCHOR BOLT Bung “Pr 5) nea STRUCTURE OF RETRACTOR BOLT Lock washer d=o lo) ‘Spring washer AnchorBD -102 BODY (INTERIOR AND EXTERIOR) FRONT SEAT BELT BUCKLE REPLACEMENT 1. Remove the following items frst. + Front seat assembly (See page 8D- 84), + Front seat recliner cover (See page BD- 85). 2. Remove the wire harness of buckle from seat 3, Installation Is the reverse of removal. > Bol, 6x 1.26mm, 45~ 55Nm (450 ~ s50kgfem, 33 ~ s01beR) ‘Ancor Lock washer REAR SEAT BELT BUCKLE REPLACEMENT 4. After cushion frame hinge mounting botts, fold the ‘cushion (See page 8D- 92). 2. Remove the seat belt buckle (A). 3, Installation is the reverse of removal > : Bol, 6 1.25mm, 45~ 55m (450 ~ Ssakgfrem, 33~ Aol Ne STRUCTURE OF BUCKLE BOLT ot ‘Spring washor Breer wanesSEAT BD -103 HEIGHT ADJUSTER REPLACEMENT 41. Remove the following items first. + Front seat assembly (See page 8D- 84). + Frontand rear door scuff trim (See page BD- 69). + Front seat belt upper and lower anchor (Gee page BD- 100), + Center pillar ower and upper trim (Gee page BD- 68). 2. Looesn the mounting bolt, then remove the height ad- juster (A), 3, Installation is the reverse of removal (450 SS0kgtrcm, 33 ~ 401bt)