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  • 1. PREPARATION SST(SPECIAL SERVICE TOOLS) 09804-24010 Luggage Compartment Door Torsion Bar Tool 09812-00010 Door Hinge Set Bolt Wrench 09806-30010 Windshield Moulding Remover LUBRICANT Classification MP grease Capacity Imp. qtsUS qtsLiters Item -BODY PREPARATION BO-5
  • 2. SSM(SPECIAL SERVICE MATERIALS) 08850-00080 Windshield glass adhesive set No.35 or equivalent 08850-00070 Windshield glass adhesive set No. 15 or equivalent 08850-00090 Windshield glass adhesive set No.45 or equivalent 08850-00051 Adhesive (Super Special) or equivalent 08833-00030 Auto glass sealer or equivalent -BODY PREPARATION BO-6
  • 3. 3. CHECK ADHESIVE HARDENING TIME After main and hardening agents are mixed, leak tests should be made only after the hardening time has elapsed. Example: The hardening time for adhesive set No. 35 with and ambient temperature of 25°C (77°F) is 2 1 / 2 hours. NOTICE: Do not drive the vehicle until at least double the hardening time has elapsed. 2. CHECK ADHESIVE USABLE TIME After mixing main and hardening agents, finish glass installation within the specified time as shown. Example: For glass installation in an ambient tempera- ture of 25° C (77°F), apply adhesive set No. 35 within 45 minutes. 1. CHOOSE SUITABLE ADHESIVE SET Use an adhesive set suitable for the ambient temper- ature. Windshield glass adhesive set No. 35 Windshield glass adhesive set No. 45 Windshield glass adhesive set No. 15 15 - 35°C (59 - 95°F) 35 - 45°C (95 - 113°F) Ambient temperature 0-15°C (32 - 59°F) 08850-00070 08850-00080 08850-00090 Part NamePart No. -BODY PREPARATION BO-7
  • 4. HOOD HOOD ADJUSTMENT HINT: Since the centering bolt is used as the hood hinge and lock set bolt, the hood and lock cannot be adjusted with it on. Substitute the bolt with washer for the centering bolt. 1. ADJUST HOOD IN FORWARD / REARWARD AND LEFT/RIGHT DIRECTIONS Adjust the hood by loosening the hood side hinge bolts. 2. ADJUST FRONT EDGE OF HOOD IN VERTICAL DIRECTIONS Adjust the hood by turning the cushions. 3. ADJUST HOOD LOCK (a) Remove five screws and the radiator grill. (b) Adjust the lock by loosening bolts. (c) Install the radiator grill with five screws. -BODY HOOD BO-8
  • 5. FRONT DOOR COMPONENTS (4 Door) -BODY FRONT DOOR BO-9
  • 6. COMPONENTS (Cont’d) (2 Door) -BODY FRONT DOOR BO-10
  • 7. 2. REMOVE DOOR INSIDE HANDLE (a) Remove the screw and slide the handle forward. (b) (4 Door) Disconnect the handle from the control link and remove the handle. (2 Door) Disconnect the handle from two control links and remove the handle. FRONT DOOR ADJUSTMENT 1. ADJUST DOOR IN FORWARD/ REARWARD AND VERTICAL DIRECTIONS Using SST, adjust the door by loosening the body side hinge bolts. SST 09812 - 00010 3. ADJUST DOOR LOCK STRIKER (a) Check that the door fit and door lock linkages are adjusted correctly. (b) Loosen the striker mounting screws to adjust. (c) Using a plastic hammer, tap the striker to adjust it. FRONT DOOR DISASSEMBLY (See pages BO-9 and 10) 1. REMOVE REGULATOR HANDLE Pull off the snap ring with a shop rag and remove the regulator handle and plate. 2. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL DIRECTIONS Loosen the door side hinge bolts to adjust. HINT: Substitute the bolt with washer for the center- ing bolt. (See page BO-8 ) -BODY FRONT DOOR BO-1 1
  • 8. 4. REMOVE REAR VIEW MIRROR HINT: Tape the screwdriver tip before use. (a) (w/Manual Remote Control Mirror) Remove the screw and the knob. (b) Insert the taped screwdriver in the side shown here and pry off the cover. Prying off the cover in the other sides may damage the cover. (c) Remove three screws and the mirror. 3. REMOVE DOOR TRIM (a) Remove two screws and the armrest. (b) Insert a screwdriver between the door trim and the panel to pry out. HINT: Tape the screwdriver tip before use. (c) Remove the door trim. 5. REMOVE DOOR UPPER TRIM (a) Remove two clips. (b) Pry out the clips from the edge of the weatherstrip and remove the door upper trim. 6. REMOVE DOOR OUTER WEATHERSTRIP Pry out the clips from the edge of the weatherstrip and remove the weatherstrip. 7. REMOVE SPEAKER (a) Remove three screws and the speaker. (b) Disconnect the connector. -BODY FRONT DOOR BO-12
  • 9. 13. REMOVE DOOR LOCK (4 Door) (a) Disconnect the link from the door lock and remove the link. (b) Disconnect two links from the outside handle and the door lock cylinder. (c) Remove three screws. (d) Remove the door lock through the service hole. 10. REMOVE DOOR GLASS HINT: Insert a shop rag inside the panel to prevent scratching the glass. (a) (4 Door) Remove two glass mounting bolts. (2 Door) Remove two glass mounting nuts. (b) Remove the door glass by pulling it upward. 8. REMOVE SERVICE HOLE COVER (a) Using a clip remover, remove two screw grommets. (b) Remove service hole cover. 9. REMOVE DOOR GLASS RUN Pull the glass run upward to remove it. 12. REMOVE WINDOW REGULATOR (a) Remove two equalizer arm bracket mounting bolts. (b) Remove three regulator mounting bolts. (c) Remove the regulator through the service hole. 11. REMOVE REAR LOWER FRAME (a) Remove the bolt. (b) Remove the frame through the service hole. -BODY FRONT DOOR BO-13
  • 10. FRONT DOOR ASSEMBLY (See pages BO-9 and 10) 1. BEFORE INSTALLING PARTS. COAT THEM WITH MP GREASE (a) Apply MP grease to the sliding surface and gears of the window regulator. NOTICE: Do not apply grease to the spring of the window regulator. (2 Door) (a) Remove the silencer. (b) Disconnect the links and remove the links. (c) Remove two clips. (d) Disconnect two links from the outside handle and the door lock cylinder. (e) Remove three screws. (f) Remove the door lock through the service hole. 14. REMOVE OUTSIDE HANDLE Remove two bolts and the outside handle with the lock cylinder. 15. REMOVE DOOR LOCK CYLINDER Remove the retainer and the lock cylinder from the outside handle. (b) Apply MP grease to the sliding surface of the door lock. -BODY FRONT DOOR BO-14
  • 11. 4. INSTALL DOOR LOCK (4 Door) (a) Install the door lock with three screws. (b) Connect two links to the outside handle and the door lock cylinder. (c) Connect the link to the door lock. (2 Door) (a) Install the door lock with three screws. (b) Connect two links to the outside handle and the door lock cylinder. (c) Install two clips. (d) Connect the links. (e) Install the silencer. 5. INSTALL WINDOW REGULATOR (a) Place the regulator through the service hole. (b) Install three regulator mounting bolts. 2. INSTALL DOOR LOCK CYLINDER Install the lock cylinder with the retainer to the out- side handle. 6. INSTALL REAR LOWER FRAME (a) Put in the frame to the door frame. (b) Install the bolt. 3. INSTALL OUTSIDE HANDLE Install the outside handle with two bolts. -BODY FRONT DOOR BO-15
  • 12. 7. INSTALL DOOR GLASS HINT: Install a shop rag inside the panel to prevent scratching the glass. (a) Insert the glass to the frame. (b) (4 Door) Install two glass mounting bolts. (2 Door) Install two glass mounting nuts. 8. INSTALL DOOR GLASS RUN Insert the glass run to the door frame. 9. ADJUST DOOR GLASS Adjust the equalizer arm up to down and tighten if where dimensions A and B, as shown are equal. 10. INSTALL SERVICE HOLE COVER (a) Seal the service hole cover with adhesive. HINT: Bring out the links through the service hole cover. (b) Insert the lower edge of the cover into the panel slit. (c) Seal the panel slit with cotton tape. NOTICE: Do not block the trim clip sealing with the tape. (d) Install two screw grommets. 11. INSTALL SPEAKER (a) Connect the connector. (b) Install the speaker with three screws. -BODY FRONT DOOR BO-16
  • 13. 16. INSTALL DOOR INSIDE HANDLE (a) (4 Door) Connect the handle to the control link. (2 Door) Connect the handle to two control links. (b) Push the inside handle in the door panel and slide it rearward. (c) Install the screw. 12. INSTALL DOOR OUTER WEATHERSTRIP Install the claw of the clips into the upper panel slit and push the moulding on to the panel. 13. INSTALL DOOR UPPER TRIM (a) Install the claw of the clips into the upper panel slit and push the weatherstrip on to the panel. (b) Install two clips. 14. INSTALL REAR VIEW MIRROR (a) Install the mirror with three screws. (b) Install two cover. (c) (w/Manual Remote Control Mirror) Install the knob and the screw. 15. INSTALL DOOR TRIM (a) Tap the trim by hand and fix it in place with the clips. (b) Install the armrest with two screws. -BODY FRONT DOOR BO-17
  • 14. 17. INSTALL REGULATOR HANDLE With door window fully closed, install the plate and the regulator handle with the snap ring as shown. -BODY FRONT DOOR BO-18
  • 15. REAR DOOR COMPONENTS -BODY REAR DOOR BO-19
  • 16. REAR DOOR ADJUSTMENT 1. ADJUST DOOR IN FORWARD/ REARWARD AND VERTICAL DIRECTIONS (Upper Side) Loosen the body side hinge nuts to adjust. (Lower Side) Loosen the body side hinge bolts to adjust. REAR DOOR DISASSEMBLY (See page BO - 19) 1. REMOVE REGULATOR HANDLE Pull off the snap ring with a shop rag and remove the regulator handle and plate. 3. ADJUST DOOR LOCK STRIKER (a) Check that the door fit and door lock linkages are adjusted correctly. (b) Loosen the striker mounting screws to adjust. (c) Using a plastic hammer, tap the striker to adjust it. 2. REMOVE DOOR INSIDE HANDLE (a) Remove the screw and slide the handle forward. (b) Disconnect the handle from the control link and remove the handle. 2. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL DIRECTIONS Loosen the door side hinge bolts to adjust. -BODY REAR DOOR BO-20
  • 17. 3. REMOVE DOOR TRIM (a) Remove two screws and the armrest. (b) Insert a screwdriver between the door trim and the panel to pry out. HINT: Tape the screwdriver tip before use. (c) Remove the door trim. 8. REMOVE DOOR GLASS HINT: Insert a shop rag inside the panel to prevent scratching the glass. Disconnect the glass from the regulator arm and remove the glass by pulling it upward. 6. REMOVE SERVICE HOLE COVER (a) Using a clip remover, remove two screw grommets. (b) Remove service hole cover. 7. REMOVE DOOR GLASS RUN Pull the glass run upward to remove it. 4. REMOVE DOOR UPPER TRIM (a) Remove the clip. (b) Pry out the clips from the edge of the weatherstrip and remove the door upper trim. 5. REMOVE DOOR OUTER WEATHERSTRIP Pry out the clips from the edge of the weatherstrip and remove the weatherstrip. -BODY REAR DOOR BO-21
  • 18. REAR DOOR GLASS REPLACEMENT (See page BO-19 ) 1. REMOVE GLASS CHANNEL WITH SCREWDRIVER OR LIKE OBJECT 2. APPLY SOAPY WATER TO INSIDE OF WEATHER- STRIP 3. INSTALL CHANNEL BY TAPPING IT WITH PLASTIC HAMMER 12. REMOVE DOOR LOCK (a) Remove the silencer. (b) Remove three clips. (c) Disconnect two links from the door lock and remove two links. (d) Disconnect the link from the outside handle. (e) Remove three screws. (f) Remove the door lock through the service hole. 9. REMOVE DIVISION BAR (a) Remove the screw under the weatherstrip. (b) Remove two bolts and the division bar. 10. REMOVE QUARTER WINDOW GLASS WITH WEATHERSTRIP Remove the quarter window glass together with the weatherstrip by pulling it forward. 11. REMOVE WINDOW REGULATOR (a) Remove three regulator mounting bolts. (b) Remove the regulator through the service hole. 13. REMOVE OUTSIDE HANDLE Remove two bolts and the outside handle. -BODY REAR DOOR BO-22
  • 19. REAR DOOR ASSEMBLY (Sea page BO-19 ) 1. BEFORE INSTALLING PARTS. COAT THEM WITH MP GREASE (a) Apply MP grease to the sliding surface and gears of the window regulator. NOTICE: Do not apply grease to the spring. 3. INSTALL DOOR LOCK (a) Install the door lock with three screws. (b) Connect the link to the outside handle. (c) Connect two links to the door lock and install two links. (d) Install three clips. (e) Install the silencer. (b) Apply MP grease to the sliding surface of the door lock. 4. INSTALL WINDOW REGULATOR (a) Place the regulator through the service hole. (b) Install three regulator mounting bolts. 2. INSTALL OUTSIDE HANDLE Install the outside handle with two bolts. -BODY REAR DOOR BO-23
  • 20. 9. INSTALL SERVICE HOLE COVER (a) Seal the service hole cover with adhesive. HINT: Bring out the link through the service hole cover. (b) Insert the lower edge of the cover into the panel slit. (c) Seal the panel slit with cotton tape. NOTICE: Do not block the trim clip sealing with the tape. (d) Install two screw grommets. 7. INSTALL DOOR GLASS HINT: Insert a shop rag inside the panel to prevent scratching the glass. Place the glass in the door cavity and connect the glass with the regulator arm. 8. INSTALL DOOR GLASS RUN Insert the glass run to the door frame. 5. INSTALL QUARTER WINDOW GLASS WITH WEA- THERSTRIP 6. INSTALL DIVISION BAR (a) Install the division bar with two bolts. (b) Install the screw under the weatherstrip. 10. INSTALL DOOR OUTER WEATHERSTRIP Install the weatherstrip with clips to the panel. -BODY REAR DOOR BO-24
  • 21. 12. INSTALL DOOR TRIM (a) Install the door trim with clips to the inside door panel by tapping. (b) Install the armrest with two screws to the door panel. 11. INSTALL DOOR UPPER TRIM (a) Insert the claw of the clips into the upper panel slit and push the weatherstrip on to the panel. (b) Install the clip. 14. INSTALL REGULATOR HANDLE With door window fully closed, install the plate and the regulator handle with snap ring as shown. 13. .INSTALL DOOR INSIDE HANDLE (a) Install the handle with the control link. (b) Install the screw. -BODY REAR DOOR BO-25
  • 22. LUGGAGE COMPARTMENT DOOR LUGGAGE COMPARTMENT DOOR ADJUSTMENT (a) Forward/rearward and left/right adjustments loosen the bolts. (b) For vertical adjustment of front end of door, increase or decrease the number of washers. LOCK AND STRIKER ADJUSTMENT Loosen the mounting bolts to adjust the lock and striker. TORSION BAR REMOVAL REMOVE TORSION BAR FROM LUGGAGE COMPART- MENT DOOR HINGE (a) Install SST to the torsion bar on the hinge side. SST 09804-24010 (c) Slowly lift SST, and remove the torsion bar with SST from the torsion bar bracket. (d) Remove the torsion bar from the center bracket. (e) Do the same for the other side. (b) Push down on SST, and pull the luggage compartment door hinge from the torsion bar. -BODY LUGGAGE COMPARTMENT DOOR BO-26
  • 23. TORSION BAR INSTALLATION INSTALL TORSION BAR TO LUGGAGE COMPARTMENT DOOR HINGE (a) Insert the torsion bar into the bracket as shown. (b) Connect the torsion bar to the center bracket. (c) Install SST to the torsion bar of the hinge side. SST 09804-24010 (d) Slowly lift the torsion bar with SST and place on the torsion bar bracket. (e) Slowly push down SST, and install the torsion bar to the luggage compartment door hinge. (f) Slowly lift SST, and install it. (g) Do the same for the other side. -BODY LUGGAGE COMPARTMENT DOOR BO-27
  • 24. WINDSHIELD MOULDING REMOVAL 1. REMOVE WIPER ARMS (a) Remove two caps. (b) Remove two nuts and two wiper arms. 2. REMOVE COWL LOUVER (a) Remove two caps. (b) Remove seven screws and the cowl louver. 3. REMOVE WINDSHIELD MOULDING Using a knife, cut off the moulding as shown. NOTICE: Do not damage the body with the knife. WINDSHIELD MOULDING COMPONENTS -BODY WINDSHIELD MOULDING BO-28
  • 25. WINDSHIELD MOULDING INSTALLATION (See page BO-28 ) 1. CUT ADHESIVE AT MOULDING INSTALLATION AREA Using the knife, cut off the adhesive around the mou- Iding installation area. 2. APPLY ADHESIVE AT MOULDING INSTALLATION AREA 4. INSTALL COWL LOUVER (a) Install the cowl louver with seven screws. (b) Install two caps. 5. INSTALL WIPER ARMS (a) Install two wiper arms with two nuts. (b) Install two caps. 3. INSTALL WINDSHIELD MOULDING Place the moulding onto the body and tap it by hand. -BODY WINDSHIELD MOULDING BO-29
  • 26. ROOF DRIP SIDE FINISH MOULDING REMOVAL REMOVE ROOF DRIP SIDE FINISH MOULDING Using SST, pull oft the roof drip moulding from front ends. SST 09806-30010 ROOF DRIP SIDE FINISH MOULDING INSTALLATION INSTALL ROOF DRIP SIDE FINISH MOULDING Attach the upper edge of the moulding to the body flange. Tap on the moulding by hand. ROOF DRIP SIDE FINISH MOULDING COMPONENTS -BODY ROOF DRIP SIDE FINISH MOULDING BO-30
  • 27. SIDE PROTECTION MOULDING Precautions for storing moulding materials: • Store in cool place, avoiding direct sunlight, high tem- perature and dust. • The moulding is of polyvinyl chloride, so do not allow it to come in contact with thinner or other solvent, open flame, or boiling water. • The storage time for the moulding and adhesive are limited to about 9 months. COMPONENTS -BODY SIDE PROTECTION MOULDING BO-31
  • 28. 2. REMOVE MOULDING AND ADHESIVE (a) Pull off the moulding by cutting the adhesive with a knife. (b) Scrape off adhesive from the body with a cutter or sandpaper. NOTICE: • Remember that 30-80mm (1.18-3.15in.) of the ends of the moulding are glued tightly with a strong adhesive. • Do not reuse moulding. SIDE PROTECTION MOULDING INSTALLATION (See pages BO-31 and 34) 1. CLEAN MOULDING MOUNTING SURFACE Wipe off stains with cleaner. 1001i-01 SIDE PROTECTION MOULDING REMOVAL 1. REMOVE ENDS OF MOULDING Using a scraper, pry the moulding loose about 30mm (1.18in.) from the ends. HINT: Tape the scraper tip before use. 3. HEAT MOULDING Using a heat light, heat the moulding to 30 - 60°C (86 -140 °F). NOTICE: Do not heat the moulding excessively. The temperature should not be higher than 80_C (176°F). 2. HEAT BODY MOUNTING SURFACE Using a heat light, heat the body mounting surface tc 30 - 50_C (86-122°F). NOTICE: When the moulding is installed, the temperature of the mounting surface should be 20°C (68°F) or higher -BODY SIDE PROTECTION MOULDING BO-32
  • 29. 4. APPLY ADHESIVE TO MOULDING Apply adhesive to both punched out ends of the moulding. NOTICE: Install the moulding within 7 minutes after app- lying the adhesive. Part No. 08850-00051 5. LIFT MOULDING RELEASE SHEET FROM FACE OF MOULDING NOTICE: When the moulding release sheet is removed, be sure that no dirt or dust can get onto the uncovered area. 6. INSTALL MOULDING Push the moulding to the body as shown in the illus- tration. NOTICE: • Be sure that the body and moulding are heated to the proper temperature. • Do not depress the adhesive - coated parts ex- cessively just hold them down with your thumb. • Scrape off any overflowing adhesive with a plastic spatula and clean the surface with a dry rag. • After installation, do not wash the vehicle for 24 hours. -BODY SIDE PROTECTION MOULDING BO-33
  • 30. (2 Door) (4 Door) -BODY SIDE PROTECTION MOULDING BO-34
  • 31. WINDSHIELD REMOVAL 1. REMOVE WIPER ARMS (a) Remove two caps. (b) Remove two nuts and two wiper arms. 2. REMOVE COWL LOUVER (a) Remove two caps. (b) Remove seven screws and the cowl louver. 3. REMOVE FRONT PILLAR GARNISH Remove the garnishes by pulling. 4. REMOVE INNER REAR VIEW MIRROR Remove two bolts and the inner rear view mirror. 5. REMOVE WINDSHIELD MOULDING (See step 3 on page BO-28 ) WINDSHIELD COMPONENTS -BODY WINDSHIELD BO-35
  • 32. WINDSHIELD INSTALLATION (See page BO-35 ) 1. CLEAN AND SHAPE CONTACT SURFACE OF BODY (a) Cut away any rough areas with a knife. HINT: Leave as much of the urethane layer on the body as possible. (b) Clean the cutting surface of the urethane gum with a piece of shop rag saturated in cleaner. HINT: Even if all the urethane has been removed, clean the body. 2. CLEAN REMOVED GLASS BEFORE INSTALLATION (a) Using a scraper, remove the urethane gum sticking the glass. (b) Clean the glass with cleaner. NOTICE: Do not touch the glass after cleaning it. NOTICE: When separating, take care not to damage the paint and interior and exterior ornaments. To prevent scratching the safety pad when removing the windshield, place a plastic sheet between the piano wire and safety pad. (c) Cut the adhesive by pulling the piano wire around it. (d) Remove the glass. NOTICE: Leave as much of the urethane layer on the body as possible when cutting off the glass. 3. POSITION GLASS (a) Place glass in correct position. (b) Check that all contacting parts of the glass rim are perfectly even. (c) Place reference marks between the glass and body. (d) Remove the glass. 6. REMOVE WINDSHIELD GLASS (a) Push piano wire through from the interior. (b) Tie both wire ends to wooden blocks or like object. HINT: Apply adhesive tape to the outer surface to keep the surface from being scratched. -BODY WINDSHIELD BO-36
  • 33. 5. INSTALL DAM Install the dam with double-stick tape as shown in the drawing. NOTICE: Do not touch the glass face after cleaning it. 6. COAT CONTACT SURFACE OF BODY WITH PRIMER ”M” Using a brush, coat the contact surface on the body with Primer M. NOTICE: • Let the Primer coating dry for 10 minutes or more. Make sure that the installation of the glass is fin- ished within 2 hours. • Use care not to leave any part of the contact surface uncoated or excessively coated, as Primer M and G serve to boost the adhesive power of the urethane to the glass or body. • Do not keep any of the opened Primer M and G for later use. 8. MIX ADHESIVE COATING NOTICE: • Be sure that installation of the glass is finished within us- able time. (See step 2 on BO-7 ) • The mixture should be made in 5 minutes or less. (a) Thoroughly clean the glass plate and putty spatula with solvent. (b) Thoroughly mix 500 g (17.64 oz.) of the main agent and 75 g (2.65 oz.) of the hardening agent on a glass plate or like object with a putty spatula. 7. COAT CONTACT SURFACE OF GLASS WITH PRIMER ”G” (a) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G. (b) Before the Primer dries, wipe it off with a clean cloth. NOTICE: Be sure that installation of the glass is finished within 70 minutes. 4. CLEAN CONTACT SURFACE GLASS Using cleaner, clean the contact surface black-colored area around the entire glass rim. NOTICE: Do not touch the glass face after cleaning it. -BODY WINDSHIELD BO-37
  • 34. (a) Position the glass so that the reference marks are lined up, and press in gently along the rim. (b) Using a spatula, apply adhesive on the glass rim. (c) Use a spatula to remove any excess or protruding adhesive. (d) Fasten glass securely until the adhesive sets. 11. INSPECT FOR LEAKS AND REPAIR (a) Perform a leak test after the hardening time has ela- psed. (b) Seal any leaks with auto glass sealer. Part No. 08833-00030 or equivalent. 12. INSTALL FOLLOWING PARTS: • Windshield moulding (See page BO-29 ) • Inner rear view mirror • Front pillar garnish • Cowl louver • Wiper arms 9. APPLY ADHESIVE (a) Cut off the tip of the cartridge nozzle to make a hole 5 mm (0.20 in) in diameter. Fill the cartridge with adhe- sive. (b) Load the cartridge into the sealer gun. (c) Coat the glass with adhesive on all contact surfaces along the ridge. Adhesive height: If adhesive remains on body 3.5-5.0 mm (0.138-0.197 in.) If no adhesive remains on body 8-10 mm (0.31-0.39 in.) 10. INSTALL GLASS HINT: Confirm that the dam is attached the body panel as shown in the drawing. -BODY WINDSHIELD BO-38
  • 35. QUARTER WINDOW GLASS REMOVAL REMOVE THE QUARTER WINDOW GLASS IN THE SAME MANNER AS THE BACK WINDOW GLASS (See step 2 on pages BO-40 and 41) QUARTER WINDOW GLASS INSTALLATION INSTALL THE QUARTER WINDOW GLASS IN THE SAME MANNER AS THE BACK WINDOW GLASS (See steps 1 to 7 on pages BO-41 to 42) QUARTER WINDOW GLASS COMPONENTS -BODY QUARTER WINDOW GLASS BO-39
  • 36. INSTRUMENT PANEL COMPONENTS -BODY INSTRUMENT PANEL BO-43
  • 37. 3. REMOVE DOOR SCUFF PLATE AND COWL SIDE TRIM (a) Remove the cap from the cowl side trim. (b) Release the tab fitting in the rear edge of the scuff plate. (c) Using a clip remover, remove the scuff plate clips from rear side. (d) Remove the cowl side trim from the scuff plate by pulling. 4. REMOVE STEERING WHEEL (See page SR-5 ) INSTRUMENT PANEL REMOVAL (See page BO-43 ) 1. DISCONNECT BATTERY CABLE FROM NEGATIVE TERMINAL 2. REMOVE FRONT PILLAR GARNISH Remove the garnishes by pulling. HINT: Screw sizes in the illustration on the previous page are indicated using the code below for removal and installation of instrument panel. O=6 (0.24) L=22 (0.87) O=5 (0.20) L=16 (0.63) O= 5 (0.20) L=16 (0.63) mm (in.) Shape ShapeShape Code Code Code SizeSizeSize -BODY INSTRUMENT PANEL BO-44
  • 38. 8. REMOVE LOWER NO.1 FINISH PANEL (a) Using a screwdriver, remove the opening covers. HINT: Tape the screwdriver tip before use. (b) Remove the screw. (c) Remove four bolts. (d) Remove the panel. 9. REMOVE COMBINATION SWITCH (a) Disconnect the connectors. (b) Remove three screws and the combination switch. 7. REMOVE HOOD RELEASE LEVER (a) Remove two screws. (b) Slide the lever forward to remove it. 6. REMOVE CONSOLE BOX Remove four screws and the console box. 5. REMOVE STEERING COLUMN COVER Remove four screws and the column covers. -BODY INSTRUMENT PANEL BO-45
  • 39. 12. REMOVE LOWER NO.2 FINISH PANEL (a) Using a screwdriver, remove the opening covers. HINT: Tape the screwdriver tip before use. (b) Remove the screw. (c) Remove four bolts. (d) Remove the panel by pulling. 11. REMOVE COMBINATION METER (a) Remove the bolt. (b) Remove two screws. (c) Remove the meter, then disconnect the connectors. 10. REMOVE CLUSTER FINISH CENTER UPPER PANEL (a) Remove two screws. (b) Remove the panel by pulling, then disconnect the connectors. 13. REMOVE CENTER CLUSTER FINISH PANEL Remove the panel by pulling, then disconnect the connector. 14. REMOVE RADIO (a) Remove four bolts. (b) Remove the radio, then disconnect the connectors. -BODY INSTRUMENT PANEL BO-46
  • 40. 18. REMOVE DUCT HEATER TO REGISTER NO.2 Remove the screw and the duct. 19. REMOVE JUNCTION BLOCK NO.1 Remove two screws and hang the junction block No. 1. 20. REMOVE INSTRUMENT PANEL Remove the bolt, three nuts and the instrument panel. 17. REMOVE HEATER CONTROL PLATE (a) Pull off the heater control knobs. (b) (w/A/C) Pry oft the A/C switch. (c) Using a screwdriver, pry out the heater control plate. HINT: Tape the screwdriver tip before use. (d) Remove three screws and hang the heater control. 15. REMOVE LOWER CENTER FINISH PANEL Remove six screws and the panel. 16. REMOVE CLOCK Using a screwdriver, remove the clock then discon- nect the connector. HINT: Tape the screwdriver tip before use. -BODY INSTRUMENT PANEL BO-47
  • 41. 21. REMOVE FOLLOWING PARTS FROM INSTRUMENT PANEL • Defroster nozzle • Duct heater to register No.1 • Duct heater to register No.3 • No.1 register • Instrument panel center bracket • Instrument panel No.1 mounting bracket INSTRUMENT PANEL INSTALLATION (See page BO-43 ) INSTALL INSTRUMENT PANEL PARTS BY FOLLOWING REMOVAL SEQUENCE IN REVERSE -BODY INSTRUMENT PANEL BO-48
  • 42. SEAT COMPONENTS Front Seat -BODY SEAT BO-49
  • 43. COMPONENTS (Cont’d) -BODY SEAT BO-50
  • 44. Front Seat Belts (USA-for Passenger’s Seat) SEAT BELT COMPONENTS (USA-for Driver’s Seat and CANADA-4 Door) -BODY SEAT BELT BO-51
  • 45. COMPONENTS (Cont’d) (USA - For Driver’s Seat and CANADA - 2 Door) Rear Seat Belts -BODY SEAT BELT BO-52
  • 46. SEAT BELT INSPECTION Emergency Locking Retractor (ELR) and Automatic Locking Retractor (ALR) type 1. RUNNING TEST (IN SAFE AREA) for all seats: (a) Fasten the front seat belts. (b) Drive the car at 10 mph (16 km/h) and make a very hard stop. (e) Check that the belt is locked and cannot be extended at this time. HINT: Conduct this test in a safe area. If the belt does not lock, remove the belt mechanism assembly and conduct the following static check. Also, whenever installing a new belt assembly, verify the proper oper- ation before installation. 2. STATIC TEST for all seats: (a) Verify that the belt locks when pulled out quickly. (b) Remove the locking retractor assembly. (c) Tilt the retractor slowly. (d) Verify that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out at over 45 degrees of tilt. If a problem is found, replace the assembly. except for driver’s seat and shoulder belt: (e) Pull out the whole belt, release it slightly and then pull it out again. (f) Verify that the belt cannot be extended further. If a problem is found, replace the assembly. -BODY SEAT BELT BO-53
  • 47. HINT: 1. The height of the left and right pointers must be equal. 2. Always calibrate the tracking gauge before measuring or after adjusting the pointer height. 3. Take care not to drop the tracking gauge or otherwise shock it. 4. Confirm that the pointers are securely in the holes. (c) When using a tape measure, avoid twists and bends in the tape. (d) When tracking a diagonal measurement from the front spring support inner hole to the suspension member upper rear installation hole, measure along the front spring support panel surface. (Two-dimensional distance) • Horizontal distance in forward / rearward between the centers of two measuring points. • The height format imaginary standard line. (b) In cases in which only one dimension is given, left and right are symmetrical. (c) The dimensions in the following drawing indicate actual distance. Therefore, please use the dimensions as a reference. BODY DIMENSIONS General Information 1. BASIC DIMENSIONS (a) There are two types of dimensions in the diagram. (Three-dimensional distance) • Straight-line distance between the centers of two measuring points. 2. MEASURING (a) Basically, all measurements are to be done with a tracking gauge. For portions where it is not possible to use a tracking gauge, a tape measure should be used. (b) Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers. -BODY BODY DIMENSIONS BO-54
  • 48. ENGINE COMPARTMENT (Three-Dimensional Distance) -BODY BODY DIMENSIONS BO-55
  • 49. BODY OPENING AREAS (Side View: 4 Door) (Three- Dimensional Distance) -BODY BODY DIMENSIONS BO-56
  • 50. BODY OPENING AREAS (Side View: 2 Door) (Three- Dirnensional Distance) -BODY BODY DIMENSIONS BO-57
  • 51. BODY OPENING AREAS (Rear View) (Three-Dimensional Distance) -BODY BODY DIMENSIONS BO-58
  • 52. (Three-Dimensional Distance) UNDER BODY -BODY BODY DIMENSIONS BO-59
  • 53. UNDER BODY (Cont’d) (Two- Dimensional distance) -BODY BODY DIMENSIONS BO-60
  • 54. SERVICE SPECIFICATIONS TORQUE SPECIFICATION (USA- for Driver’s Seat and CANADA, 4 Door) Seat outer belt shoulder anchor x Body Shoulder retractor - front x Body Seat outer belt lower side x Body Seat outer belt lower side x Body Shoulder retractor - rear x Body Shoulder belt inner guide x Seat (USA- for Passenger’s Seat) Lap belt inner buckle x Seat Shoulder buckle x Front door CRS, tether anchor x Body Adjustable anchor x Body Seat center hinge x Body Seat x Seat center hinge Shoulder anchor x Body Seat inner belt x Body Lap retractor x Body Seat inner belt x Seat Seat track x Body Seat hinge x Body Seat x Seat hinge Seat back x Body Front Seat Belts Part tightened Rear Seat Belt Clevis x Body SEAT BELTS ELR x Body ELR x Body Front Seat Rear Seat 48in.-lbf 69in.-lbf 69in.-Ibf 69in.-lbf 69in.-lbf 69in.-lbf 69in.-lbf kgf-cm ft-lbf SEAT 400 440 440 400 440 440 440 440 210 110 440 195 195 7.8 5.4 375 N- m 7.8 7.8 7.8 7.8 7.8 -BODY SERVICE SPECIFICATIONS BO-61

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