Body

PREPARATIONSST(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 qtsLitersItem

-BODY PREPARATIONBO-5

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


3. CHECK ADHESIVE HARDENING TIMEAfter main and hardening agents are mixed, leak testsshould be made only after the hardening time haselapsed.Example: The hardening time for adhesive set No. 35with and ambient temperature of 25°C (77°F) is 2 1 /2 hours.

NOTICE: Do not drive the vehicle until at least double thehardening time has elapsed.

2. CHECK ADHESIVE USABLE TIMEAfter mixing main and hardening agents, finish glassinstallation 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 within45 minutes.

1. CHOOSE SUITABLE ADHESIVE SETUse an adhesive set suitable for the ambient temper-ature.

Windshieldglass adhesiveset No. 35Windshieldglass adhesiveset No. 45

Windshieldglass adhesiveset No. 15

15 - 35°C(59 - 95°F)

35 - 45°C(95 - 113°F)

Ambienttemperature

0-15°C(32 - 59°F)

08850-00070

08850-00080

08850-00090

Part NamePart No.


HOODHOOD ADJUSTMENTHINT: Since the centering bolt is used as the hoodhinge and lock set bolt, the hood and lock cannot beadjusted with it on. Substitute the bolt with washerfor the centering bolt.

1. ADJUST HOOD IN FORWARD / REARWARD ANDLEFT/RIGHT DIRECTIONSAdjust the hood by loosening the hood side hingebolts.

2. ADJUST FRONT EDGE OF HOOD IN VERTICAL DIRECTIONSAdjust 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 HOODBO-8

FRONT DOORCOMPONENTS

(4 Door)

-BODY FRONT DOORBO-9

COMPONENTS (Cont’d)

(2 Door)


2. REMOVE DOOR INSIDE HANDLE(a) Remove the screw and slide the handle forward.(b) (4 Door)Disconnect the handle from the control link andremove the handle.(2 Door)Disconnect the handle from two control links andremove the handle.

FRONT DOOR ADJUSTMENT1. ADJUST DOOR IN FORWARD/ REARWARD ANDVERTICAL DIRECTIONSUsing SST, adjust the door by loosening the body sidehinge bolts.SST 09812 - 00010

3. ADJUST DOOR LOCK STRIKER(a) Check that the door fit and door lock linkages areadjusted 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 HANDLEPull off the snap ring with a shop rag and remove theregulator handle and plate.

2. ADJUST DOOR IN LEFT/RIGHT AND VERTICALDIRECTIONSLoosen the door side hinge bolts to adjust.HINT: Substitute the bolt with washer for the center-ing bolt. (See page BO-8 )

-BODY FRONT DOORBO-1 1

4. REMOVE REAR VIEW MIRRORHINT: 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 hereand pry off the cover. Prying off the cover in the othersides 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 thepanel 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 weatherstripand remove the door upper trim.

6. REMOVE DOOR OUTER WEATHERSTRIPPry out the clips from the edge of the weatherstripand remove the weatherstrip.

7. REMOVE SPEAKER(a) Remove three screws and the speaker.(b) Disconnect the connector.


13. REMOVE DOOR LOCK(4 Door)(a) Disconnect the link from the door lock and remove thelink.(b) Disconnect two links from the outside handle and thedoor lock cylinder.(c) Remove three screws.(d) Remove the door lock through the service hole.

10. REMOVE DOOR GLASSHINT: Insert a shop rag inside the panel to preventscratching 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 RUNPull 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.


FRONT DOOR ASSEMBLY(See pages BO-9 and 10)1. BEFORE INSTALLING PARTS. COAT THEM WITHMP GREASE(a) Apply MP grease to the sliding surface and gears ofthe window regulator.

NOTICE: Do not apply grease to the spring of the windowregulator.

(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 thedoor lock cylinder.(e) Remove three screws.(f) Remove the door lock through the service hole.

14. REMOVE OUTSIDE HANDLERemove two bolts and the outside handle with thelock cylinder.

15. REMOVE DOOR LOCK CYLINDERRemove the retainer and the lock cylinder from theoutside handle.

(b) Apply MP grease to the sliding surface of the doorlock.


4. INSTALL DOOR LOCK(4 Door)(a) Install the door lock with three screws.(b) Connect two links to the outside handle and the doorlock 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 doorlock 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 CYLINDERInstall 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 HANDLEInstall the outside handle with two bolts.


7. INSTALL DOOR GLASSHINT: Install a shop rag inside the panel to preventscratching 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 RUNInsert the glass run to the door frame.9. ADJUST DOOR GLASSAdjust the equalizer arm up to down and tighten ifwhere 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 holecover.(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.


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 itrearward.(c) Install the screw.

12. INSTALL DOOR OUTER WEATHERSTRIPInstall the claw of the clips into the upper panel slitand push the moulding on to the panel.

13. INSTALL DOOR UPPER TRIM(a) Install the claw of the clips into the upper panel slitand 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.


17. INSTALL REGULATOR HANDLEWith door window fully closed, install the plate andthe regulator handle with the snap ring as shown.


REAR DOORCOMPONENTS

-BODY REAR DOORBO-19

REAR DOOR ADJUSTMENT1. ADJUST DOOR IN FORWARD/ REARWARD ANDVERTICAL 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 HANDLEPull off the snap ring with a shop rag and remove theregulator handle and plate.

3. ADJUST DOOR LOCK STRIKER(a) Check that the door fit and door lock linkages areadjusted 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 andremove the handle.

2. ADJUST DOOR IN LEFT/RIGHT AND VERTICALDIRECTIONSLoosen the door side hinge bolts to adjust.


3. REMOVE DOOR TRIM(a) Remove two screws and the armrest.(b) Insert a screwdriver between the door trim and thepanel to pry out.HINT: Tape the screwdriver tip before use.(c) Remove the door trim.

8. REMOVE DOOR GLASSHINT: Insert a shop rag inside the panel to preventscratching the glass.Disconnect the glass from the regulator arm andremove 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 RUNPull 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 weatherstripand remove the door upper trim.

5. REMOVE DOOR OUTER WEATHERSTRIPPry out the clips from the edge of the weatherstripand remove the weatherstrip.


REAR DOOR GLASS REPLACEMENT(See page BO-19 )1. REMOVE GLASS CHANNEL WITH SCREWDRIVEROR LIKE OBJECT2. APPLY SOAPY WATER TO INSIDE OF WEATHER-STRIP3. INSTALL CHANNEL BY TAPPING IT WITH PLASTICHAMMER

12. REMOVE DOOR LOCK(a) Remove the silencer.(b) Remove three clips.(c) Disconnect two links from the door lock and removetwo 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 WEATHERSTRIPRemove the quarter window glass together with theweatherstrip 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 HANDLERemove two bolts and the outside handle.


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 ofthe 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 twolinks.(d) Install three clips.(e) Install the silencer.

(b) Apply MP grease to the sliding surface of the doorlock.

4. INSTALL WINDOW REGULATOR(a) Place the regulator through the service hole.(b) Install three regulator mounting bolts.

2. INSTALL OUTSIDE HANDLEInstall the outside handle with two bolts.


9. INSTALL SERVICE HOLE COVER(a) Seal the service hole cover with adhesive.HINT: Bring out the link through the service holecover.(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 GLASSHINT: Insert a shop rag inside the panel to preventscratching the glass.Place the glass in the door cavity and connect theglass with the regulator arm.8. INSTALL DOOR GLASS RUNInsert the glass run to the door frame.

5. INSTALL QUARTER WINDOW GLASS WITH WEA-THERSTRIP6. INSTALL DIVISION BAR(a) Install the division bar with two bolts.(b) Install the screw under the weatherstrip.

10. INSTALL DOOR OUTER WEATHERSTRIPInstall the weatherstrip with clips to the panel.


12. INSTALL DOOR TRIM(a) Install the door trim with clips to the inside door panelby 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 slitand push the weatherstrip on to the panel.(b) Install the clip.

14. INSTALL REGULATOR HANDLEWith door window fully closed, install the plate andthe regulator handle with snap ring as shown.

13. .INSTALL DOOR INSIDE HANDLE(a) Install the handle with the control link.(b) Install the screw.


LUGGAGE COMPARTMENT DOORLUGGAGE COMPARTMENT DOORADJUSTMENT(a) Forward/rearward and left/right adjustments loosenthe bolts.(b) For vertical adjustment of front end of door, increaseor decrease the number of washers.

LOCK AND STRIKER ADJUSTMENTLoosen the mounting bolts to adjust the lock andstriker.

TORSION BAR REMOVALREMOVE 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 SSTfrom 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 compartmentdoor hinge from the torsion bar.

-BODY LUGGAGE COMPARTMENT DOORBO-26

TORSION BAR INSTALLATIONINSTALL TORSION BAR TO LUGGAGE COMPARTMENTDOOR 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 thetorsion bar bracket.

(e) Slowly push down SST, and install the torsion bar tothe luggage compartment door hinge.

(f) Slowly lift SST, and install it.(g) Do the same for the other side.

-BODY LUGGAGE COMPARTMENT DOORBO-27

WINDSHIELD MOULDING REMOVAL1. 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 MOULDINGUsing a knife, cut off the moulding as shown.

NOTICE: Do not damage the body with the knife.

WINDSHIELD MOULDINGCOMPONENTS

-BODY WINDSHIELD MOULDINGBO-28

WINDSHIELD MOULDING INSTALLATION(See page BO-28 )1. CUT ADHESIVE AT MOULDING INSTALLATIONAREAUsing the knife, cut off the adhesive around the mou-Iding installation area.2. APPLY ADHESIVE AT MOULDING INSTALLATIONAREA

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 MOULDINGPlace the moulding onto the body and tap it by hand.

-BODY WINDSHIELD MOULDINGBO-29

ROOF DRIP SIDE FINISH MOULDINGREMOVALREMOVE ROOF DRIP SIDE FINISH MOULDINGUsing SST, pull oft the roof drip moulding from frontends.SST 09806-30010

ROOF DRIP SIDE FINISH MOULDINGINSTALLATIONINSTALL ROOF DRIP SIDE FINISH MOULDINGAttach the upper edge of the moulding to the bodyflange. Tap on the moulding by hand.

ROOF DRIP SIDE FINISH MOULDINGCOMPONENTS

-BODY ROOF DRIP SIDE FINISH MOULDINGBO-30

SIDE PROTECTION MOULDINGPrecautions 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 arelimited to about 9 months.

COMPONENTS

-BODY SIDE PROTECTION MOULDINGBO-31

2. REMOVE MOULDING AND ADHESIVE(a) Pull off the moulding by cutting the adhesive with aknife.(b) Scrape off adhesive from the body with a cutter orsandpaper.

NOTICE:

• Remember that 30-80mm (1.18-3.15in.) of theends of the moulding are glued tightly with a strongadhesive.

• Do not reuse moulding.

SIDE PROTECTION MOULDINGINSTALLATION(See pages BO-31 and 34)1. CLEAN MOULDING MOUNTING SURFACEWipe off stains with cleaner.

1001i-01

SIDE PROTECTION MOULDING REMOVAL1. REMOVE ENDS OF MOULDINGUsing a scraper, pry the moulding loose about 30mm(1.18in.) from the ends.HINT: Tape the scraper tip before use.

3. HEAT MOULDINGUsing 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 SURFACEUsing a heat light, heat the body mounting surface tc30 - 50�C (86-122°F).

NOTICE: When the moulding is installed, the temperatureof the mounting surface should be 20 °C (68°F) or higher


4. APPLY ADHESIVE TO MOULDINGApply adhesive to both punched out ends of themoulding.

NOTICE: Install the moulding within 7 minutes after app-lying the adhesive.

Part No. 08850-000515. LIFT MOULDING RELEASE SHEET FROM FACE OFMOULDING

NOTICE: When the moulding release sheet is removed, besure that no dirt or dust can get onto the uncovered area.

6. INSTALL MOULDINGPush the moulding to the body as shown in the illus-tration.

NOTICE:

• Be sure that the body and moulding are heated tothe 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 plasticspatula and clean the surface with a dry rag.

• After installation, do not wash the vehicle for 24hours.


(2 Door)

(4 Door)


WINDSHIELD REMOVAL1. 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 GARNISHRemove the garnishes by pulling.4. REMOVE INNER REAR VIEW MIRRORRemove two bolts and the inner rear view mirror.5. REMOVE WINDSHIELD MOULDING(See step 3 on page BO-28 )

WINDSHIELDCOMPONENTS

-BODY WINDSHIELDBO-35

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 thebody as possible.(b) Clean the cutting surface of the urethane gum with apiece 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 stickingthe glass.(b) Clean the glass with cleaner.

NOTICE: Do not touch the glass after cleaning it.

NOTICE: When separating, take care not to damage thepaint and interior and exterior ornaments.

To prevent scratching the safety pad when removingthe windshield, place a plastic sheet between thepiano 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 thebody 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 areperfectly 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 tokeep the surface from being scratched.


5. INSTALL DAMInstall the dam with double-stick tape as shown inthe drawing.

NOTICE: Do not touch the glass face after cleaning it.

6. COAT CONTACT SURFACE OF BODY WITHPRIMER ”M”Using a brush, coat the contact surface on the bodywith 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 surfaceuncoated or excessively coated, as Primer M and Gserve to boost the adhesive power of the urethaneto the glass or body.

• Do not keep any of the opened Primer M and G forlater use.

8. MIX ADHESIVE COATINGNOTICE:

• 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 spatulawith solvent.(b) Thoroughly mix 500 g (17.64 oz.) of the main agentand 75 g (2.65 oz.) of the hardening agent on a glassplate 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 glassand 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 finishedwithin 70 minutes.

4. CLEAN CONTACT SURFACE GLASSUsing cleaner, clean the contact surface black-colored area around the entire glass rim.

NOTICE: Do not touch the glass face after cleaning it.


(a) Position the glass so that the reference marks arelined 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 protrudingadhesive.(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 5mm (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 surfacesalong the ridge.

Adhesive height:If adhesive remains on body3.5-5.0 mm (0.138-0.197 in.)If no adhesive remains on body8-10 mm (0.31-0.39 in.)

10. INSTALL GLASSHINT: Confirm that the dam is attached the bodypanel as shown in the drawing.


QUARTER WINDOW GLASS REMOVALREMOVE THE QUARTER WINDOW GLASS IN THE SAMEMANNER AS THE BACK WINDOW GLASS(See step 2 on pages BO-40 and 41)

QUARTER WINDOW GLASS INSTALLATIONINSTALL THE QUARTER WINDOW GLASS IN THE SAMEMANNER AS THE BACK WINDOW GLASS(See steps 1 to 7 on pages BO-41 to 42)

QUARTER WINDOW GLASSCOMPONENTS

-BODY QUARTER WINDOW GLASSBO-39

INSTRUMENT PANELCOMPONENTS

-BODY INSTRUMENT PANELBO-43

3. REMOVE DOOR SCUFF PLATE AND COWL SIDETRIM

(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 rearside.(d) Remove the cowl side trim from the scuff plate bypulling.4. REMOVE STEERING WHEEL(See page SR-5 )

INSTRUMENT PANEL REMOVAL(See page BO-43 )1. DISCONNECT BATTERY CABLE FROM NEGATIVETERMINAL2. REMOVE FRONT PILLAR GARNISHRemove the garnishes by pulling.

HINT: Screw sizes in the illustration on the previouspage are indicated using the code below for removaland installation of instrument panel.

�=6 (0.24)L=22 (0.87)

�=5 (0.20)L=16 (0.63)

�= 5 (0.20)L=16 (0.63)

mm (in.)

Shape ShapeShape Code CodeCodeSizeSizeSize


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 BOXRemove four screws and the console box.

5. REMOVE STEERING COLUMN COVERRemove four screws and the column covers.


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 theconnectors.

13. REMOVE CENTER CLUSTER FINISH PANELRemove the panel by pulling, then disconnect theconnector.

14. REMOVE RADIO(a) Remove four bolts.(b) Remove the radio, then disconnect the connectors.


18. REMOVE DUCT HEATER TO REGISTER NO.2Remove the screw and the duct.19. REMOVE JUNCTION BLOCK NO.1Remove two screws and hang the junction block No.1.20. REMOVE INSTRUMENT PANELRemove 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 PANELRemove six screws and the panel.16. REMOVE CLOCKUsing a screwdriver, remove the clock then discon-nect the connector.HINT: Tape the screwdriver tip before use.


21. REMOVE FOLLOWING PARTS FROM INSTRUMENTPANEL

• 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 FOLLOWINGREMOVAL SEQUENCE IN REVERSE


SEATCOMPONENTS

Front Seat

-BODY SEATBO-49


-BODY SEATBO-50

Front Seat Belts(USA-for Passenger’s Seat)

SEAT BELTCOMPONENTS

(USA-for Driver’s Seatand CANADA-4 Door)

-BODY SEAT BELTBO-51


(USA - For Driver’s Seatand CANADA - 2 Door)

Rear Seat Belts


SEAT BELT INSPECTIONEmergency Locking Retractor (ELR) andAutomatic Locking Retractor (ALR) type1. 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 veryhard stop.(e) Check that the belt is locked and cannot be extendedat this time.HINT: Conduct this test in a safe area. If the belt doesnot lock, remove the belt mechanism assembly andconduct the following static check. Also, wheneverinstalling a new belt assembly, verify the proper oper-ation before installation.

2. STATIC TESTfor 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 15degrees or less, and cannot be pulled out at over 45degrees 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 pullit out again.(f) Verify that the belt cannot be extended further.If a problem is found, replace the assembly.


HINT:1. The height of the left and right pointers must be equal.2. Always calibrate the tracking gauge before measuringor after adjusting the pointer height.3. Take care not to drop the tracking gauge or otherwiseshock it.4. Confirm that the pointers are securely in the holes.(c) When using a tape measure, avoid twists and bends inthe tape.(d) When tracking a diagonal measurement from thefront spring support inner hole to the suspensionmember upper rear installation hole, measure alongthe 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 andright are symmetrical.(c) The dimensions in the following drawing indicateactual distance. Therefore, please use the dimensionsas a reference.

BODY DIMENSIONSGeneral Information1. 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 atracking gauge. For portions where it is not possible touse a tracking gauge, a tape measure should be used.

(b) Use only a tracking gauge that has no looseness in thebody, measuring plate, or pointers.

-BODY BODY DIMENSIONSBO-54

ENGINE COMPARTMENT

(Three-Dimensional Distance)


BODY OPENING AREAS (Side View: 4Door)

(Three- Dimensional Distance)


BODY OPENING AREAS (Side View: 2Door)

(Three- Dirnensional Distance)


BODY OPENING AREAS (Rear View)




UNDER BODY


UNDER BODY (Cont’d)

(Two- Dimensional distance)


SERVICE SPECIFICATIONSTORQUE 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 SPECIFICATIONSBO-61

Business

Body