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. 42-1

BODYCONTENTS 42109000119

DOOR ............................. 21DOOR ASSEMBLY ..................... 30DOOR GLASS AND REGULATOR ...... 34DOOR HANDLE AND LATCH .......... 37DOOR TRIM AND WATERPROOF FILM....................................... 32

GENERAL INFORMATION .............. 21ON-VEHICLE SERVICE ................ 28SEALANT ............................. 21SERVICE SPECIFICATIONS ............ 21SPECIAL TOOLS ...................... 21TROUBLESHOOTING .................. 22WINDOW GLASS RUNCHANNEL ANDDOOR OPENING WEATHERSTRIP ..... 41

FENDER ............................ 8FENDER ................................ 8SEALANT .............................. .8

FUEL FILLER DOOR ................ 9

SUNROOF . . . . . . . . . . . ..m........... 42ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 46SEALANT . . . . . . . . . . . . . ..*............. 42SERVICE SPECIFICATIONS ............ 42SPECIAL TOOLS ...................... 42SUNROOF ............................ 48TROUBLESHOOTING .................. 43

TRUNK LID ......................... 4SPECIAL TOOL ............ : ........... .4TROUBLESHOOTING ................... .4TRUNK LID ............................. 5

UNDER COVER .................... 55WINDOW GLASS .................. 10

ADHESIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . 10QUARTER WINDOW GLASSc2-door models> . . . . . . . . . . . . . . . . . . . . . . 17REAR WINDOW GLASS . . . . . . . . . . . . . . . 19

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42-2 BODY - HoodHOOD 42100070010. . *TROUBLESHOOTING . >-..-

Symptom Probable cause RemedyImproper closure Striker and latch not properly aligned Adjust the alignmentDifficult locking and unlockingUneven body clearance incorrectly installed hood Adjust the installation of hoodUneven height Incorrect hood bumper height Adjust the hood bumper height

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42-4 BODY - Trunk LidTRUNK LID .SPECIAL TOOL

42100060079. ..

Tool Tool number and name Supersession ApplicationMB991 244 MB991 244-01 Removal and installation oftrunk lid torsion barTorsion bar removerand installer

8991244

TROUBLESHOOTING 42100070027Symptom Probable cause RemedyImproper closure Striker and latch not properly aligned Adjust the alignmentDifficult locking and unlockingUneven body clearance Incorrectly installed trunk lid Adjust the installation of trunk lidUneven height Incorrect trunk lid bumper height Adjust the trunk lid bumper height

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BODY - Trunk Lid . 42-5TRUNK LIDREMOVAL AND INSTALLATION

.Cd

+A, .B1

Trunk lid panel removall License elate liahtl License plate girnish(Refer to GROUP 51.)1. Bumper2. Cylinder lock retainer3. Trunk lid lock cylinder4. Trunk lid latch5. Trunk lid torsion bars6. Trunk lid panelTrunk lid latch removal4. Trunk lid latchTrunk lid hinge removal steps

steps

l Rear shelf trim (Refer to GROUP 52A.)6. Trunk lid panel assembly7. Trunk lid hinge

Trunk lid striker removal stepsl Rear end trim cover(Refer to GROUP 52A.)8. Trunk lid striker

8RIM0261

42100220064

8

Adjustment of clearance around

00004813

Trunk lid release handle and cableremoval stepsl Front seat (L.H.)(Refer to GROUP 52A.)l Rear seat (Refer to GROUP 52A.)l Scuff plate (L.H.), quarter trim (L.H.)(Refer to GROUP 52A.)l Front scuff plate (L.H.), rear scuff plate(L.H.), center pillar trim lower (L.H.)(Refer to GROUP 52A.)l Trunk side trim (L.H.)(Refer to GROUP 52A.)4. Trunk lid latch9. Trunk lid release handle10. Trunk lid release cableTrunk lid weatherstrip removal

.A4 11. Trunk lid weatherstrip removal

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42-6 BODY - Trunk LidTrunk lid torsion bars

MB991 244 18A020400004519

IA0009

REMOVAL SERVICE POINT+A,TRUNK LID TORSION BAR REMOVAL1.2.

Disconnect the body harness and the harness connectorof the rear shelf lower panel.install the special tool as shown in the figure, and thenremove the torsion bar from the link while pushing thespecial tool downwards. Next, repeat the procedure fromthe other side.CautionBe sure to attach the special tool properly, as thebody or parts could be damaged when the torsionbar is removed from the special tool.

INSTALLATION SERVICE POINTS.A+ TRUNK LID WEATHERSTRIP INSTALLATIONInstall the trunk lid weatherstrip so that the marking and thejoint are aligned with the body center line.

I\I.B+TRUNK LID TORSION BAR INSTALLATION1. Check the color of the identification mark at the middleof the torsion bars to make sure that the correct torsionbars are being used.

Torsion bar 1 Identification color

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BODY - Trunk Lid . 42-7Trunk lid torsion bars

MB991 244 WA028400004519

Trunk lid inner panel

ory?FF

A18P0082

2. Insert the end of the torsion bar through the link sidemating hole.

3. Using the special tool attached to the tortion bar asillustrated, twist the bar to connect it to the link. Thenhang the bar on the holder.CautionBe sure to attach the special tool properly, as thebody or parts could be damaged when the torsionbar is removed from the special tool.

.C+ BUMPER INSTALLATIONInstall the bumper as shown in the figure.

INSPECTION 42100400031TRUNK LID LATCH SWITCH CONTINUITY CHECK

Switch position Terminal No.1 Body groundON (Latch open) 0 0OFF (Latch shut)

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42-8 BODY - FenderFENDER . 42100050045.SEALANT

ItemSplash shield

FENDER

Specified sealant3M ATD Part No. 8625 or equivalent

RemarkRibbon sealer

42100190129

REMOVAL AND INSTALLATIONPre-removal and Post-installation Operation(1) Front Bumper Removal and Installation

18M0035Sealant: 3M ATD Part No. 8625or equivalent

00004814

Removal steps1. Stone guard2. Splash shield 3. Ornament4. Fender

,

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BODY - Fuel Filler Door 42-9FUEL FILLER DOOR 42100250131REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation(1) Front Seat (L.H.) Removal and Installation(Refer to GROUP 52A.)(2) Rear Seat Removal and Installation(Refer to GROUP 52A.)(3) Scuff Plate (L.H.) and Quarter Trim Removal andInstallation (Refer to GROUP 52A.)

(4) Front Scuff Plate (L.H.), Refer Scuff Plate (L.H.) andCenter Pillar Trim Lower (L.H.) Removal andInstallation (Refer to GROUP 52A.)(5) Trunk Side Trim (R.H.) Removal and Installation(Refer to GROUP 52A.) .

I Fuel filler door height and clearanceadjustment

18M026000005017

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42-10 BODY - Window GlassWINDOW GLASS 42200050079. .ADHESIVESI tems I Specified adhesives I

WindshieldQuarter window glass

1 Rear window glass

SPECIAL TOOLS 42200060072Tool Tool number and name

MB990449Window moldingremover

MB990480Glass holder

SupersessionGeneral service tool

General service tool

ApplicationRemoval of the window molding

Removal and installation ofwindow glass

TROUBLESHOOTING 42200070044Symptom Probable cause / RemedyWater leak throughwindshield Defective sealDefective body flange

Fill sealantCorrect

Water leak through Defective sealquarter window Defective body flangeFill sealantCorrect

Water leak through Defective sealrear window Defective body flangeFill sealantCorrect

.

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BODY - Window Glass 42-11WINDOW GLASS 42200010053GENERALThe windshield and window glass are attached by an urethane-base adhesive to the window frame.This adhesive not only provides improved glass holding and sealing, but also permits use of body openingshaving a greater structural strength.ADHESIVE

Adhesive Kit Quantity _3M ATD Part No. 8609 SUPER FAST URETHANE One cartridge3M ATD Part No. 8608 SUPER FAST URETHANE As requiredPRIMER *

RESERVE ITEMSReserve Items Applications QuantityWire (dia. length) For cutting adhesive Five pieces of wire0.6 mm x 1 m (.02 in. x 3.3 ft.)Adhesive gun For adhesive application OneWiping rags As requiredSealer For prevention of water leaks and As requiredgathering after adhesive application3M ATD Part No. 8906 or equivalent For cleaning As requiredGlass holder TwoSpacers (Service Part) As requiredWindow molding (Service Part) OneDam (Service Part) As requiredTectyl 506T (Valvoline Oil Company) - As required

42-12

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BODY - Window Glass

Body side

iCleaning of adhesion surface

Reusing the glass

Cut off the resrdual adhesive until the thicknessis less than 2 mm (.08 In.). Clean the adhesionsurface with 3M ATD Part No. 8906 or equivalent,and let dry for 3 minutes or more.

WORKING PROCESS _

Window glass installation procedure

Completelyut off all of the residualadhesive.Clean the adhesion surface with 3M ATD Part

Clean off any dirt adhering to the adhesionze Gluing of window dam and window spacerAttach the window spacer to set the positions Glue the window dam and window spacer to the glass, following the standard position allthe way around the inside edge of the glass.tApplication of primer

Apply to the adhesion surface of the body, andlet dry for 3 minutes or more.

Application of primerApply sufficient primer evenly to the adhesion surface so that there is no patchiness.After application, let dry for 3 to 30 minutes.

tApplication of adhesiveWithin 30 minutes after applying the primer, apply the adhesive evenly all the way aroundthe inside edae of the alass.

Installing the glassAfter applying the adhesive, lightly press the glass evenly so that it adherescompletely

CleaningAfter removing any adhesive that is sticking out or adhering to the bodyor glass with a spatula, etc., clean off with 3M ATD Part No. 8906 or equiva-1 ent. cChecking for water leaksCarry out a shower test to check that no water will leak through.

.

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BODY - Window Glass 42-13WINDSHIELD 42200100266REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation(1) Front Pillar Trim Removal and Installation(Refer to GROUP 52A.) (2) Headlining Removal and Installation(Refer to GROUP 52A.)

A-.-j .A-J

Section A-A Section B-B Section C-C mm (in.)

Adhesive: 3M ATD Part No. 8609 Super Fast Urethane and 3M ATD Part No. 8608 Super Fast UrethanePrimer or eaubment

tRemoval steps1. Roof drip molding

18M020100004661

4. Windshield spacer

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42-14 BODY - Window Glass

A18M0209

MB990480

REMOVAL SERVICE POINTS *+A, ROOF DRIP MOLDING REMOVALUse the special tool to lever out the molding.CautionIf the molding has become warped, it should not be reused.

+B, WINDSHIELD REMOVAL1. In order to protect the body (paint surface), apply clothtape to all body areas around the installed windshield.2. Using a sharp-point drill, make a hole in the windshieldadhesive.3. Pass the piano wire from the inside of the vehicle throughthe hole.4. Pull the piano wire alternately from the inside and outside

along the windshield to cut the adhesive.CautionDo not let the piano wire touch the edge of thewindshield.5. Make mating marks on the windshield and body.

6. Use the special tool to remove the windshield.

7. Use a knife to cut away the remaining adhesive so thatthe thickness is within 2 mm (.08 in.) around the entire

BODY - Window Glass 42-15

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t

a.

9.

10.

Finish the flange surfaces so that they are smooth.Caution(1) Be careful not to remove more adhesive than isnecessary.(2) Be careful also not to damage the paintwork onthe body surface with the knife. If the paintworkis damaged, repair the damaged area with repairpaint or anti-rust agent.When reusing the glass, remove the adhesive stilladhering to the glass, and clean with 3M ATD Part No.6906 or equivalent.Clean the body side in the same way.CautionLet the cleaned places stand for 3 minutes or more,and carry out the next procedures after they havedried. Also, do not touch any surface that has beencleaned.

INSTALLATION SERVICE POINTS,A+ CLIP/WINDOW DAM/WINDOW SPACER/WINDSHIELD UPPER MOLDING/WINDSHIELD

INSTALLATION1.

2.

3.4.

5.

When replacing the glass, temporarily set the glass againstthe body, and place a mating mark on the glass andbody.Use 3M ATD Part No. 6906 or equivalent to degreasethe inside and outside of the windshield and the bodyflanges.Soak a sponge in the primer, and apply evenly to theglass and the body in the specified places.Apply the primer, and then let it dry for 3 to 30 minutes.Caution(1) The primer strengthens the adhesive, so be sureto apply it evenly around the entire circumference.However, a too thick application will weaken theadhesive.(2) Do not touch the coated surface.

Attach the window dam in the specified positions so that 42-16 BODY - Window Glass

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Clip

8. Fill a sealant gun with adhesive. Then apply the adhesiveevenly around the windshield within 30 minutes afterapplying the primer.NOTECut the tip of the sealant gun nozzle into a V shapeto simplify adhesive application.

9. Place the clips onto the clip studs.

10.

11.

12.

Align the mating marks on the glass and the body, andlightly press the windshield evenly so that it adherescompletely.Use a spatula or the like to remove any excessiveadhesive. Clean the surface with 3M ATD Part No. 8906or equivalent. Install the roof drip molding before theadhesive hardens.Try not to move the vehicle until theadhesive sets.Wait 30 minutes or more, and then test for water leakage.Caution(1) Do not move the vehicle unless absolutklynecessary.(2) When testing for water leakage, do not pinch theend of the hose to spray the water.


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QUARTER WINDOW GLASS c2-door models> 42200250158REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation(1) Quarter Trim, Center Pillar Trim and Rear Pillar TrimRemoval and Installation (Refer to GROUP 52A.) (2) Headlining Removal and Installation(Refer to GROUP 52A.)

B

A A

> B

Section A-A . Section B-B

18M0268

Adhesive: 3M ATD Part No. 8609 Super Fast Urethane and 3M ATD Part No. 8608 Super Fast UrethanePrimer or equipment

6

Removal steps

118M0225

00004816


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REMOVAL SERVICE POINT -dAbQUARTER WINDOW GLASS REMOVAL .Remove the quarter window glass by the same procedureas for the windshield. (Refer to P.42-14.)

--- A21 (.83)

Section A-A Dual-lock fastener

Y 1.5 (.059)mm (in.) A18M0223

INSTALLATION SERVICE POINTS.A4 WINDOW DAM/DUAL-LOCK FASTENER/QUARTER

WINDOW GLASS INSTALLATION1.

2.3.4.5.

Use 3M ATD Part No. 8906 or equivalent to degreasethe window dam and dual lock fastener mounting surfaceson both the glass and the body.Attach the window dam.install the dual lock fastener to the shown position.Apply primer and adhesive. (Refer to P.42-17.)Install the glass in the same way as for the windshield.(Refer to P.42-15.)


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REAR WINDOW GLASS 42200160154REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation(1) High Mounted Stop Light Removal and Installation(Refer to GROUP 54.)(2) Rear Pillar Trim Removal and Installation(Refer to GROUP 52A.)

(3) Headlining Removal and Installation(Refer to GROUP 52A.)

Section A-A

v Primer16 (63) Primer(Entirecircumference)

Section B-B mm (in.)

Adhesive: 3M ATD Part No. 8609 Super Fast Urethane and 3M ATD Part No. 8608 Super Fast UrethanePrimer or equipment

88/

1

- 9nl45

716M020300004663

Removal steps


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REMOVAL SERVICE POINTS *+A,ROOF DRIP MOLDING/ REAR WINDOW LOWER

MOLDING REMOVALUse the special tool to lever out the molding.CautionIf the molding has become warped, it should not be reused.

+B,REAR WINDOW GLASS REMOVALRemove the rear window glass by the same procedure asfor the windshield. (Refer to P.42-14.)

Window dam attachment position atlefl and right of glass

Section A-A16 mm (.63 in.)

Transparent dot mark1810204Window dam attachment position atbottom of glass Section B-B

18.5 mm (.728 in.)

16M020500004664

INSTALLATION SERVICE POINT.A+ CLIP/WINDOW DAM/REAR WINDOW GLASS

1.

2.

INSTALLATIONUse 3M ATD Par-t No. 8906 or equivalent to degreasethe inside and outside edges of the rear window glassand the surface of the body flange.Attach the window dam in the specified positions so thatthere are no bends or lifts on the inside of the rear windowglass.NOTE ?Attach the dam at the bottom of the glass so that theclearance at both left and right will be the same duringinstallation.

c .BODY - Door 42-21

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DOOR 42300010032GENERAL INFORMATIONPOPERATIONPower windows

l When the power window (main or sub) switchis depressed (UP or DOWN) with the ignitionswitch in the ON position, current flows throughfusible link No. 6 to the power window motor.This energizes the power window motor,causing the door window glass to open or close.

l When the power window lock switch is placedin the LOCK (OFF) position, no switch otherthan the main switch at the drivers side windowcan operate the power window motor.

l The power window motor has a circuit breakerthat protects the motor from damage causedby excessive current.

SERVICE SPECIFICATIONS 42300030076Items Standard valueDoor outside handle play mm (in.) 3.6 (.142) or moreDoor inside handle play mm (in.) 5.3 (.209) or more

SEALANT 42300060034u

Item Specified sealant RemarkWaterproof film 3M ATD Part No. 8625 or equivalent Ribbon sealer

SPECIAL TOOLS 42300060066Tool 7- Tool number and name

MB991 502Scan Tool (MUT-II)

MB991 529Diagnostic troublecode check harness

MB990784Ornament remover

SupersessionMB991 496-OD

ApplicationETACS-ECU input signal check-ing

Tool not necessary if scan ETACS-ECU input signal check-tool cMUT-II> is available ing (when using a voltmeter)

General service tool 1 Removal of switch, trim, etc.

42-22 BODY - Door

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Tool Tool number and nameMB991 223Harness setA: MB991219

Test harnessB: MB991 220LED harnessC: MB991 221LED harnessadapterD: MB991 222Probe

SupersessionMB991 223

ApplicationMeasurement of terminal voltageA: Connector pin contact pres-sure inspectionB, C: Power circuit inspectionD: Commercial tester connection

TROUBLESHOOTING 42700200011DIAGNOSTIC FUNCTIONINPUT SIGNAL INSPECTION POINTS When Using the Scan Tool1. Connect the scan tool to the data link connector.

CautionThe scan tool should be connected or disconnectedafter turning the ignition switch to the OFF position.

BODY - Door . 42-23

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When Using the Voltmeter1. Use the special tool to connect a voltmeter between the

ground terminal and the ETACS terminal of the data linkconnector.2. If the voltmeter indicator deflects once when the eachswitch is operated (ON/OFF), the ETACS-ECU input signalfor that switch circuit system is normal.x

STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING 42700210014Does notI reoccurGather information from customer. 1.1 Check trouble symptoms. - intermittent malfunction.1 eoccurs

Refer to the INSPECTION CHARTFOR TROUBLE SYMPTOMS.

.

INSPECTION CHART FOR TROUBLE SYMPTOMS 42700180018Trouble symptom Inspection ReferenceI procedure pageNone of the door lock functions operate. 1 42-23The other door(s) does not lock or unlock by the door lock switch or the front 2 42-24passengers side door lock key cylinder. (However, they can be operated by thedrivers inside door lock knob.)The other door(s) does not lock or unlock by the drivers inside door lock knob or 3 42-25drivers side door lock key cylinder.Some doors do not lock or unlock. 4 42-25

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMSInspection Procedure 11 None of the door lock functions operate. / Probable causeI he cause may be a malfunction of the ETACS-ECU power supply circuit system l Malfunction of ETACS-ECUor of the ground circuit system. l Malfunction of wiring harness or connector I

Voltage between 1 and body groundVoltage between 2 and body ground -) Check the harnesswire betweenusible

lmk No.1 or No.2 and J/B, and repairOK if necessary.

42-24 BODY - Door

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Inspection Procedure 2The other door(s) does not lock or unlock by the door lock Probable cause Lswitch or the front passengers side door lock cylinder.(However, they can be operated by the drivers inside doorlock knob.)The door lock switch, the door lock key cylinder switch (R.H.), the ETACS-ECU, l Malfunction of door lock switchharness or connector may be defecttve. l Malfunction of door lock key cylinder switch (R.H.)

l Malfunction of ETACS-ECUl Malfunctron of wiring harness or connector

Measure atthe door lock switch connec-tors G-11, G-02.l Disconnect the connector and

measure at the harness side.l Voltage between 3 and body ground

l Voltage between 5 and body ground

l Voltage between 10 and body

groundl Voltage between 1 and body groundl Voltage between 3 and body ground

OK: Battery positive voltageIOK1

Measure at the door lock key cylinderswitch (R.H.) connector G-03.l Disconnect the connector and

Voltage between 3 and body groundVoltage between 1 nd body ground

NG NGd Check the following connectors: w RepairG-11, G-02, B-29, B-15, B-69

OKfCheck trouble symptoms. Check the harness wire between door

/ _OK

+I Check the harness wire between doorlock key cylinder switch (R.H.) and con-nector B-15 and repair if necessary.

Door lock switch continuitycheck (Referto P.42-40.)

JG~ Replace

~ NGCheck the following connectors: * Repaircontinuity check. (Refer to P.42-39.) B-29, G-11 +

NG B-15, G-02, G-03

Replace

Check the harness wires between door

Replace the ETACS-ECU.

BODY - Door 42-25

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Inspection Procedure 3The other door(s) does not lock or unlock by the drivers Probable causeinside door lock knob or drivers side door lock keycylinder. 2The front door lock actuator (L.H.), the door lock key cylinder (L.H.), the ETACS-ECU, l Malfunction of front door lock actuator (L.H.)harness or connector may be defective. l Malfunction of door lock key cylinder switch (L.H.)

l Malfunction of ETACS-ECUl Malfunction of wiring harness or connector

Check the scan tool input signal.(1) Front door lock actuator switch

(L.H.) input srgnal0K:The scan tool buzzer sounds

once when the front door lockactuator moves from the lockedto the unlocked position, or fromthe unlocked to the lockedposition.

(2) Door lock key cylinder switch (L.H.)input signal0K:The scan tool buzzer sounds

once when the door lock keycylinder switch (L.H) isunlocked. (4 NG

1K- Replace the ETACS-ECU. 151) NG NG- Check thefrontdoor w Replace

(Refer to P.42-38.)OK NG/ Check the followinq connectors: 1 * Repair

1 G-16, B-29, B-69 - IIOKt

Check trouble symptoms. NG c Check the harness wares between thefront door lock actuator (L.H.) andETACS-ECU, between front door lockactuator (L.H.) and ground and repairif necessary.

NG * Repair(L.H.). (Refer to P.42-39.) G-12, B-29, B-69 I _+ G

Replace Check the harness wires between thedoor lock key cylinder switch (L.H.) andETACS-ECU, between door lock keycylinder switch (L.H.) and ground, and

Inspection Procedure 4Some doors do not lock or unlock. Probable causeThe cause may be a malfunction of the door lock actuator or of a wiring harness l Malfunction of door lock actuatoror connector. l Malfunction of wiring harness or connector

NGCheck the door lock actuator of the door that does not operate. b Replace(Front: Refer to P.42-38.)(Rear: Refer to P.42.39.)

OKOKCheck the following connectors:

G-16, B-29, B-69 G-07, B-15, B-69 G-05, E-17, B-69 G-14, E-03, B-69

i NG

- Check trouble symptoms.NG

Check the harness between the ETACS-ECU and the door lockactuator of the door that does not operate, and repair if necessary.

42-26 BODY - Door.

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TROUBLESHOOTING HINTSPower windows

4

1. All door windows cannot be operated or closed.l Check the fusible link No. 6.l Check the multi-purpose fuse No. 6.l Check the power window relay.l Check the power window main switch.2. Some door window cannot be opened or closed.1) Neither power window main nor sub switch is activated.

l Check power window main switch.l Check defective power window motor.2) Either power window main or sub switch is inoperative.l Check inoperative power window switch.GLASS AND DOORS

12300070108

Symptom Probable cause 1RemedyWater leak throughdoor window glass Incorrect window glass installation/ Gap at upper window glass

Adjust positionAdjust position

Door windowmalfunction Incorrect window glass installationDamaged or faulty regulatorAdjust positionCorrect or replace

Water leak throughdoor edge Cracked or faulty weatherstrip Replace

Water leak from doorcenter

Drain hole cloggedInadequate waterproof film contact or damage

Remove foreign objectsCorrect or replace

Door hard to open Incorrect latch or striker adjustment AdjustDoor does not openor close completely Incorrect door installationDefective door check strap

Door check strap and hinge require grease

Adjust positionCorrect or replace

Apply grease -Uneven gap between Incorrect door installation Adjust positionbodyWind noise arounddoor Weatherstrip not holding firmly Adjust fit of doorImproperly installed weatherstrip or setting of Repair or replaceweatherstrip

Improperly closed door AdjustImproperly fit door AdjustImproper clearance between door glass and door Adjust

BODY - Door. 42-27

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1610264 I

Remove A18M0264

Ex. Noise produced A18M0265here

cut tapento A18,,,0266pieces

HOW TO LOCATE WIND NOISES(1)

(2)

(3)

(4)(5)

(6)

(7)

Attach cloth tape to every place, such as panel seams,projections, molding seams, glass and body seams, etc.which might conceivably be the source of wind noise.Then make a road test to check that the places not coveredby tape are not sources of wind noise.

Remove the strips of tape one by one, making a roadtest after each is removed, until a wind noise sourceis discovered.

When such a place is found, cover it again and repeatthe procedure to check if there are any other noise source.If no others -are found, the last remaining tape is theonly source.

Cut the remaining piece of tape into smaller pieces, attachit again as it was before, and then remove the piecesone by one to narrow down the source.

Check that wind noise occurs when the last remaining

42-28 BODY - Door

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ON-VEHICLE SERVICE A 42300090074DOOR FIT ADJUSTMENT .

If the clearance between the door and the vehicle bodyis uneven, affix protective tape to the fender around thehinge and to the edge of the door. Then use the specialtool to loosen the door hinge mounting bolts on the body,and adjust the clearance around the door so that itbecomes even.If the door and the body are not flush with each other,use the special tool to loosen the door hinge mountingbolts. Then align the door.CautionDo not apply more than 98 Nm (72 ft.lbs.) to the specialtool (MB991164).

If the door opening and closing is heavy, adjust themeshing of the striker and the door latch (in the longitudinaldirection) by adding shims to the striker and by movingthe striker up and down or to the left and right.

PDOOR WINDOW GLASS ADJUSTMENT 42300100128Check that the door glass moves securely along the doorglass runchannel when the window glass is fully raised andfully lowered. If the glass does not move correctly, adjustbY1.2.

3.

the following procedure.Remove the door trim and the waterproof film. (Referto P.42-32.)Loosen the mounting screw through the adjusting holewith the door window glass fully closed, and lower thedoor window glass slightly.Close the door window glass fully again, and tighten thedoor glass mounting screw securely through the adjusting ,hole.

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18MOOOa 00004523

00004524

DOOR OUTSIDE HANDLE PLAY CHECK 423001600891.

2.

Check that the door outside handle play is within thestandard value range.Standard value (B): 3.6 mm (.142 in.) or moreIf the door outside handle play is not within the standardvalue range, check the door outside handle or the doorlatch assembly. Replace, if necessary.

CIRCUIT BREAKER (INCORPORATED IN THEPOWER WINDOW MOTOR) INSPECTION 429oo17o1. Press the power window switch to the UP position to

fully close the window glass, and keep pressing the switchfor a further 10 seconds.

2. Release the power window switch from the UP positionand immediately press it to the DOWN position. Thecondition of the circuit breaker is good if the power windowglass starts to move downward within 60 seconds.

DOOR INSIDE HANDLE PLAY CHECK ANDADJUSTMENT I 42300160123Check that the door inside handle play is within thestandard value range.Standard value (A): 5.3 mm (.209 in.) or moreIf the door inside handle play is outside the standardvalue range, remove the door trim. (Refer to P.42-32.)Loosen the inside handle mounting screws, and thenmove the inside handle back and forth to adjust the play.

42-30 BODY - DoorIl

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DOOR ASSEMBLY _ 42300220152REMOVAL AND INSTALLATION .

I

I ost-installation Operation0 Door Fit Adjustment (Refer to P.42-28.)I IFront door

2620

18AOl29

22 Nm16 ft.lbs.Rear door

22 Nml6 Mbs- 26 Nm20 l-t.lbs.

22 Nm16 ft.lbs.

18M000300004530

Door assembly removal steps1. Harness connector2. Spring pinStriker removal steps6. Striker

BODY - Door . 42-31

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Front Rear

Identifihation mark Identification mark

AlEM

NStroke

AlEN

StrokeWA0159

INSTALLATION SERVICE POINTbAdDOOR LOWER HINGE/DOOR UPPER HINGEINSTALLATIONThe door hinges differ according to where they are used,so check the identification marks before installation.

Applicable location Identificationmark 1

Front lefl side door

Front right side door

Rear left side door

Rear right side door

Upper hinge FlLower hinge ElUppeknge ElLower hinge FlUpper hinge AlLower hinge _ KlUpper hinge BlLower hinge Ll

INSPECTIONDOOR SWITCH CONTINUITY CHECKFront door switch (L.H.)

42300600062

Switch Terminal No.position 1 12 13Open (ON) 1 0 I A I 0Depressed(OFF) / /

Front door switch (R.H.) and rear door switchSwitch Terminal No.position t 1 I2Open (ON)Depressed(OFF)

42-32 BODY - Door_)

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DOOR TRIM AND WATERPROOF FILM 42300430135REMflVAL AND INSTALLATION_I .- I I.__ .I__ -_ .--- -- ----Front door

8

18M0252

00004817

Sealant:3M ATD Part. No. 8625 or equivalent

NOTE+ : Resin clip position

I

Removal steps+A, .A4 1. Clio Regulator handle Escutcheon

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dOTE* : Resin clip position

Removal steps4A, .A4 1.

.A4 2

.Al 347

Clip Regulator handle Escutcheon Pull handle boxCover

18UO43018UO392 00000124

Sealant:3M ATD Part. No. 8625 orequivalentL

18M002300004531

8. Door trim9. Power window switch10. Power window switch panel11. Door inside handle12. Pull handle bracket13. Waterproof film

REMOVAL SERVICE POINT+A, CLIP REMOVALRemove the clip by using a shop towel, and then removethe regulator handle.

INSTALLATION SERVICE POINT

42-34 BODY - DoorDOOR GLASS AND REGULATOR

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REMOVAL AND INSTALLATION sI I

I re-removal OperationII) Door Trim and Waterproof Film Removal (Refer to P.42-32.)(2) Door Beltline Inner Weatherstrip Removal (Referto P.42-41 .)Front door

+

10MQ227

Front window regulator assemblyremoval steps1. Door window glass2. Door window glass holder3. Window regulator assembly4. Power window motor

I IPost-installation Operation(1) Door Window Glass Adjustment (Refer to P.42-28.)(2) Door Beltline Inner Weatherstrip Installation (Referto P.42-41 .j(3) Door Trim And Waterproof Film Installation (Referto P.42-32 .)

Rear door

18MQ228

00004721 c

Stationary window glass removalstepsl Window glass runchannel (Refer toP.42-41.)1. Door window glass5. Door center sash6. Stationary window alass andweatherstrip assembly7. Stationary window glass8. Stationary window weatherstrip

Rear window regulator assemblyremoval stepsl Window glass runchannel (Refer toP.42-41.)1. Door window glass2. Door window glass holder3. Window regulator assembly

BODY - Door 42-35REMOVAL SERVICE POINT

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+A,DOOR CENTER SASH REMOVAL1. Remove the door outer opening weatherstrip from the

door center sash only.2. Remove the door center sash mounting screws, and thenremove the door center sash from the door panel.

INSPECTION 42900180052POWER WINDOW RELAY CONTINUITY CHECK

00004818

POWER WINDOW MOTOR CHECK 429001500531. Connect a battery directly to the motor terminals andcheck that the motor runs smoothly.

2. Check that the motor runs in the opposite direction whenthe batterv is connected with the polarity reversed.

42-36 BODY - DoorPOWER WINDOW SWITCH CONTINUITY CHECK

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2-door models

4-door models

16M0263

Main switchTerminal No. Power window switch (normal) Power window switch (lock)

UP OFF DOWN UP OFF DOWNFront (L.H.) 6*, 13*2 0

I*i 8*2 0 15"l g*2 Y 0 0I I9*' , 12*2 0

Front (R.H.) 6*, 13*2 0 07*1 3*2 08*, 11*2 0 09*' , 12*2 0

Rear 13L.H.)*2 . 0, 02 0 012 0

Rear 13(FW*2

0 0.

BODY - Door . 42-37Sub switch

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16M0262

I I I

Sub 14 I 0 ~ 0switch 5678

DOOR HANDLE AND LATCH 42300460134REMOVAL AND INSTALLATION

Pre-removal Operationl Door Trim Removal (Refer to P.42-32.) .^I...(1) Door Inside Handle Play Check (Refer to P42-29.)(2) Door Outside Handle Play Check (Refer to P.42-29.)(3) Door Trim Installation (Refer to P.42-32.)

Front door Rear door

4 18M0019 - 18M0020

00004533

Front door handle and door latchassembly removal steps Door check removal steps1. Door inside handle1. Door inside handlel Waterproof film (Refer to P.42-32.)2. Door outside handle3. Door lock key cylinder4. Rear lower sash

_ l Waterproof film (Refer to P-42-32.)8. Spring pin.A+ 9. Door check 42-38 BODY - Door 1

r INSTALLATION SERVICE POINT 1

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3A\Identification mark A16E0052cL.H.>

View A

Lock -

16MOOl 6

View 6 Unlock

Install the door check so that the identification mark facesupward..A+ DOOR CHECK INSTALLATION

Applicable location Identification mark2-door models 4-door models

L.H. Front door YL XLRear door - 16L

R.H. Front door YR XRRear door - 16R

INSPECTION 42300610072FRONT DOOR LOCK ACTUATOR CHECK

UNLOCK position

Rod position Terminal No. Rod operation

4 6LOCK - 0 LOCK position -UNLOCK positionUNLOCK Q - UNLOCK position -LOCK position

BODY - Door . 42-39 REAR DOOR LOCK ACTUATOR CHECK 42300520051

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cR.H.>View B

L. B18M001400004526

10so444

L.H.: Unlock

cL.H.>Rod position / Terminal No. Rod operation

2 3LOCK Q - LOCK position -UNLOCK positionUNLOCK - @ UNLOCK position -LOCK position

Rod position Terminal No. Rod operation

2 3LOCK - + LOCK position -UNLOCK positionUNLOCK a---Q _ UNLOCK position -LOCK position

DOOR LOCK KEY CYLINDER SWITCH CONTINUITYCHECK I 42300630085

Terminal No.Switch position L.H. R.H.

1 2 3 1 2 3LOCK 0 0 0 0Neutral (OFF)UNLOCK 0 0 0 0

BODY - DoorDOOR LOCK SWITCH CONTINUITY CHECK 42700120066

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2-door models

Door lock switch Terminal No.Switch position 1 2 3

LOCK 0 0OFFUNLOCK 0 0

A16M0262 I Ih

BODY - Door . 42-41WINDOW GLASS RUNCHANNEL AND DOOR OPENING

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WEATHERSTRIP 42300310110REMOVAL AND INSTALLATION

4A, .A4

Front door Rear door

Door inner opening weatherstripremoval stepsl Cowl side trim (Refer to GROUP 52A.)l Quarter trim (Refer to GROUP 52A.)l Center pillar lower trim (Refer to GROUP 52A.)1. Door inner opening weatherstripDoor outer opening weatherstripremoval2. Door outer opening weatherstrip

Door window glass runchannelremoval3. Door window glass runchannelDoor beltline inner weatherstripremoval stepsl Door trim (Refer to P.42-32.)4. Door beltline inner weatherstripDoor beltline molding removall Door mirror (Refer to GROUP 51.)5. Door beltline molding

REMOVAL SERVICE POINT

42-42 BODY - Door/SunroofINSTALLATION SERVICE POINT *.A+DOOR OUTER OPENING WEATHERSTRIP _

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INSTALLATIONThe clip color identifies the left and right weatherstrips, sobe sure to use the colors so as to install correctly.Applicable location Identification color

2-door models 4-door modelsL.H. Front door Brown White

Rear door - RedR.H. Front door Yellow Pink

Rear door - Dark brownSUNROOF 42600030044SERVICE SPECIFICATIONS

I Items Standard value I1 Roof lid glass operating current A / 7 or less [at 20C (68F)]Sunroof motor clutch slippage torque Nm (ttlbs.) 4.7 - 6.2 (3.5 - 4.6)

SEALANT . 42600050067

1tem / Specified sealant I1 Rail cover assembly / 3M ATD Part No.8531 or 3M Part No.8646 or equivalent 1SPECIAL TOOLS 42600060029

Tool Tool number and name Supersession ApplicationMB991 223 Measurement of terminal voltage

A: Connector pin contact pres-A: MB991219 sure inspectionTest harness B, C: Power circuit inspectionB: MB991 220 D: Commercial tester connectionLED harnessC: MB991 221LED harnessD: MB991 222Probe

BODY - Sunroof 42-43TROUBLESHOOTING 42600170029

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STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTINGGather information from customer.

Does not,Check trouble symptoms. Intermittent malfunction. 11 eoccursRefer to the INSPECTION CHARTFOR TROUBLE SYMPTOMS.

INSPECTION CHART FOR TROUBLE SYMPTOMS 42600200117Trouble symptom 1 nspection procedure 1Reference pageThe sunroof does not operate when the ignition switch is turned 1 42-43to ON.The motor does not reverse its direction when a load of 140 N 2 42-45(32 Ibs.) or more is applied while the sunroof is closing.The timer does not operate for 30 seconds after the ignition 3 42-45switch is turned to OFF,The sunroof operates when the drivers side door is opened 4 42-45within 30 seconds after turning the ignition switch to OFF.

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMSInspection Procedure 1

The sunroof does not operate when the ignition switch isturned to ON.One of the following items may be defective.l Sunroof switchl Sunroof motorl Sunroof-ECU0 Power supply circuitl Ground circuit

Probable causel Malfunction of sunroof switchl Malfunction of sunroof motorl MatfunctIon of sunroof-ECUl Malfunction of winng harness or connector

42-44 BODY - Sunroof/Measure1 -1 NG -*

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NG *E-06, B-28, B-67, B-56 Repair

$NGCheck the following connectors:B-28, E-06

1 OKCheck trouble symptoms.

OK* Repair

iCheck trouble symptoms.

i NGNGCheck the harness wire between sunroof-ECU andground, and reparr if necessary.

t -/ NGCheck sunroof switch contmuity (Refer to P.42.50.) I + RepairOK

NGMeasure at the sunroof-ECU connector E-06. b RepairDisconnect the connector and measure at the harness side.Continuity between 2 and body groundOK: Continuity present when UP sunroof switch is onContinuity between 3 and body groundOK: Continuity present when CLOSE/DOWN sunroof switch

is on

/E-05, E-06OK

Check trouble symptoms.1NG

Continuity between 4 and body groundOK: Continurty present when OPEN sunroof switch is on

OK *

~ NGCheck the sunroof motor. (Refe: to P.42-50.)Check limit switch continuity. (4-door models: refer to P.42-50.)(2-door models: refer to P.42-50.)

/OK1Measure at the sunroof motor col Disconnect the connector and measure at the harness side.l Continuity between

OK: Contrnurtvbody ground

I

OK

- Replace

B-28, E-08

Check trouble symptoms.

1NG

1 heck the harness wrre between sun- 1) roof motor and ground, and repair i f /

necessary.

- Repair

NG

BODY - SunroofInspection Procedure 2

The motor does not reverse its direction when a load of Probable cause

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140 N (32 Ibs.) or more is applied while the sunroof isclosing. f-.The sunroof-ECU monitors the load conditions from the amount of current flowing l Malfunction of sunroof-ECUto the motor. If more than the constant amount of current is flowing, the drrectronof motor operation is reversed to prevent jamming.If the motor does not reverse direction even when an excessive load is bemg applied,the cause may be a malfunctron of the sunroof-ECU.

Replace the sunroof-ECU.

Inspection Procedure 3The timer does not operate for 30 seconds after the Probable causeignition switch is turned to OFF.The sunroof-ECU has a timer function which operates for 30 seconds after the ignition l Malfunction of sunroof-ECUswitch is turned to OFF. If the timer does not operate, the cause may be a malfunction l Malfunction of wiring harness or connectorof the sunroof-ECU or of the wirina harness or connector.

NGMeasure at thm1 NGB-06. B-28. B-67. B-56

+ Repair

OKNG --) Check the harnesswire betweenfusible

link No.1 and sunroof-ECU, and repalr

/ Replace the sunroof-ECU.

Inspection Procedure 4The sunroof operates when the drivers side door is Probable causeopened within 30 seconds after turning the ignition switchto OFF.One of the following items may be defective.l Front door switch (L.H.)l Sunroof-ECUl Ground circuit

l Malfunction of the front door switch (L.H.)l Malfunction of sunroof-ECUl Malfunction of wiring harness or connector

NGMeasure at the sunroof-ECU connector B Check the following c ---+ RepairE-06. B-28, E-06l Disconnect the connector and

measure at the harness side.Continuity between 13 and bodyground Check trouble symptoms.OK: Continuity

OK Check the harness wire between sun-roof-ECU and ground and repair if nec-

I rty. (Refer to P.42-31.) Replace

42-46 BODY - Sunroof 1Hose-----!I ON-VEHICLE SERVICE -

4426OOO9OOM

WATER TEST

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Check if there are any leaks in the sunroof by the followingprocedure.1. Fully close the roof lid glass.2. Adjust the water pressure so that water comes out ofthe hose to a height of approximately 50 cm (20 in.)when the hose is held vertically facing upward.3. Hold the end of the hose approximatery 30 cm (12 in.)above the roof and let the water run onto the weatherstripfor 5 minutes or more.4. While doing this, check if any water leaks through into

the passenger compartment from around the roof lid glass.

\\l___-------- Side decoration coverI _/< A18P0093 1

SUNROOF FIT ADJUSTMENT 42600100141I.2.3.

Fully close the roof lid glass.Fully open the sunshade.c4-door models>(1)

(2)

16POO9700004628

Remove the side decoration cover.

To adjust the forward, backward and sideways positionof the roof lid glass, loosen the six roof lid glassassembly mounting nuts and then adjust the glassforward, backward or sideways.NOTEIf the adjustment cannot be made by loosening theadjustment nuts, the roof lid glass or the motor havenot been fully closed, so they should be adjustedto the fully closed positions.

BODY - Sunroof 42-47(3) To adjust the height of the roof lid glass, loosen the

four guide (A) assembly mounting screws and thenmove the roof lid glass assembly along the slot in

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the guide (A) assembly to adjust the height of theroof lid glass.

4. (1) Loosen the roof lid glass assembly mounting screws(four screws), and then slide the roof lid glassassembly along the slot in the drive cable assemblyto adjust the height of the roof lid glass.

5. After adjustment, check to be sure that the sunroofoperates smoothly.

42-48 BODY - SunroofSUNROOF 42600120260REMOVAL AND INSTALLATION

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c4-door models>Post-installation Operation(1) Sunroof Water Test (Refer to P.42-46.)(2) Sunroof Fit Adjustment (Refer to P.42-46.)

6.

Roof lid glass assembly removalsteps1. Side decoration cover2. Roof lid glass assemblySunroof switch removal steps3. Sunroof switch cover4. Sunroof switchDrain hose removal steps

hsheet metalclip position.

A18M0254

Sunroof-ECU removal steps5. Headlining7. Sunroof-ECUSunroof motor removal steps5. Headlining8. Sunroof motorSunroof assembly removal steps5. Headlining

,

BODY - Sunroof. 42-49

c2-door models>

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(1) Sunroof Water Test (Refer to P.42-6.).(2) Sunroof Fit Adjustment (Refer to P.42-6.)

n

1. Roof lid glass assemblySunroof switch removal steps2. Sunroof switch cover3. Sunroof switchDrain hose removal steps

A18M0353Sunroof motor removal steps4. Headlining+C, .A+ 7. Sunroof motorSunroof assembly removal steps4. Headlining5. Drain hose connection8. Dome light bracket

42-50 BODY - SunroofREMOVAL SERVICE POINTS * -+A,SlDE DECORATION COVER REMOVAL .

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\l____-------- Side decoration cover

18PO102

Remove the clips, and then remove the side decoration cover. e-

48, DRAIN HOSE REMOVALTie a cord to the end of the drain hose, and wind tape aroundthe tie until it is smooth. Then pull the drain hose out fromthe passenger compartment.

(C, SUNROOF MOTOR REMOVALCautionAlways close the roof lid glass fully before removingthe sunroof motor. If the fully-closed positions of the rooflid glass and the sunroof motor are not the same, thesunroof will not operate properly.

INSTALLATION SERVICE POINTS.A+ SUNROOF MOTOR INSTALLATIONIf the fully-closed position of the sunroof motor is incorrect,set the motor to the fully-closed position by the proceduregiven below before installing the motor.1.2.

Connect an ammeter between terminals (4) and (5)*l,(c)*2 of the motor connector.Connect battery between terminals (1) and (2) operatethe motor until the position is reached at which continuityswitches from on to off or from off to on, and then installthe motor.NOTE

BODY - Sunroof . 42-51.B( DRAIN HOSE INSTALLATION1. Tie the cord that was used during removal to the endof the drain hose, and wind tape around it so that there

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20-30 mm

~18A0213

Drive gear

is no unevenness.2. Pull the cord to pull through the drain hose.

3. Make the protrusion from the drain hose grommet asshown in the illustration.

INSPECTION 42600130089ROOF LID GLASS OPERATION CURRENT CHECK1.2.

Remove the sunroof fuse and connect an ammeter asshown in the illustration.Press the sunroof switch to the ON position, and thenmeasure the operation current in the intervals betweenthe points when the sunroof starts to operate, when itis fully open, when it is fully closed and when it is fullytilted up.

3.Standard value: 7 A or less [at 20C (6OF)]If the operation current is outside the standard value,check the following points.l Installation condition, warping or jamming of sunroofassemblyl Sticking of drive cablel Tilt of roof lid glass

SUNROOF MOTOR CHECK 42600250051

42-52 BODY - SunroofLIMIT SWITCH CONTINUITY CHECK 426002700331. Remove the limit switches from the sunroof motor, and

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18PO102

Limit switch 2, 3(Red) (White) /

/ \ Limit switch 1(Black) (blue)18PO103

00004529

ON-IFF-

18POO98

then check the operation of the limit switches. ISwitch position Terminal No.4 5 6 7Limit switch 1 ON 0 0

OFFLimit switch 2 ON 0 0

OFFLimit switch 3 ON 0 0

OFF2. Check the identification colors. Then install the limitswitches as shown in the illustration.

LIMIT SWITCH CONTINUITY CHECK c2-DOORMODELS> 42600270040Remove the limit switch from the sunroof motor, and thencheck the operation of the limit switch.

SUNROOF SWITCH CONTINUITY CHECK 42600160095Switch position

Slide openOff

Terminal No.3 4 5 6

0 0

Tilt up1 , 1 1

0 / 0 ISlide close, Tilt down I I-Jr-A-c

BODY - Sunroof 42-53DISASSEMBLY AND REASSEMBLYc4-door models>

42600140136

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I

J

l EM0130

4

Sealant:3M ATD Part No.8531 or 3M PartNo.8646, or equivalent

NOTEQ : indicates the sheetclip position.

18MQ255

00004820

Disassembly steps1. Side decoration cover 7. Drive unit assembly

42-54 BODY - SunroofDISASSEMBLY AND REASSEMBLYe2-door models>

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1: 8M0356Sealant:3M ATD Part No.8531 or 3M PartNo.8646, or equivalent

l

16 IBM035400006974

Disassembly steps I .BODY - Under Cover 42-55UNDER COVER 42100050083L SEALANT

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+I_Item Specified sealantSplash shield 3M ATD Part No. 8625 or equivalent

RemarkRibbon sealer

?JNDER COVER 42100280055REMOVAL AND INSTALLATION

NOTEThe components which are marked with * are alsoequipped at the right side.

Removal steps1. Front splash shield*2. Rear splash shield*3. Under cover side panel

Documents

42 Body