Professional Documents
Culture Documents
42-1
BODY
CONTENTS
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 19
Door Fit Adjustment . . . . . . . . . . . . . . . . . 19
Door Window Glass Adjustment . . . . . . 19
WINDOW GLASS . . . . . . . . . . . . . . . . . . . . . . . . . 8
WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DOOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 22
ADHESIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 8
WINDOW REPAIR . . . . . . . . . . . . . . . . . . . . . . . 8
DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE SPECIFICATIONS . . . . . . . . . . . . 18
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 18
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 19
BACK DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SERVICE SPECIFICATION . . . . . . . . . . . . . 39
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 39
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 39
CONTINUED ON NEXT PAGE
42-2
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 40
Back Door Fit Adjustment . . . . . . . . . . . . 40
Back Door Handle Play Check . . . . . . . 40
BACK DOOR ASSEMBLY . . . . . . . . . . . . . . 41
BACK DOOR TRIM AND WATERPROOF
FILM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
BACK DOOR HANDLE AND LATCH . . . . 44
SUNROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SERVICE SPECIFICATION . . . . . . . . . . . . . 47
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 47
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 47
Water Test . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Sunroof Fit Adjustment . . . . . . . . . . . . . . . 47
SUNROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
42-3
BODY - Hood
HOOD
REMOVAL AND INSTALLATION
7
5
6
22 4 Nm
9
7
4
5
1
9.0 2.0 Nm
5.0 1.0 Nm
5. Hood weatherstrip
D Washer hose
(Refer to GROUP 51.)
6. Hood
7. Hood bumper
8. Hood support rod
(Refer to GROUP 51.)
9. Hood support rod
(Refer to GROUP 51.)
42-4
BODY - Hood
B
B
A
A
Section A - A
6
15 0.5 mm
20 0.5mm
W0382AL
Clip positions
7
Section A - A
A
A
Clip
: Clip positions
42-5
BODY - Fender
FENDER
REMOVAL AND INSTALLATION
Caution: SRS
Do not strike the front impact sensor when removing or installing the fender.
Pre-removal and Post-installation Operation
D Front Bumper Removal and Installation
(Refer to GROUP 51.)
D Front Mud Guard Removal and Installation
(Refer to GROUP 51.)
Section A A
3
A
Clip
Removal steps
1. Splash shield
AA" "AA 2. Side turn signal lamp
3. Fender
MB990784
Front of vehicle
42-6
Fender panel
Front of vehicle
3
3
Removal steps
AA" "AA 1. Rivet
2. Fuel filler door panel assembly
3. Fuel filler door lock hook assembly
4. Lid lock release handle
D Heater deck cross assembly
(Refer to GROUP 55.)
42-7
Fuel filler
door panel
assembly
Drill
Riveter
Body
panel
1
Rivet
2
Riveter
Flange surface
Rivet
42-8
WINDOW GLASS
ADHESIVE
Items
Specified adhesive
Windshield
SPECIAL TOOL
Tool
Number
Name
MB990480
Window
holder
Use
glass
WINDOW REPAIR
ITEMS NEEDED
Name
Remarks
Adhesive
3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or
equivalent
Primer
Spacers
Dam
Isopropyl alcohol
Adhesive gun
42-9
WORKING PROCESS
Body side
Application of primer
Apply to the adhesion surface of the
body and let dry for 3 minutes or more.
Application of primer
Apply sufficient primer evenly to the adhesion surface so that there is no patchiness. After
application, let dry for 3 to 30 minutes.
Application of adhesive
Within 30 minutes after applying the primer, apply the adhesive evenly all the way around
the inside edge of the glass.
42-10
WINDSHIELD
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
D Deck Garnish Removal and Installation
(Refer to GROUP 51A.)
D Headlining Removal and Installation
3
2
4
1
Section A A
Section B B
10
32.5
Primer
Primer
B
C
Section C C Unit: mm
Primer
Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent
Removal steps
1. Wiper deicer connector (Refer to
GROUP 51.)
AA" "AA 2. Windshield
42-11
Caution
Do not let the piano wire touch the edge of the
windshield.
5. Make alignment marks on the windshield and body.
6. Use the special tool to remove the windshield.
42-12
1.
2.
3.
4.
5.
Glass stopper
13.2mm
22.5mm
Windshield spacer
Caution
(1) The primer strengthens the adhesive, so be sure to apply it evenly around the entire
circumference. However, a too thick application will weaken the adhesive.
(2) Never touch the primer-applied surface.
Windshield moulding
Marking
Windshield
Notch
Ceramic line
42-13
10 mm
15 mm
NOTE
Cut the tip of the sealant gun nozzle into a V shape
to simplify adhesive application.
8. Align the mating marks on the windshield and the body,
and lightly press the windshield evenly so that it adheres
completely.
9. Use a spatula or the like to remove any excessive
adhesive. Install the windshield moulding before the
adhesive sets. After the windshield is installed, wait until
the adhesive sets.(Refer to P.42-9.)
10. Wait thirty minutes or more, and then test for water
leakage.
Caution
(1) Do not move the vehicle unless absolutely
necessary.
(2) When testing for water leakage, do not pinch the
end of the hose to spray the water.
42-14
<Short wheelbase>
6
4
3
7
Section A A
Clip
Body panel
Primer
AA"
Removal steps
1. Lever
2. Quarter window link
3. Rubber and nut
4. Quarter window glass
5. Quarter window glass
6.
7.
AA" "AA 8.
9.
Quarter
Quarter
Quarter
Quarter
window
window
window
window
weatherstrip
hinge
moulding
garnish
42-15
Quarter window
glass
15 mm
8.5 mm
15 mm
Caution
The areas which have been cleaned of adhesive
should be allowed to stand for three minutes or more
until they are completely dry before continuing to
the next step. Furthermore, do not touch the surfaces
after they have been cleaned.
2. Apply an even coating of primer to the adhesion surface
of the quarter window glass, while being careful not to
miss any places.
3. Apply the specified sealant to the quarter window glass
in the locations specified, and then install the quarter
window moulding to the quarter window glass.
Adhesive:
3M ATD part No.8513 Grommeted Sealant or
equivalent
42-16
3
2
5
A
A
D
3
B B
C
C
4
1
Section B B
Section A A
12.5
12.5
Primer
Unit: mm
Section D D
Section C C
Primer
18
Primer
13
24.5
12.5
Primer
Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent
Removal steps
1. Harness connector
AA" "AA 2. Back door glass
"AA 3. Dual lock fastener
42-17
Section A A
Window dam
Align with
edge of glass
Back door glass
Raised section of
body flange
Glass
stopper
installation holes
42-18
BODY - Doors
DOORS
SERVICE SPECIFICATIONS
Items
Standard value
2.0 or more
5.3 or more
SEALANT
Items
Specified sealant
Remark
Waterproof film
Ribbon sealer
SPECIAL TOOLS
Tool
Number
Name
Use
MB990784
Ornament remover
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
MB990900
MB991164
or
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
BODY - Doors
42-19
TROUBLESHOOTING
DIAGNOSIS FUNCTION
The power window and central door locking is controlled by the Smart Wiring System (SWS). For
troubleshooting, refer to GROUP 54B - Troubleshooting.
ON-VEHICLE SERVICE
MB990900 or
MB991164
Striker
Shim
42-20
BODY - Doors
Front
2. With the door window glass fully closed, loosen the door
glass mounting screws through the adjusting holes, and
then lower the door window glass slightly.
3. Fully close the door window glass again, and then fully
tighten the door glass mounting screws through the
adjusting holes.
Rear
Adjusting
hole
Adjusting
hole
Runchannel
Door
sash
Lower sash
BODY - Doors
42-21
Section B - B
B
A
42-22
BODY - Doors
DOOR ASSEMBLY
REMOVAL AND INSTALLATION
Post-installation Operation
Door Fit Adjustment (Refer to P.42-19.)
FRONT DOOR
4, 5
6
3
26 4 Nm
11 2 Nm
1
21 4 Nm
8
5
2
Striker removal steps
6. Striker
7. Striker shim
Door switch removal steps
8. Door switch cap
9. Door switch
42-23
BODY - Doors
REAR DOOR
4, 5
6
4
26 4 Nm
11 2 Nm
2
8
21 4 Nm
5
Door assembly removal steps
1. Harness connector
2. Door check connecting bolt
3. Door assembly
4. Door upper hinge
5. Door lower hinge
3
Striker removal steps
6. Striker
7. Striker shim
Door switch removal steps
8. Door switch cap
9. Door switch
INSPECTION
DOOR SWITCH CONTINUITY CHECK
Switch position
Released (ON)
Depressed (OFF)
Terminal number
1
2
42-24
BODY - Doors
22
4
16
22
18
21
Sealant:
3M ATD Part No. 8625 or equivalent
2
12
13
10
19
11
15
20
17
4.91.0 Nm
8
14
Removal steps
1. Power window switch and power
window switch panel assembly
2. Power window switch panel
3. Power window switch
4. Delta cover, inner
5. Door lamp assembly
AB" "BA 6. Clip <Vehicles without power windows>
"BA 7. Escutcheon <Vehicles without power windows>
"BA 8. Regulator handle <Vehicles without
power windows>
9. Door inside handle cover and door
trim assembly
AA"
10.
11.
12.
AC"
13.
14.
15.
16.
17.
18.
19.
20.
21.
"AA 22.
42-25
BODY - Doors
REAR DOOR
21
Sealant:
3M ATD Part No. 8625 or equivalent
20
11
15
13
17
16
10
19
14
21
12
18
5
4.91.0 Nm
Removal steps
1. Power window switch and power
window switch panel assembly
2. Power window switch panel
3. Power window switch
4. Door lamp assembly
AB" "BA 5. Clip <Vehicles without power windows>
"BA 6. Escutcheon <Vehicles without power windows>
"BA 7. Regulator handle <Vehicles without
power windows>
8. Door inside handle cover
9. Door belt line moulding assembly
AA"
AC"
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
"AA 21.
Door trim
Door inside handle cover
Door grip
Rear arm restraint cover
Door grip bracket
Door grip upper retainer
Door grip lower bracket
Arm restraint bracket
Speaker
Power window switch bracket
Door inside handle
Waterproof film
42-26
BODY - Doors
<Long wheelbase>
B
View B
B
View C
View A
View A
View A
View C
View B
E
D
E
D
Section A - A
Section C - C
Section B - B
Door lamp
lens
Door trim
Door trim
Door lamp
lens cover
Clip
Clip
Section D - D
Section E - E
42-27
BODY - Doors
REAR DOOR
View B
B
B
View A
View A
View B
Section A - A
E
E
Door trim
Clip
Section C - C
Section B - B
Section D - D
Section E - E
Door trim
Clip
Door lamp
lens
Door trim
Clip
Door lamp
lens cover
Door trim
NOTE
: Clips positions
: Claws positions
Claw
42-28
BODY - Doors
REMOVAL SERVICE
POINTS
MB990784
Inside handle
MB990784
A
Section A - A
Inside handle
cover
Claw
Inside
handle
Inside
handle
cover
Claw
42-29
BODY - Doors
INSTALLATION SERVICE POINTS
<Front door>
Waterproof film
Horizontal line
30
Front of vehicle
INSPECTION
POWER WINDOW SUB SWITCH CONTINUITY CHECK
Switch position
Terminal No.
1
UP
DOWN
W0755AU
NOTE
Power window main switch uses SWS system, for the power
window main switch check, refer to GROUP 54B - SWS.
42-30
BODY - Doors
Post-installation Operation
D Door Window Glass Adjustment (Refer to P.42-20.)
D Door Trim and Waterproof Film Installation (Refer
to P.42-24.)
2
3
6
7
5.40.5 Nm
<Vehicles with power windows>
5.40.5 Nm
<Vehicles without power windows>
42-31
BODY - Doors
REAR DOOR
Pre-removal Operation
Door Trim and Waterproof Film Removal (Refer to
P.42-25.)
Post-installation Operation
D Door Window Glass Adjustment (Refer to P.42-20.)
D Door Trim and Waterproof Film Installation (Refer
to P.42-25.)
10
1
8
5
2
8
5.40.5 Nm
<Vehicles with power windows>
5.40.5 Nm
<Vehicles without power windows>
Removal steps
1. Door belt line moulding assembly
2. Door window glass runchannel
AA" "CA 3. Center sash
"BA D Check operation
4. Rear door window glass
5. Glass holder
Door outer
opening weatherstrip
Center sash
42-32
BODY - Doors
INSTALLATION SERVICE POINTS
"AA POWER WINDOW MOTOR ASSEMBLY/POWER
WINDOW REGULATOR ASSEMBLY
INSTALLATION
Power window motor assembly and window regulator
assembly pre-installation operations
1. Connect the power window motor assembly to the body
side harness connector, and then turn the ignition switch
ON.
2. Operate the power window motor assembly for 5 - 10
seconds by pressing the power window switch to the
UP position.
NOTE
This operation will cause the limit switch inside the power
window motor assembly to be reset.
Caution
(1) The power window motor assembly should not
be operated again until it is installed to the glass.
(2) The clamping prevention function does not
operate the first time that the glass is fully closed.
"BA CHECK OPERATION
1. Install the glass to the power window motor assembly.
2. Press the power window switch to fully-close the glass,
and then return the glass to the fully-open position.
NOTE
This operation will program the power window-ECU.
"CA CENTER SASH INSTALLATION
Securely insert the center sash into the window rear sash
(door).
INSPECTION
POWER WINDOW RELAY CONTINUITY CHECK
Battery voltage
Not applied
Applied
Terminal No.
1
3
42-33
BODY - Doors
Post-installation Operation
D Door Inside Handle Play Check (Refer to P.42-21.)
D Door Outside Handle Play Check (Refer to P.42-21.)
D Door Trim Installation (Refer to P.42-24.)
REAR DOOR
FRONT DOOR
2
3
5.91.0 Nm
5.91.0 Nm
1
5
4
6
Left door
Identification mark
20L
Right door
20R
Left door
26L
Right door
26R
42-34
BODY - Doors
Outer
Inner cable
cable end
Clip
Left side
INSPECTION
<Front door>
<Left side>
View A
Lock
Unlock
Terminal No.
1
Rod operation
LOCK
LOCK to UNLOCK
UNLOCK
UNLOCK to LOCK
LOCK*
<Right side>
View B
Rod operation
Unlock
UNLOCK*
Lock
NOTE :
*: drivers side only
<Right side>
Rod position
Terminal No.
1
Rod operation
4
Rod operation
LOCK
LOCK to UNLOCK
UNLOCK
UNLOCK to LOCK
LOCK*
UNLOCK*
NOTE :
*: drivers side only
42-35
BODY - Doors
Rear door
<Left side>
<Rear door>
<Left side>
Lock
Rod position
View A
Terminal No.
2
3
LOCK
UNLOCK
Unlock
<Right side>
LOCK to UNLOCK
UNLOCK to LOCK
<Right side>
A
Lock
View B
Rod operation
Unlock
Rod position
LOCK
UNLOCK
Terminal No.
2
3
Rod operation
LOCK to UNLOCK
UNLOCK to LOCK
42-36
BODY - Doors
FRONT DOOR
3
3
1
Long wheelbase
Short wheelbase
Sectional view of
clip position
Sectional view of
clip position
Clip
Clip
3
Door window glass runchannel
removal steps
"AA 4. Door window glass runchannel
D Front door trim (Refer to P.42-24.)
5. Door belt line inner weatherstrip
Door beltline moulding removal
6. Door beltline moulding
42-37
BODY - Doors
REAR DOOR
6
3
1
Adhesive tape:
Double-sided tape [23 mm width and
0.8 mm thickness], dry adhesive
2
Sectional view of
clip position
Clip
Clip
Clip
Clip
42-38
BODY - Doors
REMOVAL SERVICE POINT
15 mm
4 mm
8 mm
Thickness
1mm
FRONT DOOR
Notch
B
A
Edge seal rubber
A: 87 mm
B: 106 mm (Long wheelbase)
B: 98 mm (Short wheelbase)
42-39
75 mm
BACK DOOR
SERVICE SPECIFICATION
Item
Standard value
2.3
SEALANT
Item
Specified sealant
Remark
Waterproof film
Ribbon sealer
SPECIAL TOOL
Tool
Number
Name
Use
MB990784
Ornament remover
TROUBLESHOOTING
NOTE
Power window main switch uses SWS system, for the power window main switch check, refer to
GROUP 54B - SWS.
42-40
ON-VEHICLE SERVICE
BACK DOOR FIT ADJUSTMENT
1. If the striker and latch mesh badly, move the striker forward
and backward or right and left to adjust.
2. If uneven clearance is present between back door and
body, reposition the hinge and striker and/or change the
thickness of shim (change the number of shim) to adjust
the clearance.
Section A - A
42-41
Pre-removal Operation
D High - mounted Stop Lamp Installation (Refer to
GROUP 54A.)
D Spare Tyre Installation
D Back Door Fit Adjustment (Refer to P.42-40.)
214 Nm
3
4
2
1
214 Nm
9 112 Nm
7
214 Nm
1
10
11
12
3, 5
8
Removal steps
D Back door trim and waterproof film
(Refer to P.42-43.)
1. Harness connector
2. Back door assembly
3. Back door upper hinge
4. Shim
5. Back door lower hinge
6.
7.
8.
"BA 9.
"AA 10.
11.
12.
Shim
Damper mail
Back door stopper
Striker
Back door opening weatherstrip
Door switch
Back door bumper, female
42-42
Latch centre
Striker centre
+1.5 mm
1.5 mm
Striker
Latch
INSPECTION
DOOR SWITCH CONTINUITY CHECK
Switch position
Released (ON)
Pressed (OFF)
Terminal No.
1
42-43
3
Clip
A
2
5
A
A
Sealant:
3M ATD Part No. 8625 or equivalent
10
: Clip positions
"AA
Removal steps
1. High-mounted stop lamp cover
D High-mounted stop lamp
(Refer to GROUP 54A.)
2. Door pull handle
3. Back door upper trim
4. Toolbox assembly
5.
6.
7.
8.
9.
10.
42-44
1
1
5.91.0 Nm
INSPECTION
View A
Lock
Unlock
LOCK
UNLOCK
Terminal No.
2
3
Rod operation
LOCK to UNLOCK
UNLOCK to LOCK
42-45
Battery
Open
Claw
ON-VEHICLE SERVICE
HOW TO REPLACE A BATTERY OF THE
TRANSMITTER
1. Remove the set screw to remove the battery from the
transmitter.
2. Install a battery with its (+) side face-down.
O-ring
Screw
42-46
MUT-II connected
Within 10 seconds
Hazard ON
switch
OFF
5.
6.
7.
8.
9.
NOTE
(1) The doors will lock and unlock once after pressing
the hazard switch six times, and the system will switch
to registration mode.
(2) The hazard switch alternates between ON and OFF
each time pressing the hazard switch (Refer to
illustration).
Press the lock switch or unlock switch of the transmitter
switch, and then press it two times within 10 seconds
of the first press. This will register the code.
After registration is completed, the doors will be
automatically locked and unlocked once.
If you are using more than two transmitters or have added
a second transmitter, the same registration procedure
should be carried out for the remaining transmitters, and
it should be carried out within one minute after registration
of the code for the first transmitter has been completed.
The registration procedure are all the same for all
transmitters.
Registration mode will be terminated under the following
conditions.
D When the encrypted codes for four transmitters have
been registered;
D When one minute has passed after registration mode
started;
D When the MUT-II is disconnected (earth is released);
D When the ignition key is removed;
After registration mode has been completed, carry out
the followings to make sure that the keyless entry system
operates.
D Pull the ignition key out.
D Close all of the doors.
BODY - Sunroof
42-47
SUNROOF
SERVICE SPECIFICATION
Items
Standard value
7 or less
TROUBLESHOOTING
The sunroof is controlled by the SWS (Smart Wiring System). For troubleshooting procedures, refer to
GROUP 54B - SWS Diagnosis.
ON-VEHICLE SERVICE
WATER TEST
Hose
Approx. 30cm
42-48
BODY - Sunroof
SUNROOF
REMOVAL AND INSTALLATION
Post-installation Operation
D Sunroof Water Test (Refer to P.42-47.)
D Sunroof Fit Adjustment (Refer to P.42-47.)
<Long wheelbase>
<Short wheelbase>
BODY - Sunroof
42-49
Drain hose
Grommet
20 - 30 mm
42-50
BODY - Sunroof
"BA SUNROOF MOTOR ASSEMBLY INSTALLATION
<INSTALLATION OF REMOVED MOTOR ASSEMBLY>
1. Install the roof lid glass assembly and the sunroof motor
assembly with the sunroof motor assembly in the
fully-closed position.
2. Connect the sunroof motor assembly harness connector
and the sunroof switch harness connector to the vehicle
wiring harness connector.
3. Operate the sunroof and check that it operates correctly.
42-51
BODY - Sunroof
INSPECTION
Fuse
Slide close,
Tilt down
Tilt up
Open
Switch position
Terminal No.
3
Open
Off
Tilt up
Slide close, Tilt down
42-52
BODY - Sunroof
16
Sealant:
3M ATD Part No. 8531 or 8646 Auto
Sealant or equivalent
1
2
6
4
5
<Long wheelbase>
16
11 12
<Short wheelbase>
10
7
13
8
9
14
3
15
Disassembly steps
1. Roof lid glass assembly
2. Weatherstrip
3. Sunroof motor
4. Roof drip channel
5. Rear drip assembly
6. Sun shade assembly
7. Drive cable assembly
AA" "AA 8. Shaft
AA"
AB"
AC"
AC"
9.
10.
11.
12.
13.
14.
15.
16.
Drive cable
Roof window deflector panel assembly
Deflector
Deflector link
Set plate
Front cover
Cable guide casing
Guide rail sub-assembly
BODY - Sunroof
42-53
Approx.
200 mm
Shaft
Drive cable assembly
Flat-tipped
screwdriver
A
Roof window
deflector panel
assembly
Section A - A
Flat-tipped
screwdriver
Roof window
deflector panel
assembly
Flat-tipped
screwdriver
A
A
Section A - A
Flat-tipped
screwdriver
Deflector
Deflector link
42-54
BODY - Sunroof
Hollow in shaft
Shaft
Shaft
insertion
direction