(GENERAL INFORMATION .. ALIGNMENT ADJUSTMENTS HOOD LOCK CONTROL CABLE FUEL LID OPENER RADIATOR GRILLE INSTRUMENT PANEL. ‘TRIMS ... RESIN TOP ‘SOFT TOP .. TTARPAULINBoDy GENERAL INFORMATION e 80DY COLOR INFORMATION Barty ector Dashes color cote x Beets = Se z wwii | owt Erthcomnee | nen or = ee = mn et | a wasup mune | eo Sierse, | wihs Set Bees Es aes COLOR CODE OF THE WORLD SSE wa] ares me @ mei a oo —|— es | os a Serf aaen_| rome | sea —an moe [wa rama comme | aes | wa mare fs ‘ran aeoar | — ae —[ re — [a canes | om | a nome — per a BODY STRIPE INFORMATION ‘TRIM INFORMATIONS L “Trim color code or oy Seta code ‘A code that has beon satin alphabetical order Seat main materia!Bopy Bopy ‘There are two kinds of body shapes: They are the resin top specifications and the simole ype tarpaulin specifications, These twe epecticatons empioy basicaly tha same cody constuction. Body shell Feorcements are provided at variovs pats of the body inorder that adequate rigicty may be assured and the noise and vibration levels may be reduced! Basicaly, the resin tp vehicle and sof top vohice share the same shel The resin top vehicle (which has the identical ogy constuction with te simple type tarpaulin vehicle) fers from the standard tarpauin ype vehicle in detalea constuctionDY. Resin top vehicle ‘The rear upper body made of FAP (ber glass relnforoed plastic) & composed of root panel and side panels. ‘The Font roo is equipped with an FRP removable ype rot. ‘The reat upper body section is attached to the body by means of bos. Such constuction allows easy removal and instalation o ths section Ii, therefore, possible replace this secton wth the simple 1ype {arpauin wrich s avalable as optional equipment Furtermore, as regards he roe oe, incorporeios a tit- up mechaniom which allows the roar part of the rool to be raoed. Tha ack door plase has boon so designed that it can be removed or installed easly ftom tho back door parel “Be | Ga | 7 oo a Bos -Bopy @ 2007 scien ody sealers applied to the body panel mating surfaces and deor-soshood hemming sections go that rust preventive and water-proo! charactersics may be svengthened.BODY PARTS WHERE GALVANIZED STEEL SHEETS ARE USED \ \ Froretinger RA.BODY PARTS WHERE HIGH-TENSILE STEEL SHEETS ARE USEDBopy @ snencens (On all models, various silencers are provided atthe dash panel and focx panel eo as 9 prevent the noe atthe vehice exterior and engine trom boing ansmited int the vehicle interior. Furthermore, on those vehicles with EF specications, a anoise contol moasire iencers (glass wool pkia polyester base unwoven cloth) are mounted en tha apton fender ash aenear "lor sencer Som 8 Sra \ spr sont (3:8 rn) te Noonan Tear ep ane Sap whew seve stes Vator Wario [oe Festa norco pad 7aphalehat« Ca fak| Aap nee Coa tot te (Centar oa soe pad ‘Aspha chet + Camano” | Aap tee Coon ft o Frotjecratercerped | Aap ebst ‘pra es @| em a oar rear cnr ad ‘phar snet ‘Aron fender stance (Ont for FI vet) 20-9ALIGNMENT ADJUSTMENTS e ENGINE HOOD ALIGNMENT ADJUSTMENT Engin hoodtortont fender 989 eZ Hood roe fora e@ Spestea vatce 4 Seer eT ore aaeeery = Netto exceed 154m (0.06 ron) = ifrrce betty atari aces: Mots excood |S nen 08 r=) 1. Adesment of engine hood se-tont fender gap Loosen the bots @. Perform the adjustment by moving the noes. 2. Hood lock agusment Loosen the tnee attaching bots ofthe hood lock. Pelee the adjustment by moving the hood lock. (fjustthe hood lock h sich a way that you wil feel a sight Tooeenees whien the center section of the hood end Ie pushed strongly) Bo 7Bopy FRONT DOOR ALIGNMENT ADJUSTMENT Front doortoiront ender Lares ® Se Bie 2 sy pee Bren a cael ae Serereae es 8 ERIE cn EE om ee (canis rent omsret et er Bopy ROLL OVER CENTER GARNISH Removal 11" Remove the remevable roct lock garish and removable roo lock base assembly 2. Disengage the lps. 3. Remove the rollover center garish Installation 11 Insal he rll over coctor garish withthe four cips. 2. Install the removable ‘oot eck garish and removabie root loo base assomby. ‘COWL SIDE TRIM BOARD Removal 1. Daongage the cipe @, using a screwetivr. 2. Disengage the cli ® of ernove the bot 3. Remove tne cow side rim boars, Instatation 1 Insta the cowl side tin board withthe clip ® and clio ® otat, FRONT DOOR SCUFF PLATE Removal 1. Disongage the clips, using a sccewctiver. 2. Remove the font dear ecu plate. Instatiation 11 stall the trot door scut plate with the cin. QUARTER INSIDE TRIM BOARD Removal 11 Disengege the cps, using a scrowever. 2 Remove the quater inside tim board, Installation 1. Alga the clip in place. Install he quarter insie trim board bby dghtlytapaing around te cps by hand 80-42 ‘Gry sassenperalce cleracuppecvence Ghe vy ® ~~ 8BODY @ rear ROOF HEADLINING Components feet mscsng fac Seactnng wa ener Removal 1 2 a erove the rea rol ber. Rerpove the reot headlining wim rtainar by reroving the Femnove the oot heading, Installation 1 2 3 ‘Mask the periphery of the rear roo! headlining. Apply the ‘bond. (Surstar-Mace Penguin cemant 4386) Affix the reas 100! heading. {natal ho rear neacicing tr retiner by the screws. Intl the roar rO8 bar 20-43 * Sone apae stoneBopy RESIN TOP e COMPONENTS Str eda wr pre! 8 RSF Bare patra foarte gas rere Siewrweam ren, {© cuaner window ok bac (8 Back ooo osu rolong & Sree ge gan 8 Bisstating nt REMOVAL 1. Remove the caps tor resin panol ataching bots (10 points) egy e ‘Then remove the resin top panel attaching bolts {12 points). ‘Y NOTE: s \ ‘When removing the caps, use a cloth to avoid any damage toto vhice body. ee 2, Remove the mounting roll over bracket by removing the i. ee Remove the resin top panel fom the vehicle.DISASSEMBLY 1. Remove the quarter window olasselated parts 2, Remove the outside mouicing jin. back coor outside ‘moulding and back door upper weathers, 3. Remove the roo! headtning trim retaner by removing the 4, Separate ine rear root panel and outer rear side upper panel by remeving the serews, 5, Remove te rear reo! panel packing, ASSEMBLY 1. Poel off the liner of a wo-faced adhesive tape which is Installed en the rear root pane! paokng, Then, neal tre ‘ea ref panel packing onto the rear ron panel * BOs * sok oor ups wear oukingBODY 2. Apply the achesive agent specified below othe section ® (Got right anc let gies) at th font eido of te rear root anol, as incicated inthe right igure, ‘Adhesive Agent To Be Used ‘Surstar-Made Penguin Seal #2558 2, Ache packing o the section @ at the rear side ofthe ‘ear root panel. 4. Appl the adnesive agent spacing below the section @ (beth ght and let skdos) atthe rear side ofthe rear root panel, as indicated inthe ight gure ‘Adheaive Agent To Be Used: Cémedine 3708 5. Install the plate nut onthe outer esr sice upper panel NOTE: ‘+ Be sure to install the plate nut in such a direction that the nut side may face upward. 6. Instlthe outer rear side upper panel onthe rear roo pane.BODY © sesso rer ar ener ste per pre eri 8 aac IO we ‘@ cosa) a esate) ©2000) shatone Entrgedview at aseson Table of bolts and nuts, etc. oe | blo C$a (© prarroctionarsceuppareser | @ Awa Saree Ber ip wee © seewn wane © Seem ryan ren nia en 5 oem Seca 27 ar 1we Eskrem Freon | ire szonnaig re ame coor gee. 80-47 *Bopy 8. Ate back door opening packing onthe rear rot pane ‘8. Insta the back door upper weatherstip tothe rear rot pane. 10. Insert the mut plate into the corresponding section of the ‘ar oF panel 3 incicated inthe right igure, 11. Apply the flowing bonding agert given below to the font Sige Ofte rear roof panel atthe section B (both right and leftaldes), as nccated in the aight gure, Bonding Agent: Cemedine 3708 12. Instal he resin top pane! to the vehicle. 13. (retail he anaching bols and caps (10 ports). 14. Install he mounting rol over bracket withthe screws. 15. Install he quarter window aesemb)y. B08 Pan@ sort top COMPONENTS: TARPAULIN © ee seonecue are etna 2, Detach te fouten points of hooks. 80-49 *Bopy 2. lupe man vows any ec sou e Caine Nouite ws foul tceonBerarirpass mane anny woe woven ne wpean en [-—= Sian sown aga rong be an 4. Untie the band fing tarpaulin atthe roll ba. 5. Working trom the rear side, wind the tarpaulin toward the ‘tort so that te nner side ofthe tarpaulin can face upward. 6 Remove the tarpaulin by loosing the font tarpaulin etaner ‘ataching screws, 7. How to fold removed-arpauln@ eataion 16 Install the tarpaulin wih tightening the font tarpaulin reeainerataching sores, 2. Cover the tarpaulin over te vehicle body by twening the taspauin over 3. The the band to fix the tarpaulin atthe rol ae. 4, Affine magic tape a the conte bow (1 point} anctne ear ‘bow (2 point 5, Lower al ftenere 8. atic tne magic tapes, 7. tach the hooks fourteen points atthe rear body sie 80-51"Bopy ‘TARPAULIN BOW Removal 1. Remove the tarpauin assem. 2. Remove the center tarpaulin bow aesembly by removing the two ataching Bats ‘3, Remove the rear tarpaulin bow assembly by removing the four atacing bots. instalation {1 stall he rear tarpaulin bow assembly withthe four attach- Ing bots. 2. lestall Pe center tarpaulin bow assembly with the two al- ‘aching bot. 4, Install the tarpauin assembly.BODY @ tarPauun ‘COMPONENTS, 3 Nooo chr wsadn vse Frente cover trpauin bow St @ Topas ow oreo REMOVAL 1 Ce ok (4st ped @ | Sewers, ornove th two handles that retan the trot tarpaulin bow assambhy Remove the tarpaulin assembly or the frenttarpauln bow ‘assert * 80-83 -BODY INSTALLATION 4 2 Install the tarpautn trim (arpautin assembiy) to the front ‘arpauin bow. Fic the front tarpaulin bow with two hendtes. ‘natal the nooks (3 points) tothe reer bow, Install the hooks (14 ports) of the terpauin to the male hooks of te vericie boc.‘TARPAULIN BOW Removal 4. Remove the tarpaulin acsombly. 2. Remove the tarpauin bow assembly by removing the six Installation 1 Instal th tarpauiin bow assembly wth the six sere. 2. Instat the tarpauin assomby. Disassembly 1. Removal of rear top cover tarpaulin bow subassembly. (1) Remove the nut (@) Remove the washer and head pin from the tarpaulln bow babe. (6) Remove the rar top cover tarpaulin bow subassembly a aegi.Neirpain Dow aso Removal oft top cover tarpaulin bow subassembly (1) Remove the "=" ring (2) Remove te head pin rom the tarpaulin bow base (@) Remove tha font top cover tarpaulin bow eubassarbly ‘rom the tarpauin bow base, ssconty 1 Fae tor peo pain bow sassy © Fiat Son ae erence (a teat eed bets © rg a, Sula osreb scarey (ema re Se yaar en (ahaa mado ace anBODY SUNROOF e ‘COMPONENTS bb {8 Romorabe xt oe norte (8 farmnabe ov cx oars Sy {8 Remorse et ck gare REMOVAL 1. Remeval of remevable rot lock handle assembly (1) Pull the handie toward! you while pushing he lok but tons. (2) Remove the hana trom the vehicle by pusting the Tinks athe right and let sides. 3, alse the rot. Remove thereof by pulling tt upward. NOTE: ‘= Do not raise the suntoot more than 70 degrees. tthe sunvoot is reged in xcoss of 70 degrees, tho sunroof wilintertero with the body, resulting in ings detormation ‘or sunroof breakage. ‘+ When the sun roa s remove, do net hang on or sit on ‘the suntoot frame. poss *@ cisassenary 1. Remove the sunroof heating assembly by removing the cis, 2 Remove the roof headining bracket and removable roo! lock handle bracket by remaving the soreve 3. Remove the removable rot hinge plat and removable roo! hinge by removing the ns. ASSEMBLY + Ira the removable rot hinge plate an remavable root hinge wt ine ns 2. Intl the oot healing bract and rerovable oo lok — = nance bracket wth the stews. 3. nstalaon of euroo!heainng assorbty (3) Ensure at ne dips ere etched to te sunco head tng aor. (2) nal te suo! heacining esserby tothe rot panel INSTALLATION 1. Align e hinge on te surat ont endo catch cn tho rot @ ec cen Shanon ean o postion om dagonshy Upper back drechon 2. Close te oo, push the et and ght inks on the hance tnd push ro the hole on te base secu. 3. Look me hand by puaning ful eican sound can be Deara: Make sore tal tw handle oched 80-57 *Bopy WINDOWS e FRONT WINDSHIELD ‘Components Removal 1. Removal of windshield wipes arm assribly (1) Remove te windshiet wiper arm cover. {2) Remove the windshield wiper arm asseriby by remov- Ing tha ataching nut of fe fort wiper arr assemoly, 2. Removal ot ner rearview miro assembly (@) Remove the room lame co (2) Remove me inner rear view mor by removing he tee screws, and daconnaet the connecter. 80-88Bopy 3. Removal ont windshies glass Uifrecsing weatrerevip) (1) Paste ip section ofthe weatherstrp outward trom the bbogy fange, using 8 sorewarver or a bamiboa spatula ‘This operation fs pecoxmed from the vec intr. Note: ‘Be very careful not to scratch the body pint irish eur- face, (2) Remove the front windshield weatheretrp fom he front wodshield glass (Gf not using weatherstip) (3) Cuting oft the weatherstrip tio with kia, from the outs (2) Push he glass wit an even force, rm the interior. (8) Remove tho front windshield weatherstip trom the bocy. Inspection and clesning 11 Clean he adheelon gections ofthe glass and body, using 2a solvent such as alcohol oF white gasotne. Installation 4. Insill the front windshield westherer'p to the front vrndshield glass. 2, Installation of Font windshield gla, (1) Set en operation rape to te weathersrip. NOTE: + Never reuse any weatherstip which exhibits deteriora: ‘ion. Faure t abserve tis Intuction wal cause water leakage. (2) Apply soap water tothe body ange contact sections fof ihe westhersip. Also, apply soap wala o the body flange. (a) instal the tont windshield glase tothe body. * 80-59 + Borneman Joc Soap water soplying portion = ~ x *BoDy (4) Hold the ane end ofthe rope that is euspencing inthe ‘hile nseror. Pull he rope in such an angle that allows the weathers to cross over the flange. While ‘oing, pound the surface one glass at points adjacent tote weathersiro ‘Scere in otder thatthe windshield may be nstalle ins positon (6) Pound the surface ofthe giass using one's palm trom the vehicle extenor so thatthe wincshield may be set tied in place. (6) Application ct non-dryng window seater \ierking fom the outside, apply te non-eying window ‘sealer Batwoon tie weathersinp and the Glass as wel ‘3s between the weathers and the body NOTE: + Remove the any excessive sealer. (7) Water eakage check I water loskage exe, dy tho leaky point thoroughly. Ther fil the leaky port wth the non-arying sealer 2. Instlation of inner eearvew rrr assersy (1) Connect the connoctor (2) Ista the inner rearview miror with the three sorows, {@) Attach the oom lamp cover. 4 Instaction of windshield wiper arm assorbly (4) Operate the wiper motor, unl assumes the automatic. ‘sopping postion (@) Sotthe wiper azme atthe postions indicate inthe right figure (@) Tig the put and atach the ront wiper aim cover.@ exc 000n atass 1. Remove the spare tre, e 2, Remove the rear wiper arm assembly. eroval the rear window dettogger groune harnece (4) Remove te attaching Dott © dlecomnect the rear wire low delfogger ground harness from tho back Soc, NoTE: ‘+ After the hamess has been disconnected, rlnstal the bolt to the back door for next use, (2) Disconnect ne comectorfor the rear window defogger e alot side. Bo-6t *Bopy 4 Remove te handles (4-poins, CAUTION: ‘+ When instaling the back door glass, make sure thatthe handles have been tightened postvely (our pelts). '5. Remove the rear window glass Installation 1. Insal e back door glass assembly tothe body using the ‘eur handles, 2. Incl te rear window detfogger ground harness. 3. Install the rear wiper arm assembly 4, Install the spear treBODY @ 3 3 3 8 3 ® S 6 user wo ck garish Siero le ‘Guar weno ce act Site Woon ioe ar ‘Stare windon ings 1. Romove the rear rl ar 2. Removal of quarer window glass easemoly (3) Remove the quarter window lock garnish, (2) Remove tho screws ataching he quarter window lock tothe boy, (8) Remove the screws ttacing the quarer window hinge tothe boey (4) Remove the quarter window assembly from the boo. ‘3. lemeve te querer winow lock and quarter windou hinge from the quarter window assemby, Installation 11 Install the quarter window lock and quarter window hinge to the quarter window assembly. 2. Install the quarter wncow assembly tothe body, 8 flows (1) instal the quart window ninge to the boxy wen the (2) Install the quarter window lock to the body with the NOTE: 1+ When tightening the serew, fil the ut with an adhosive ‘agent (instantaneous adhesive agent (9) Insta the quarter window lek garish 3 Ital the rear rol bar * 80-62 *BoDy FRONT DOOR DOOR TRIM AND SERVICE HOLE COVER Pert dor re nna bart 8Sag ee user peeaee se tp — =e $ fener 11 Rlomeoval of door armrest assorbly (1) Remove te to sorews. (@) Remove the door arvest assembly frm tent doar. (G) Ramove be screw. 2. Remove the front door inside handle bezel by rerrening the 3, Removal of fent door window reguato handle assembly (1) Pull off me snap ring wit a cloth as indleated in the fou. (2) Remove the fort door window regulator angle and oo" regulator inside handle pate 44. Rerave the ront door tr board subassembly Dy remov- Ing the clipe '5, Femave the ront door service hale cover.Bopy Instalttion 1 Insaltion of ront door services hele cover (2) Aticbutyttape tothe points indicated inthe right gue. (2) inser the cover att lower enc it the aperture at he lower side ofthe oor panel. Ax adhesive tape onthe holes NOTE: 1. Never plug the clip hole ofthe door tim with acheive ‘ape. 2, Replace any service hole cover which exhibits rupture, 2. Installation of front door tin panel assembly (1) Ensure thatthe cps are sttaoned to the rant door tiem ‘panel assembly (2) install the front door rim panel assembly to the front oor 3, Install the front door inside handle bezel and door armrest assembly. 4, Installation oftront door window regulato handle assembly, (1) lnstal the door regulator inside nancte pate (2) Set the snap ting to the font Goor window regulator hance, (@) Ineal the front door window regulator handle in the angle specified inthe right figure.BODY DOOR LOCK AND OUTSIDE DOOR HANDLE e camponena ieegzy~ nese 3 Fee cS Shes meee SFE rhe e 8 hone mete 4. Remove te front door tin-alated pats. 2. Remove the font oor rea” wer tame subessemby om 2. Removal of fent doo! lock assembly (Q) Remove the front door inide Randle subessembly. 2) Remove the bolt. (G) Remove the front door lock assembly. es “4. Detach the front door outside handle assembly by removing the two rus ‘5. Detach the cp. Remeve the key cylinder.Installation 1 Insal te front door outside hance assembly withthe wo ruts 2. Install the key cylinder into postion wih the clo 3. Instation of ent coor lock assomby, (1) Ingtal te front door lock assembly with the three (2) Set tne conto inks and tighten the bot ®. (G) instal the fort door inside handle subassembly with ‘Pree bots. 4. Intl the front door rear lower fame subassembiy with bat 5. Install the tront door tintelated pars, DOOR GLASS AND REGULATOR men ‘Components 2 Ere oor ue a 2 Fert so sr tart earerip 3 rei Pescara Fron er nor SA Removal 1. Romove the doo: rimolated parts 2 Remove the two atlaching Cots of the font coor glass ‘subassembly. Remove the frant door glass subassernbly ‘rom the front coer. 0-67 -BODY Bs Frontcoo glass © Ftc gas Crawelwceherip _Ctarreaibasoroy 8, Remove the font door glass channel subassembly and ‘rent door glase channel weatherstp, Remove the front door window regulator assembly by remeving he five bot Remove the front door glass weathersip outer and inner. Remove the front oot glass run Remove the front door rea lower itame subassembiy. nee Installation 1 Inaal the front coor reer lower frame subassembly othe body. 2. Inet the font doer glase run en frent door Upper t0 the body ‘3. Install te font door glass weathorsrip our and inner. 4 Install the front door giass channel weathersrp and font ‘coor glass channel subassembly to the tfont door glass. 5. Iesalaion of ont door window regulator assembly (G1) Apply MP grease othe slicing section, {2 Install he tont door window regulator assembly. (Tighten the bots ote: than the bots @. Then, tighten te two bots @ at the center suction ofthe elongated hole of he door pane) {6 Installation of ont door glass subassombly (1) stall the font door glass subasser by {2 Close the front door giase fly. Ten, lower he front door glass 40 mm (1.57 inches) (@) First eesen tne batts @ and than tighten them again, 17, Install he Goer vimelated pars, * 80-68BopY e BACK DOOR COMPONENTS: ack cr aes ce aor come tery BE eee 1 eri ot ane Sor tare ay Fev waver Ay 1B Gack dor dawn ral back stpoat 1 fear Geers norte 1B Ee doo paral Back soa saves roe panel com sack soo beg cttoecoe 1B Bec Ser cna Ssrcoortn a | Rrpabrn at = _ (G) Remove tne nut wipe arm ard shield cap. (@) Remove the nul, washer and gaaker Ce 8 he * 50-69Boby 3 Femoval of back door glass (1) Remove tie back door glass defogger groundhamess ‘tacting bolt tocisconnect the rear window detlogger ‘groune hemese “rom the back door. (@) Doma ne comet re eat wndow dtoger atlet ede, (@) Remove the rear window by removing the tour andl. Remove the back door trim by removing the clipe (14 pois) Fomoue the back door service hole pane! cover No. 1 by removing the fou screws. Femove the service hole cover. Removal of ear wiper motor assembly (2) Disconnect the connecter. (@ Remove the rear wiper motor assembly by removing the tree bats, Romoval of back door lock assem () Remove the inkreaten pars {@) Remove the throe attaching scrove of tho back door lock assembly, (In the case ofthe back door opener- quipped vehicle, remove the bok @) and efscennect the connector) (@) Tack out he back doer lock assembly fom the back oot, * 0-70BODY © os err a ack rsx not ase em ba Sedo ok as. tr cue cl a er Sporwronserne vee Sy) 9. Remove the back door outside handle asserbiy by remov- ng the two nuts. 10. Datach to clip. Remove the key cylinder. 11. Remove the oar window washer-telated parts (1) Remove the rear washor nozzle essemby, Detach the hose ad lip from the nozzle assembly. (2) Remove the rear washer jar assembly with hose, Dis- e connect the connector 12, Remove the harness and grommet fram the Back door. BorBopy 18, Remove the back door down male stopper. 14. Remove the back door check subassembly. 15. Removal of back door panel (1) Remove the rors. (2) Remove the back door pane! rom the vehicle by remo ing te bots. INSTALLATION 1. Insalaion of back door panel (7) Insta the back coor panel to the vehicle with te bots. (2) intel the grommets (G) insta the Back door check sunassembly 2 Install the back door down male stopper with the two 2, Inet the harass tothe back doer. sorInataiaion of reer window washer-rlated pats, (Ci itl te rear washer jr assembly wit hose and con ‘necro te rear washer ja. (2) Ital the reer washer nozzle assembyy, anachod hoso ‘and cp tothe nozzle assembly. race the key oylinder on the back door. Secure the lack fynder with the clip, Installation of back door lock assersbly (7) tnatal the back door contol solencid assembly in the ‘back deor lock assembly. (In tha case ofthe back door ‘oparer-equipped vehicle ony) (2) las the Back door lock assembly wih the three eres inthe case ofthe back door opener-equipped veticl, instal the Bott @ and connect the connector) (9) Insta the tnkretaed pat. Inatall the service hole cover. NOTE: 1. Afb ape to the points nected in tho right lore. 21 Replace any service lle cover which exhais rupture Inatal the back door service ole panel cover No.1 by wih the fou scrows Inetalaton of Back doce en (G) Eneure atthe clipe are atached tothe back doo tim, (2) install re neck door tis to te back doer. Bo-73 ~BODY 10. Inetalaton of back door gies (1) Install he back coor glass wih the for hanes, (2) install the rear window detlogger ground harness. 11. Instaaion of wiper am and blade. (@) neal tre Gasket, washer, net and shel xp. (2) Intl the wiper arm and nt NOTE: 1. Operate the wiper motor and set the wiper arm to the ‘automatic stopping postion. 2. Set he wper arm'o the position as inckcated nthe right ‘igure. Bo-74 Fiottsde Latte \\ aseidrom Garoe ten = = a 4Bopy @ = rear Roi Bar COMPONENTS TOTO tne eit acer ot Tenren Go, Us U SA, © robs side marr Sia 2 eo achat Pr ol career 2 S dance Nera vera cove eoe REMOVAL @ 1 ee rcs eat 2 Removal of rear rll bar cover (1) Remove te magic epes, (2) Remove ths tastona. (@) Remove the rear rt bar cove from the rear rll bt. (@) Reeve the two serove, - 80-75 *Bopy 8. Remove the rear rol ba. NOTE: ‘+ Tho oar roll bar employs the TORX* serow so thatthe owner may not detach the roller bar aly. ‘Te TOIae sr ses at one sme Brncogn Sint gre OF iterated vesomak ot Tourer 6 US ° rome roRer40 ° i} i Sy \ INSTALLATION 1. Insal he rer rl bar to te boc Tigttoning Torque: 1.8-22 kgm (148-15. fe, 157 -21.6. Nm) 2. Instalation of rear ol bar cover (2) natal wp two cerows. (2) instal th rear ol bar cover tothe rear rll bar withthe fastoner and magic apes, 3, Insial th tree point rer eset bets. Tightening Torque: 2.9-5.4kg-m (21-39 fe, 26.4 -53.0Nm) * 20-76BODY FRONT SEAT For enhanced rigicty and reduced weight, the seat fram of the frat seat adopts @ pipe frame and an °S* spring stuctue The front seat uses urethane having an adequate hardness as the seat pad materia The front seat is so constracod tat te seat sl.ding pitch is 151mm (0.59 nen), wnoreae the recining (atch) angle can be adjusted in increments of 2 degrees. Consequently, is possible to mare fine ajustmert in accordance wih the body size oF the iver or passenger. “The Peadkest has been 90 designed that ts height car be adjusted in eocerdance with the diver or passenger ser (aexaapieny e077 -Be COMPONENTSREMOVAL NOTE: ‘+ The following dsassembiy and assembly procedures have boen described primarily based on a model seat 1. Remove the font seat from the vehicle by remeving the four ot DISASSEMBLY 1. Remove the neces withthe stopper pushed toward “Un. leek drecton, 2. Remove the adjusting recring release hance. 3. Remove the front seat cushion shiold,fotowing the proce- dure gen below. (1) Remave the tree attaching sews (2) Remove the front goat cushion shield by sling ft a2 Indeated in tha right igure Bore ~Boy 4. Detach the four hook rings ofthe front seatback cover, as Indested inthe oghe gute, 5. Detach the three hook rings othe front seatback cover, 28 ineeatod inthe rgnt gu, {6 Detach to Yes hook ings of he front seatback cover, 38 indicated in tho right figure. 7. Detach the thee hook rings provide atthe rear sie ofthe front eoetback cover as cicated in tho right figure, 8. Remove the seat headrest support© rerovne rot seaacrassondy (7) Remove the seatback by removing the ane smal bot and two bolts which are atacing the seatback. (2) Remove the front seat hinge cover tom the eeatback, Detach the return spring, ern the font seat cushion log assembly by ternoving the four bots, Remove the recining seat back adjuster assembly by removing the two bots, ernove the trot seat inner ack assembly by comoving the two Bios. Detach the nook rings ofthe tron seat cushion cover atthe 13 points, as ineieated in the right figure. Boat ~BODY 15. Detach the seven hook rings provided atthe front side of the font seatback cover. as incated in the right gu. 18, Remove the front seat cushion cover fom the font seat exshion assembly. ASSEMBLY 1. Installation of ont sen cushion cover (1) Install the new hook rings athe back side ofthe front ‘seat cushion (2) stall he naw hook rings atthe back side ofthe ont seat cushion, 2. Instal the front seatback cover to the front seatback. Also, instal the headrest suppor. 2. Install the reclining seatback adjuster assornly by instal Ing the wo bots. Tightening Torque: 0.6 - 1.0 kom (63-72 ib, 59-98Nm) 4 Inatall the tnt seat inner track assombiy by instaling the ‘wo bots Tightening Torque: 0.6 - 1.0 kgm (43-7204 59-98Km) 80-82© rar tor sn cuteness wih te fu oo “Tetenng Toe: 08-15 49m (65-"00RB,60-147 mp 6. lost the return sping 7. Insiliaton of front seatback assembly ‘Tignaring Tora | Tghaning Toon (1) Install he front seat rings cover fo the tront ssatback | "tr stag OBO ‘assembly. Tho, instal hom tothe seat cushion withthe | {23-2 pare eeerby. Tho. nsal rt stone Sosanar (2) Ista new hook rings to te back sie ofthe seatback £8. Install new hock rings fe the front seatback cover ate QP crenata ‘9. Install new hook rings to the front seatback cover at the three poins, as nciated inthe ight igure.Bopy 10. io tks ote oad be ot snack e Gerad ou fant cies Seka 11 Install now hook rings tothe fron saatback cover at he four Pins, as inciceted in the right gure. 12. Insta he front seat cushion shield withthe theo scrows. 18. Insta the acjusting recining release handle with the one scrow. 14, [neal the headrest. INSTALLATION Insta he front seat withthe four bots “Tigtoning Torque: 3.045 kgm (22-38 hb, 29.4 44.1 Nem)Booby REAR SEAT For enhanced rgity and ceducod weight, the seat cushion fame ofthe reer seat adopts pe frame and an *S" spring structuze. On the cher hand, the seatback frame ampleys a pipe flame and a wire tuctar, ‘The rear seat uses urethane having an adequate hardness asthe seat pad material Moreover, the rear saat empioys a foldable constuction. ln addition, te separate type rear eat ie avaiable ‘38 optional equipment. Bereh ype ascot Separate ye rar sat 50-85 *Boby BENCH TYPE REAR SEAT ‘Components, ear sat pasceoer 3: Ne a ea ator cover Siaenno. 1 ar sat cuter Ay Poot oa (6 fear seta & Hokey Removal 1. Removal of rear seat 1) Push the lock lever ©, \ ese |__| (2) Pull up the lock lover @ —=———— (G) Raise the entire seat torward Bow -© or rao 0 sat by roving te vo be Disassembly 1." Romove te rear seatoack by removing the wo bots. ‘Removal of roar seatback cover (1) Remove the band by removing te one screw. (2) Rerave the hook ring atthe back side ofthe seatback 0) Rane tetra 20-87 -BODY (4) Tum over th rear seatback cover FRomeove te rear seatback over by removing the hook rings a he front action ofthe seatback (5) Romove the rear seatback cover, ‘8, Removal of rear seat custion cover (4) Remove te four Cushion by removing the sores (2) Remove the hook ting athe back side of he rear seat (8) Tum over the rear seat cushion cover emave te hook ring a te back side ofthe rest set custion,© is tumoern rest ction cove Farot th a ot Sh Coby enon te (Sarin at he to son or cn Coon (Reno be eon sah co! ‘Assombly 1. Inatalaton of ear seat cushion cover G) tntal the naw ook ge atthe roar seat cushion cove. (2) ltl the four cushion with tho soron. 2, Installation of rear eoatback cover (9) Isai he new ook ings atte fant side of the coar se seatback (@) Lower a the fasteners. (@) instal the new hook rings at the back side of the rear NOTE: ‘+ Bovery carotulnotto smear or scratch the rear seatback cover during te assembly. ‘+ When instating the hook rings, make sure that no e wrinkle is formed on the rear seaiback cover whenever possile * 20-89 -BODY Inatall the rear seatback to the rear seat custion with the two bats. Tighoning Torque: 1.8-3.2kg-m (13-29 feb, 17.7-31.4Nm) NoTE: ‘+ Make sure thatthe rear seat cushion bots at the sight ‘and lft are Sghtaned socurly. Inst the rear seat withthe two bots, ightoring Torque: 2.0- 8.0 kgm (4-22 feb, 19.6-23.4.Nm)Bopy @ separate TPE REAR SEAT Components fee itetbes oa ee Petite Ie ees e : ™ Qrrmarcne —@ Gan Qtorseee Bass go. Seen = = Si tecnese en BEeeman — BESTE Zee 8 SR | SATE Succes Sheet sue ny Removal 1) Remove the rear seat by removing te two bolls. . Boe -Bopy Disassembly 1. Remove the rear seat fock handl. 2. Remove the rear seat lock cover 2, Remove the reer seatback lower cover. - 4. Remove the rear seatback assembly fom the rear coat custion assembly. ‘ e Femove the rear seat inner belt assembly. Remove the tension soring,BODY e. 1". Remove the we cushions. Detach te three hook rings ofthe rear seat cushion, as ingicated in the right figure Detach the tree hook rings of the roar seat cushion, 26 Inclestod in te ght igure. Remove a part the rear Seat cushion cove, Remeve the cushion Detach te three hook ngs of he rear seat cushion cover, {as indicated in the right igure, e098 -BODY 12 8, 4 Detach the tree hack rings ot the rear seat cushion cover, a8 incleated in tho right igure. Detach te tree hook rings ofthe rear seat cushion cover as indicated inthe right gure. Detach the four hook rings of the rear seat custion cover, fe incScated inthe right igure, Detach the seven hook ngs of the rear seat cushion caver Remove the rear seal cushion cover ffor the rear seat cuss Rernove the rear seat stop band from the rear seatback assembly18. 19. Raise the tastener ofthe rear seatback cover Detach the four hook rings ofthe cear egatback cover a8 ineoatea in te gh igure, Detach the four nook rng of the rear seatback cover, ae indested in the right fgure Detach the thee hook rings ofthe rear seatback cover, a6 Indiated in the right foure. Remove the rear seatback cove: rem the rear seatback assembly. Install the reer seat cove to the rear seatback assembly. 80-98 *Bopy 2. Install now nook rings 10 the rear seatback cover, as ine ‘cated inthe ight igure 3, Inetell now nook rings tothe roar seatback cover atthe four pons, as indicated in the nght gue 44 Instat naw hook ings to the rear seatback cover atthe four pins, ae indicated inthe ight figure. 5, Lower the fastaner ofthe rear seatback 6, Install the rear soat stop band. 7. Install the rear sest cushion cover to the rear seat cusrion ‘assemby. Insta new hook rings at the seven points, as ineSeated the right igure, 8. Insta new hook raga to the ear seat cushion cover atthe 13 points, as incieated in the right figure 20-96@ reat nen nck ge oir wt sa: cution cover athe 10. 1" 2 3 14 throe pois, as ncioated nthe right igure, Insta new hook rings to Be rear seat cushion cover at the ‘free points, as coated inthe righ gue. Inatallths rar seat cushion athe tres points, asindicated inthe ght igure, Install the rear seat iner bet assembly. Tightoning Torque: 2.0 4.5 kg-m (165-325 Rb, 19.6- 44.1 Nm) Install the tenston eexing, Install the rear seat cushion assembly to the rar eeatback ‘sera. Tightening Torque: 1.75 - 3.25 kgm (190+ 28.1 ib, 177-31.4Nem) Note: + Make sure thatthe rear seatback ataching bots atthe tight and left are tightened securely, 80-87 -BODY 18. Intal the rear seatback lok cover 16, Install the rear seat lock cover. 17, ntal he rer seat lock handle. Installation 1. Install he rer gest by instaling the two bots Tightening Torque: 20-30 kgm (14-221, 198-204)SEAT BELTS couPONENTS i =a Smear eve ( erm Seager mar oe ena Rear BenTENeTng ora Fn Th, 224-S90Nm Sa] =a wn oom = | om 4 srnomneronen se O57 enn INSPECTION einen ose SEES, on pain wpe sere oo hing ince te ee ee Recon Sieme tar satcaneaee Shecmnenrss! i 2 Sa Sera a Someta me + She sett te ment Sacee oan a eset sae oe , 80-99 *BODY FUEL TANK e COMPONENTS:BODY @ aamarre Removal 11, Remove te init fuel protector by removing the tree bots p. and on 2, Remove the inlet fuel tank sub hese and breather hase ag ig ‘ fo vie ey 3, Remove the fue! tank cap assemby 4. Remove the inlet box ring. ‘5. Flomove the fuel tank ler pipe ehield No. 2 BO-101BODY 6. Romove the fuel tak inlet pipe subassembly by removing the toe sovoms, Instatiation 1 Install he fuel tank niet pipe subsseebly and it shield {uo tark No, twit te tbe serews. 2. Install the fuel tank filer ape shield No, 2 NOTE: ‘The cutout section should face toward the lower side. 3. Instal the inlet box rng, 4 Install the tank eap assembly, 5. Attach the inet fuel tank sub Rose and breather hose to the fuel tak ile pipe. 6. Install tho inet tel protector with the tree bolts and one cio. 80-102Bopy FUEL TANK Removal 1. Drain the fuel fom the fuel tank by removing the drain plug. ‘After the fue|has been drained, stall the drain plug. 2 Remove the fuel ank protector subascorbly. 3, Dieconnact the fuel sender gauge connector. 4. Remove te inlet ful protector by removing the tree bots and one cp, ‘8. Rove te not tank sub hose, breather hose and clamp. 66. Flerov of fuel hose and fuel retzn hose HOE engine (1) Remove the fue pump bracket subassembly by reow- ng the three bats. (@) Farovathe clamps and separate the fuel hose and uel retum hose. HDC engino (1) Remove the clamps and separate the fuel hose and uel return hese. 2 0-108 -Boy 7. Rerrove he clamps and cleconnect he evaporation hoses. NOTE: ‘tis notnecessary to sconnect the biack hose. 18 Removal of fuel ank ascembly (4) Suppor the fuel ark assembly wit 2 jack (@) Remove the five ataching bots of he el tank 9, Remove the fuel hoses. 10. Remove te fuel sender gauge assembly by remouing the five srons. Installation 11 Inca o ue tank assombbiy (7) Insta the fuel sender gauge assembly withthe five Tightening Torque: 2kg-0m (2) Install tbe evaporation noses, (9) Intal the fue hopes tothe fue! tank asserly (@) Install the fue tank assembly with the five bots NOTE: ‘+ Tho wire hamess ofthe fuel sender gauge should be brought ouside. * Bo-104(2) Install the fuel pump bracket subassembly with the three bot, 3. Connect the fue sender gauge connecter. 4. tach the ino tank sub hose, breather nose and clamp, ‘5. [stall he inet fuel protector with the three bolts and one lp. 6. Install the fuel tank protector subassembiy with the four bats 80-105 -BODY EXHAUST PIPE COMPONENTS (Carburetor vehicle) sings 2 3 3 nee Eras Bure pe sucpe bracket No + 80-108,@ components (EFI vehicie)REMOVAL 1. Remove the transmission undercover. 2. Separate the tai pipe assembly rom the catayst converte asterrbly. (HO-E engine) 4. Separate the catalyst converter assembly from the front ‘exhaust pipe aseembly (HO-E engine) 4. Remove the exhaust pipe support ofthe tal pipe assembly 5. support of he tal pipe assembyy to veri body hanger Remove Dea pipe sey. BoB *© . oxcorec te csi ot 0, cone foe + Sonat sconce O toro te exa! pe, forthe gasket of the O, sensor fs a noneusable part and the gasket alone isnot avalabi. 7. Remove the nuts ofthe front exhaust pipe ans 2. Flemove the exhaust pipe support bracket No.1 ofthe front ‘exhaust pipe assembly. 9. Remove the font exhaust ppe assembly. ‘CAUTION: + While removing the ron exhaust pipe assembly, bo very careful notte darrage the O; sonsor. INSTALLATION 1. Temporary ntl he exhaust pipe suppor bracket No.1 @ ore rence scaon: bracket 2 Install the front exhaust pipe assembly to the exhaust mmaniols NOTE: ‘+ Be sure to install anew gasket, or it sa non-reusable part ‘Tightening Torque: 3.5 -5.0 kgm (253-36. fib, 94:3 - 490m) @ | Bersmetorenne nee nts een anspogrenve: ca * 80-109 -Bopy ‘8 Tighten the bol for the exhaust pipe support bracket No, 1 ofthe front exhaust pipe assornay Tightening Terque: 30-45 kgm (17-825 tb, 204. 44.1 Nm [Attach the muffler suppor ofthe tal pipe assembly o the vehicle body hangers atthe tree pois Install the exhaust pipe suppor of tho tal pipe assembly. “Tightening Torque: 1.0 1.8 kgm (72-118 ft, 08-157 Nn} Install the catalyst Convener assembly to the fent exhaust ‘pipe assembly. (HO-E wngine) Note: Be sure to install a new gasket, for pan. ‘Tightening Torque: 3.7 - 8.24g.m (268-976 4, 96:3-51.0Nm) oe-eusable + Be sure to tighten the two bolts and nuts evenly and progressively Intal theta pipe assombiy tothe catalyst converte ae sembly. (HD-E engine) NOTE! ++ Be sure to instal a new gasket, for its a non-eusable part Tightening Torque: 3.7 -5.2kg-m (258-376 Mb, 953-51.0Nm) + Be sure to tighten the two bolts and ruts evenly anc progressively. Connect the coupier of the O. sensor. Install te transmission undercover * Bo-119Bopy @ copy mountiInes ‘The mountings used for connecting the vehicle body to the frame have been further improved! 80 thatthe transmission of nose irom te suspensions and powertrain system to the vance body may be kept at 8 sium ive i ae = © eee ee | ES Ewe | lta remeber | Kaan | Been | Seen | Seen / Bont +BODY FRAME e The rare employs. ladder type frame which retards he transmission of vibrations and noises tom the road ‘oF engine to he body. Furhomore, the ladder type tame contributes to sot riding comion and Quieter ‘etic interior. ‘The frame has box shaped cross-section pas e20(s4s5) 75212351 Fist 1 290(1535 aco.188) __ 00139) Hausen) r 7e.wez2) Ff sxois269) 154390) “epi eon -@ soy DIMENsions - ISBODY

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