I1 Body: To Index

TO INDEX
I1 BODY I1
BODY----------------------------------------------- I1 - 1
BASIC CHECK AND ADJUSTMENT---- I1 - 1
FRONT DOOR(TRIM-RELATED) ----------- I1 - 8
DISASSEMBLING AND
ASSEMBLING --------------------------------- I1 - 8
FRONT DOOR(GLASS-RELATED) ------- I1 - 11
DISASSEMBLING AND
ASSEMBLING ------------------------------- I1 - 11
FRONT DOOR(LOCK-RELATED) -------- I1 - 13
DISASSEMBLING AND
ASSEMBLING ------------------------------- I1 - 13
REAR DOOR(TRIM-RELATED) ----------- I1 - 15
DISASSEMBLING AND
ASSEMBLING ------------------------------- I1 - 15
REAR DOOR(GLASS-RELATED)--------- I1 - 18
DISASSEMBLING AND
ASSEMBLING ------------------------------- I1 - 18
REAR DOOR(LOCK-RELATED) ---------- I1 - 20
DISASSEMBLING AND
ASSEMBLING ------------------------------- I1 - 20
BACK DOOR ----------------------------------- I1 - 22
DISASSEMBLING AND
ASSEMBLING ------------------------------- I1 - 22
FENDER ----------------------------------------- I1 - 24
REMOVAL AND INSTALLATION ------- I1 - 24
HOOD LOCK CONTROL CABLE --------- I1 - 27
REMOVAL AND INSTALLATION(RHD VEHI-
CLES) ------------------------------------------ I1 - 27
REMOVAL AND INSTALLATION(LHD VEHI-
CLES) ------------------------------------------ I1 - 29
FUEL LID CONTROL CABLE -------------- I1 - 32
FUEL FILLER OPENING LID -------------- I1 - 39
I1–1
1 BODY
1-1 BASIC CHECK AND ADJUSTMENT
1-1-1 FITTING ADJUSTMENT
(1) hood
1 Fitting dimensions
A
B
A
(b)
(a)
Fender
Fender
(c)
Hood
Hood Headlamp
B
A(A
T11B5001ES20
FITTING DIMENSIONS OF HOOD PANEL

Measuring point Specified gap Difference in Flatness (c) Difference between Deviation value
(a) height (b) right and left
A ( A Hood = Front fender 3.5 & 1.5 0 & 1.5 ( Not to exceed 1.5 Not to exceed
1.5
B Hood end ( ( 0 & 1.5 Not to exceed 1.5 (
Unit : mm
2 Fitting adjustment
a. Adjustment of the hood in longitudinal direction, and in lateral direction at the rear end
1.Loosen the hood hinge bolts to adjust.
CAUTION
• Since the centering bolt is used, adjustment must be
done only after the centering bolt is replaced with the
supplied bolt.
NOTE
• Part number of bolt:91631-60614-000
T11B5002T10
I1–2
b. Adjustment of the hood in vertical and lateral
direction at the front end
1.Remove two clips on the front bumper cover and pull the
hood lock area of the front bumper cover to provide a gap
for the tool.
T11B5003T10
2.Loosen the hood lock bolt prior to adjustment.

CAUTION
• In cases where the centering bolt has been used,
replace it with a bolt supplied for adjustment use in
advance.
NOTE
• Part number of bolt:91511-G0612-000
T11B5004T10
(2) Front & rear door

1 Articles to be prepared
SST
Shape Part No. Part name
09812-00010-000
Wrench door hinge set bolt
(09812-22010-000)
Tool
Long TORXO wrench T40
I1–3
B
550mm
150mm G
150mm150mm
C F
m
150m
C
F G
B D
D
H
E E H
I I
A A
200mm
250mm 200mm
I I
(a) (a)
(b)
(a)
Side panel outer

(b)
Fender
Front door
(b
)
Front door frame Rear door

Pillar frame
Front door frame
A(A B(B D(D
C(C
(a)
(a)
(b)
(a)
Side panel outer
(b)
Front door Rear door
(b
Rear door
)
Side panel outer

Pillar
Rear door frame
E(E F(F H(H
G(G
(b)
(a)
I(I
T11B5005ES40
I1–4
Fitting dimensions of door
Measuring point Specified gap (a) Difference in Difference between Deviation value
height (b) right and left
A ( A Front door = Front fender 4.2 & 1.2 0 & 1.5 ( Not to exceed
1.5
B ( B Front door = Side panel 4.8 & 1.5 (3.7 & 1.5 ( Not to exceed
1.5
C ( C Front door = Side panel 4.8 & 1.5 (3.8 & 1.5 ( Not to exceed
1.5
D ( D Front door = Rear door 4.2 & 1.2 0 & 1.5 Not to exceed 1.5 Not to exceed
1.5
E ( E Front door = Rear door 4.2 & 1.2 0 & 1.5 ( Not to exceed
1.5
F(F Rear door = Side panel 4.8 & 1.5 (3.5&1.5 ( Not to exceed
(Side panel 1.5
reference)
G ( G Rear door = Side panel 4.8 & 1.5 (3.1&1.5 ( Not to exceed
(Side panel 1.5
reference)
H ( H Rear door = Quarter panel 4.2 & 1.2 0&1.5 ( Not to exceed
(Rear door 1.5
reference )
I(I Front/Rear door = Rocker panel 6.0 & 1.5 ( ( Not to exceed
2.0
Unit : mm
3 Fitting adjustment (Front door)
c. Adjustment of the door at the rear end, and in vertical
and lateral directions
1.Loosen the bolt on the pillar side with the SST and perform
adjustment.
SST: 09812-00010-000
T11B5006T10
d. Adjustment of the door in vertical direction, and in lat-

eral direction at the front end
1.Loosen the bolt on the door side to adjust.
T11B5007T10
e. Adjustment of the door in longitudinal and lateral directions and the front door lock striker
1.Loosen the striker mounting screw until the striker gets loose.
TOOL: Long TORX® wrench T40
I1–5
2.Adjust the striker by tapping lightly.
T11B5008T10
4 Fitting adjustment (Rear door)

f. Adjustment of the door at the rear end, and in vertical
and lateral directions
1.Loosen the bolt on the pillar side to adjust.
T11B5009T10
g. Adjustment of the door in vertical direction, and lateral

direction at the door front end
1.Loosen the bolt on the door side to adjust.
T11B5010T10
h. Adjustment of the door in longitudinal and lateral directions and the rear door lock striker
TOOL: Long TORX® wrench T40
T11B5011T10
I1–6
(3) Back door
A A
(a)
(b)
(a)
(b)
Roof Side panel outer
Back door
Back door
A(A B(B
T11B5012ES33
Fitting dimensions of back door

Measuring point Specified gap (a) Difference in height Difference between Deviation value
(b) right and left
A ( A Back door = Roof 7.5 & 1.5 (1.0 & 1.6 ( Not to exceed 1.5
B ( B Back door = Quarter panel 5.0 & 1.5 9.8 & 1.5 Not to exceed 1.5 (
Unit : mm
I1–7
2 Fitting adjustment
i. Adjustment of the back door in vertical and lateral directions at the upper end
1.Loosen the hinge mounting bolt on the door side before the adjustment.
CAUTION
• Since the centering bolt is used, adjustment must be
done only after the centering bolt is replaced with the
supplied bolt.
NOTE
• Part number of bolt:91651-40816-000
T11B5013T10
j. Adjustment of the back door in longitudinal direction and the back door lock striker
T11B5014T10
1-1-2 CHECK THE FRAME AND THE BODY FOR ANY LOOSENING AND DAMAGE
1.Check the conditions of the tightening bolts, nuts and rivets for the frames and cross members with a
spanner.
SPECIFIED VALUE: There shall be no loosening.
2.Check the body, frame and cross member for damage such as rust, crack, deformation, and peel-off
of welding.
SPECIFIED VALUE: There shall be no damage, such as rust, crack, deformation, and peel-off of
welding.
3.Move the door by hand to ensure there are no loose hinges due to excessive play.
SPECIFIED VALUE: There shall be no loosening.
I1–8
2 FRONT DOOR(TRIM-RELATED)
2-1 DISASSEMBLING AND ASSEMBLING
2-1-1 ARTICLES TO BE PREPARED
Tool
Clip remover
Lubricant,adhesive,others
Butyl tape
2-1-2 OPERATION BEFORE DISASSEMBLY

1.Disconnect the battery negative (() terminal.
2-1-3 DISASSEMBLY AND ASSEMBLY PROCEDURES
(1) Components
c
f d
S S
S
S a
S b
h
g
S
S
T11B5015S30
(2) Disassembling and assembling procedures

j 1 a Panel, front door armrest base, upper RH/LH i 6 f Handle S/A, front door inside RH/LH
j 2 b Board Ay, front door trim, lower RH/LH i 7 g Cover, front door service hole, RH
j 3 c Garnish, front door lower frame bracket, RH/LH 8 h Master switch Ay, power window regulator
j 4 d Board Ay, front door trim, upper RH/LH (Driver's seat side)
5 e Weather-strip, front door glass, inner RH/LH 9 i Switch Ay, power window regulator (Passenger
seat side)
I1–9
2-1-4 POINTS OF DISASSEMBLY
(1) Panel, front door armrest base, upper RH/LH
1.Remove 1 screw.
2.Disengage and remove the tabs.
:Pawl position
T11B5026ET10
(2) Board Ay, front door trim, lower RH/LH

1.Remove the screws (3 locations).
2.Disengage and remove the pawls and clips.
: Clip position
T11B5027ET10
(3) Garnish, front door lower frame bracket, RH/LH

1.Disengage the pawl (a) and clip (b).
2.Slightly lift the garnish to the upward of the vehicle, and c
remove it by disengaging the pawl (c).
b
a Clip position
Pawl position
T11B5507ET10
(4) Board Ay, front door trim, upper RH/LH

1.Disengage the clips.
2.Lift the board Ay toward the upper side of the vehicle and
remove.
: Clip position
T11B5029ET10
I1–10
2-1-5 POINTS OF ASSEMBLY
(1) Cover, front door service hole, RH
1.Perform the assembling by referring to the main points given in the figure below.
Cover assembling requirement
"Cold specifications only"
Cover the hole lower section with butyl tape.

Provide an inclination for the route leading to the hole.
Affixing should be made in such a way that the hole center
section comes at the lowest point.
Section A T11B5030ES30
(2) Handle S/A, front door, inside RH/LH

CAUTION
• Be very careful not to break the threaded hole by tight-
ening the screw with an excessive torque, for an ET
screw has been employed.
• Do not use an impact driver when tightening the screw.
• If the threaded section should be broken, be sure to
use an oversized ET screw (90041-67041-000).
NOTE T11B5031T10
• ET screw: This is a screw by which a female screw is

threaded as it is tightened, utilizing the shape at the tip
end which has a self-drilling effect.
2-1-6 OPERATION AFTER ASSEMBLY

1.Connect the battery negative (() terminal.
I1–11
3 FRONT DOOR(GLASS-RELATED)
MP grease,Protective tape

2.Remove the front door service hole cover RH.
Refer to Page I1-8.
3.Remove the outer rear view mirror Ay RH/LH.

Refer to Page I3-26.

(1) Components
b c
f
C
d
B
e
B B
B
B
B
T11B5016S30
k: MP grease
I1–12
1 a Weather-strip, front door window, outer RH/LH 6 f Frame S/A, front door, rear lower, RH/LH
j 2 b Glass S/A, front door, RH/LH
3 c Run, front door glass front, RH/LH
4 d Regulator Ay, front door power window, RH/LH
5 e Frame S/A, front door, front lower, RH/LH

(1) Glass S/A, front door, RH/LH
1.Apply a protective tape to the door panel flange.
2.Operate the glass S/A until the bolts are visible.
3.Remove the bolts (2 locations).
T11B5032T10

1.Install the outer rear view mirror Ay RH/LH.
2.Install the front door service hole cover RH.

Refer to Page I1-8.

I1–13
4 FRONT DOOR(LOCK-RELATED)
Tool
TORXO wrench T30
MP grease

2.Remove the front door service hole cover RH.
Refer to Page I1-8.
3.Remove the front door rear lower frame S/A RH/LH.


(1) Components
b
a
c
T11B5501S30
k: MP grease
I1–14
1 a Cylinder Ay, front door lock, RH/LH 6 f Frame S/A, front door outside handle, RH/LH
2 b Cover, front door outside handle, RH/LH 7 g Lock Ay, front door w/motor, RH/LH
i 3 c Handle, front door outside RH
4 d Pad, front door outside handle, RH
5 e Pad, front door outside handle, LH

(1) Handle, front door outside RH/LH 1
1.While pushing the counterweight of the RH/LH front door Counter weight
outside handle frame S/A, push the handle toward the
front of the vehicle to assemble.
2
T11B5033ET10

1.Install the front door rear lower frame S/A RH/LH.
2.Install the front door service hole cover RH.

Refer to Page I1-8.

I1–15
5 REAR DOOR(TRIM-RELATED)
Tool
Clip remover
Butyl tape

(1) Components
g
d
e
c
S
S S S
h
f S
T11B5018S30

j 1 a Panel, rear door armrest base, upper RH/LH 6 f Speaker Ay, radio
j 2 b Board Ay, rear door trim, lower RH/LH i 7 g Cover, rear door service hole, RH
j 3 c Panel, rear door trim, upper RH/LH 8 h Switch Ay, power window regulator
4 d Weather-strip, rear door trim, inner RH/LH
i 5 e Handle S/A, front door inside, RH/LH

(1) Panel, rear door armrest base, upper RH/LH
1.Remove the screw (1 location).
I1–16
2.Disengage the pawls to remove.
Pawl position
T11B5034ET10
(2) Board Ay, rear door trim, lower RH/LH

1.Remove the screws (2 locations).
2.Disengage the pawls and clips to remove.
: Clip position
T11B5035ET10
(3) Panel, rear door trim, upper RH/LH

1.Disengage the clips.
2.Lift the panel Ay toward the upper side of the vehicle and
remove.
: Clip position
T11B5036ET10
I1–17
(1) Cover, rear door service hole, RH
1.Perform the assembling by referring to the main points given in the figure below.
Cover assembling requirement
30'30
0 "Cold specifications only" 80'30
0
Cover the hole lower section with butyl tape.

Provide an inclination for the route leading to the hole.
A Affixing should be made in such a way that the hole
center section comes at the lowest point.
Section A
T11B5037ES30
(2) Handle S/A, front door inside, RH/LH

CAUTION
• Be very careful not to break the threaded hole by tight-
ening the screw with an excessive torque, for an ET
screw has been employed.
• Do not use an impact driver when tightening the screw.
• If the threaded section should be broken, be sure to
use an oversized ET screw(90041-67041-000).
NOTE T11B5031T10
• ET screw: This is a screw by which a female screw is

threaded as it is tightened, utilizing the shape at the tip
end which has a self-drilling effect.
I1–18
6 REAR DOOR(GLASS-RELATE)
MP grease,Protective tape

2.Remove the rear door service hole cover RH.

(1) Components
e
f
g
c
b d
B
a
h B
B
B
T11B5019S30
k: MP grease
(2) Disassembling procedure
1 a Weather-strip, rear door glass, outer RH/LH 6 f Glass, rear door quarter window, RH/LH
2 b Run, rear door glass, RH/LH j 7 g Glass S/A, rear door, RH/LH
3 c Bar S/A, rear door window division, RH/LH 8 h Guide S/A, rear door window, front RH/LH
4 d Spacer, side window frame 9 i Regulator Ay, rear door window, RH/LH
5 e Weather-strip, rear door quarter window, RH/LH
I1–19
(3) Assembling procedure
1 h Guide S/A, rear door window, front RH/LH i 6 c Bar S/A, rear door window division, RH/LH
i 2 g Glass S/A, rear door, RH/LH i 7 i Regulator Ay, rear door window, RH/LH
3 f Glass, rear door quarter window, RH/LH 8 b Run, rear door glass, RH/LH
4 e Weather-strip, rear door quarter window, RH/LH 9 a Weather-strip, rear door glass, outer RH/LH
5 d Spacer, side window frame

(1) Glass S/A, rear door, RH/LH
1.Apply a protective tape to the door panel flange.
2.Move the glass S/A toward the back of the vehicle and remove it from the RH/LH rear door window reg-
ulator Ay.
(1) Glass S/A, rear door, RH/LH
1.Insert the glass S/A inside the door panel. Hang and hold
it with a tape.
T11B5038T10
(2) Bar S/A, rear door window division, RH/LH

1.Place the bar S/A between the RH/LH rear door glass S/A and the RH/LH rear door quarter window
weather-strip so that the RH/LH rear door glass S/A will fit in the groove of the bar S/A.
(3) Regulator Ay, rear door window, RH/LH
1.Insert the roller of the regulator Ay into the rail of the RH/LH rear door glass S/A.
2.Install the regulator Ay, while adjusting the height of the RH/LH rear door glass S/A.
1.Install the rear door service hole cover RH.

I1–20
7 REAR DOOR(LOCK-RELATED)
Tool
TORXO wrench T30
MP grease

2.Remove the rear door service hole cover RH.

(1) Components
b
c
e
d
T11B5020S30
k: MP grease
I1–21
1 a Lock Ay, rear door w/motor, RH/LH 6 f Frame S/A, rear door outside handle, S/A
2 b Cover, rear door outside handle, RH
i 3 c Handle, front door, outside RH
4 d Pad, front door outside handle
5 e Pad, front door outside handle, LH

(1) Handle, front door, outside RH 1
1.While pushing the counterweight of the RH/LH front door Counter weight
outside handle frame S/A, push the handle toward the
front of the vehicle to assemble.
2
T11B5033ET10

1.Install the rear door service hole cover RH.

I1–22
8 BACK DOOR
Tool
Clip remover
Instrument
Torque wrench

(1) Components
a
i e
f
j
h
T:27.8&8.3 {283&85}
T:27.8&8.3 {283&85}
i
h
T:27.8&8.3 {283&85}
d B
B
N
B B
B
c
B
g
C
T11B5021S30
Unit:N;m{kgf;cm}
1 a Cap, wiper arm head 6 f Handle S/A, back door outside
i 2 b Arm & blade Ay, rear wiper 7 g Lock Ay, back door
3 c Panel Ay, back door trim 8 h Stay Ay, back door
i 4 d Motor Ay, rear wiper 9 i Stud, back door stay
5 e Cover Ay, door outside handle 10 j Bolt, back door stay
I1–23
(1) Motor Ay, rear wiper
Refer to Page J2-15.
(2) Arm & blade Ay, rear wiper

I1–24
9 FENDER
9-1 REMOVAL AND INSTALLATION
Tool
Cutter knife
Protective tape
9-1-2 OPERATION BEFORE REMOVAL

1.Remove the front bumper cover.
Refer to Page I2-2.
2.Remove the cowl top ventilator louver RH/LH.

Refer to Page I2-8.
3.Remove the side turn signal lamp Ay.

4.Remove the body rocker panel moulding RH/LH (Side stone guard equipped vehicles).
I1–25
9-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) Components
~g d
f
C
B
B
C e
B
B
B
b c
C C C C
C C
C C C C
~a C ~a C
C C C C
C
C
C T11B5506S30
~:Non - reusable parts

(2) Removal and installation procedures
j 1 a Grommet, screw 6 f Panel, front fender, RH/LH
2 b Liner, front fender, RH/LH (Standard-bumper 7 g Seal, front fender to cowl side, No.2 RH/LH
equipped vehicle)
3 c Shield S/A, fender splash, front RH/LH (Aero-
bumper equipped vehicle)
j 4 d Garnish, front pillar, lower RH/LH
5 e Protector, front fender side panel, RH/LH
9-1-4 POINTS OF REMOVAL

(1) Grommet, screw
;;;;;
1.To remove the grommet, cut off the edge

TOOL: Cutter knife
Cut.
L11B5095ET10
I1–26
(2) Garnish, front pillar, Lower RH/LH
1.Apply a protective tape to the front fender panel RH/LH.
2.Disengage the pawls and clips to remove.
: Clip position
:Pawl position
T11B5039ET10
9-1-5 OPERATION AFTER INSTALLATION

1.Install the body rocker panel moulding RH/LH (Side stone guard equipped vehicles).
2.Install the side turn signal lamp Ay.

3.Install the front bumper cover.

Refer to Page I2-2.
4.Install the cowl top ventilator louver RH/LH.

Refer to Page I2-8.
I1–27
10 HOOD LOCK CONTROL CABLE
10-1 REMOVAL AND INSTALLATION(RHD VEHICLES)
1.Remove the front bumper cover.
Refer to Page I2-2.
2.Remove the front fender liner RH.

Refer to Page I2-24

(1) Components
T11B5023S16

i 1 a Cable Ay, hood lock control
I1–28
10-1-3 POINTS OF INSTALLATION
(1) Cable Ay, hood lock control
1.Perform the installation by referring to the main points given in the figure below.
C Passing through radiator support hole

Lock Ay, hood
B
D
C
B A
D
A
Passing through
cowl side hole
See to it that the marking of
the cable Ay comes at this
position when the cable is
routed. Cable Ay
Support, radiator,
upper center
Cable Ay
Panel, instrument Cable Ay
Support, radiator, upper
Lever S/A, hood lock control center
Control lever retaining section A(Across section B(Bcross section
Panel, cowltop side, RH
Panel, front fender, RH Cable Ay

Cable Ay Mark
FR washer hose
Side turn W/H
RR washer hose
Clamp
Panel, quarter inner RH
C(Ccross section D(Dcross section

T11B5040ES45
I1–29
1.Install the front fender liner RH.

Refer to Page I2-2.
10-2 REMOVAL AND INSTALLATION(LHD VEHICLES)

1.Remove the cover front bumper cover.
Refer to Page I2-2.
2.Remove the front fender liner LH.


(1) Components
T11B5504S16

i 1 a Cable Ay, hood lock control
I1–30
(1) Cable Ay, hood lock control
B C D
D
Lock Ay, hood Cable Ay
C
A
B
Passing through
Passing through cowl side hole
radiator support hole
See to it that the making
of the cable Ay comes
at this position when
the cable is routed.
Support, radiator, upper

Cable Ay center Support, radiator,
upper LH
Panel,
instrument
Lever S/A, hood lock Cable Ay
control
Control lever retaining section

A(Across section B(Bcross section
Panel, cowltop side, LH
Cable Ay
Panel, front fender, LH Mark
Cable Ay
Panel, quarter inner LH
C(Ccross section D(Dcross section

T11B5502ES45
I1–31
1.Install the front fender liner LH.

Refer to Page I2-2.
I1–32
11 FUEL LID CONTROL CABLE
11-1 REMOVAL AND INSTALLATION(RHD VEHICLES)
1.Remove the front seat Ay RH/LH.
2.Remove the rear quarter trim panel Ay LH.

3.Remove the rear console box S/A.

4.Remove the front console box S/A.

5.Remove the front floor carpet Ay (Driver's seat, front passenger's seat, left-rear seat).
I1–33
(1) Components
a
b
T:9.0&5.7 {92&57}
T11B5024S33

1 a Lever S/A, back door lock open
i 2 b Cable S/A, fuel lid lock control
I1–34
(1) Cable S/A, fuel lid lock control
L Align the marking section of

the cable to the clamp.
C
A
C
D J
D
G J
E
E
F
B
G F
K
M K
Section A
SectionB
Align the marking section of
Panel Ay, quarter trim
rear, LH
Panel Ay, quarter trim Cable S/A
Sensor Ay, rear, LH Harness
Plate, rear door scuff, LH
side airbag, LH
Cable S/A Harness
Cable S/A
Harness Harness
(with sensor) (without sensor)
C(C D(D E(E
Belt Ay, rear seat, outer LH Plate, rear door scuff, LH
Cable S/A Belt Ay, rear seat, outer

Cable S/A Carpet Ay, floor, front
LH
Cable S/A Harness
F(F G(G J(J
Carpet Ay, floor,

front
Harness
Lock S/A, fuel filler,
Cable S/A opening lid
Lever S/A, back
K(K L M T11B5041ES40
I1–35
1.Install the front floor carpet Ay.
2.Install the front console box S/A.

3.Install the rear console box S/A.

4.Install the rear quarter trim panel Ay LH.

5.Install the front seat Ay RH/LH.

11-2 REMOVAL AND INSTALLATION(LHD VEHICLES)

1.Remove the front seat Ay LH.

3.Remove the front floor carpet Ay (Driver's seat, left-rear seat).

I1–36
(1) Components
b
a
T:9.0&5.7 {92&57}
T11B5505S33

1 a Lever S/A, back door lock open
i 2 b Cable S/A, fuel lid lock control
I1–37
(1) Cable S/A, fuel lid lock control
I Align the marking section of

C
A
C H
D
D
G H
E
E
F
B J
G F
Section A
SectionB
Panel Ay, quarter trim

rear, LH Panel Ay, quarter trim Plate, rear door scuff, LH
rear, LH Cable S/A
Sensor Ay, Harness
side airbag, LH
Cable S/A
Harness Cable S/A Harness
Harness
(with sensor)
(without sensor)
C(C D(D E(E
Belt Ay, rear seat, outer LH Plate, rear door scuff, LH
Cable S/A Belt Ay, rear seat, outer

LH Cable S/A Carpet Ay, floor, front
Cable S/A Harness
F(F G(G H(H
Lock S/A, fuel filler,

opening lid
Lever S/A, back
I J T11B5503ES40
I1–38
1.Install the front floor carpet Ay.

3.Install the front seat Ay LH.

I1–39
12 FUEL FILLER OPENING LID
12-1 REMOVAL AND INSTALLATION
Tool
Hand riveter,Drill


(1) Components
~a
T11B5025S25
~:Non - reusable parts

1 a Rivet
j i 2 b Lid Ay, fuel filler opening.
12-1-4 POINTS OF REMOVAL
(1) Lid Ay, fuel filler opening
1.Secure the rivet with a tape, butyl tape, etc. from the inside of the vehicle so that the removed rivet may
not fall down to the locker section.
CAUTION
• When the head section of the rivet is removed, be sure to secure it so that the rivet may not fall
down to the locker section.
2.Apply a protective tape or cloth to prevent the lid Ay from being damaged.
I1–40
3.Lightly apply a drill to the rivet vertically. Then, grind the
flange section of the rivet, using the drill.
WARNING Flange section
• Wear safety glasses to protect your eyes from iron
powder or the like during the operation.
CAUTION
• Be careful not to damage the lid Ay area.
TOOL:
4.After the flange section of the rivet has been removed, T11B5042ET10
stop the drilling operation. Then, remove the remaining
fragments of the rivet, using pliers or the like.
WARNING
• The rivet is very hot, when removed.
(1) Lid Ay, fuel filler opening Nose piece
1.Select a nose piece with the minimum diameter for which

the mandrel of the rivet can be inserted.
CAUTION
• Any wrong selection of the nose piece will cause
improper rivet tightening and malfunctions of riveter.
M11B6011ET10
2.Mount the nose piece to the hand riveter and insert the
mandrel section of the rivet into the nose piece.
NOTE
• Part number of rivet:90042-69027-000
3.With the rivet applied strongly and vertically to the installa-
tion hole, operate the hand riveter to install the rivet.
TOOL: Hand riveter
T11B5043T16
CAUTION
• Be careful not to damage the lid Ay area. Riveter
• In cases where the rivet has not been tightened by one
riveter operation (the mandrel has not been cut),
repeat the operation again.
• If the operation is performed by prying during the hand
riveter operation, the mandrel section of the rivet will
be bent, leading to improper rivet tightening and mal-
functions of the hand riveter. Mandrel section
M11B6013ET10
I1–41
CAUTION
• If the hand riveter is operated with the rivet tilted or Riveter
floating, it will lead to improper rivet tightening.
Riveter
M11B6014ET10
CAUTION
• If the rivet is installed without press-fitting the installa-
tion parts, it will lead to improper rivet tightening.
Riveter
M11B6015ET10

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TO INDEX

FITTING DIMENSIONS OF HOOD PANEL

2.Loosen the hood lock bolt prior to adjustment.

(2) Front & rear door

Side panel outer

Front door frame Rear door

Side panel outer

Side panel outer

d. Adjustment of the door in vertical direction, and in lat-

4 Fitting adjustment (Rear door)

g. Adjustment of the door in vertical direction, and lateral

2.Adjust the striker by tapping lightly.

Fitting dimensions of back door

2-1-2 OPERATION BEFORE DISASSEMBLY

(2) Disassembling and assembling procedures

(2) Board Ay, front door trim, lower RH/LH

(3) Garnish, front door lower frame bracket, RH/LH

(4) Board Ay, front door trim, upper RH/LH

"Cold specifications only"

Cover the hole lower section with butyl tape.

(2) Handle S/A, front door, inside RH/LH

• ET screw: This is a screw by which a female screw is

2-1-6 OPERATION AFTER ASSEMBLY

3-1-2 OPERATION BEFORE DISASSEMBLY

3.Remove the outer rear view mirror Ay RH/LH.

3-1-3 DISASSEMBLY AND ASSEMBLY PROCEDURES

3-1-4 POINTS OF DISASSEMBLY

3-1-5 OPERATION AFTER ASSEMBLY

2.Install the front door service hole cover RH.

3.Connect the battery negative (() terminal.

4-1-2 OPERATION BEFORE DISASSEMBLY

3.Remove the front door rear lower frame S/A RH/LH.

4-1-3 DISASSEMBLY AND ASSEMBLY PROCEDURES

4-1-4 POINTS OF ASSEMBLY

4-1-5 OPERATION AFTER ASSEMBLY

2.Install the front door service hole cover RH.

3.Connect the battery negative (() terminal.

5-1-2 DISASSEMBLY AND ASSEMBLY PROCEDURES

(2) Disassembling and assembling procedures

5-1-3 POINTS OF DISASSEMBLY

(2) Board Ay, rear door trim, lower RH/LH

(3) Panel, rear door trim, upper RH/LH

Cover the hole lower section with butyl tape.

(2) Handle S/A, front door inside, RH/LH

• ET screw: This is a screw by which a female screw is

6-1-2 OPERATION BEFORE DISASSEMBLY

6-1-3 DISASSEMBLY AND ASSEMBLY PROCEDURES

6-1-4 POINTS OF DISASSEMBLY

(2) Bar S/A, rear door window division, RH/LH

2.Connect the battery negative (() terminal.

7-1-2 OPERATION BEFORE DISASSEMBLY

7-1-3 DISASSEMBLY AND ASSEMBLY PROCEDURES

7-1-4 POINTS OF ASSEMBLY

7-1-5 OPERATION AFTER ASSEMBLY

2.Connect the battery negative (() terminal.

8-1-2 DISASSEMBLY AND ASSEMBLY PROCEDURES

(2) Arm & blade Ay, rear wiper

9-1-2 OPERATION BEFORE REMOVAL

2.Remove the cowl top ventilator louver RH/LH.

3.Remove the side turn signal lamp Ay.

~:Non - reusable parts

9-1-4 POINTS OF REMOVAL

1.To remove the grommet, cut off the edge