B0-1

BODY

•
G E N E R A L INFORMATION , B0- 2

PRECAUTION ·· · · .. · .. .. .. .. .. B0- 4

PREPARATION B0- 5

FRONT B U M P E R B0- 6

HOOD B0- 7

FRONT DOOR B0- 8

WIPER AND WASHER,, B0- 12

WINDSHIELD MOULDING B0- 1 4

W H E E L ARCH M O U L D I N G B0- 15

WINOSHIELD B0- 16

OUARTER WINDOW GLAS5 B0- 20

.BACK W I N D O W GLASS B0- 22

REMOVABLE ROOF .. .. .. B0- 25

I N S T R U M E N T PANEL B0- 27

O N E - T O U C H TAIL GATE B 0 - 32

SEAT B 0 - 34

SEAT BELT B0- 38

SERVICE SPECIFICATIONS B 0 - 41

•
B0-2
BODY - G E N E R A L I N F O R M A T I O N

GENERAL INFORMATION
Example IOlff-OI

HANDLING PRECAUTIONS

--L-
Taping

When it is possible that the body or parts may be

•
Protective Tape scratched d u r i n g the operation, apply protective tape

before starting work.

Example:

1 . Before starting work, apply protective tape to

body surfaces around parts to be removed and

installed.

2. Before prying parts loose with a screwdriver or

scraper etc., apply protective tape to the tip of

the tool to avoid scratching parts or painted sur­

faces of the body.

Protective Tape

B04110

B02488

2 1 1 298

Battery

In order to prevent a short circuit while doing work on

the electrical circuit such as d i s c o n n e c t i n g a c o n n e c ­

tor, first turn off the ignition switch and disconnect

the negativa

before starting work.

(-) terminal cable

H I N T : When battery voltage is requirsd for operation

from the battery

•
of a f u n c t i o n i n g part, connect the c a b l e to the battery

�I B04111 when needed, and promptly disconnect it when no

l o n g a r necessary.

CAUTION:

• Work must be started after 90 seconds from the

time the ignltion switch is turnad to the "LOCK"

position and the negativa ( - ) terminal cable is dis­

connected from the battery.

• To avold arasing tha mamory of aach mamory

system, nevar use a back- up powar supply from

outsida the vehicla.

Fitting Adjustments

When removing and i n s t a ll i n g body panels w h i c h have

a preload value, after installation refer to the paga

containing the installation adjustment methods, and

make adjustments according to the required specifi­

cations.

HINT: When making adjustments, do not completely

loosen the

Tighten them

hand to a l i g n them.
bolts and nuts of the part being adjusted.

appropriately, and move the p a n el s by •

1 1
 B0-3
BODY - G E N E R A L I N F O R M A T I O N

IOOtr-01

CLIPS

The removal and installation methods of typical clips

usad in body parts are shown in ths table below.

HINT: lf the clip is damaged during the operation,

always replace it with a new clip.

Shape (Example) Remo va 1/lnstal lation

t t

Clip Remover

104118 8 04 1 17
,..

• I
II '\

L---1---------
\

Screwdriver

804 1 1 8 1 04 1 1 9

r----,
1 1

1 1

L. - - - - .,j

V
• �
804120 804121

II00)15
B0-4

BODY - G E N E R A L INFORMATION PR
• ECAUTION

CLIPS (Cont' d) .

Shape (Example)
Removal/lnstallatlon

Removal
lnstallation

804122 804123

Removal lnstallatlon

f •

1104124 804125

\OOJ12

PRECAUTION IOMX-ot

SRS ( S u p p l e m e n t a l Restraint System)

The T A C O M A is e q u i p p e d with an SRS (Supplemental Restraint System) such as the driver airbag.

F a i l u r e to carry out service operation in the correct sequence could cause the SRS to unexpect­

edly deployed d u r i n g servicing, possibly l e a d i n g to a serious a c c i d e n t . Before servicing ( i n c l u d i n g

removal or i n s t a ll a t i o n of parts, inspection or replacement), be s u r e to read the precautionary

n o t i c e s in the RS section.

•
1 1

• 1
 80-5
BODY - PREPARATION

PREPARATION
II01Nt-OI

SST(SPECIAL SERVICE TOOL)

• 09812-00010 Door Hinge Set Bolt Wrench

I0141- ..

LUBRICANT

ltem Capacity Classification

MP grease - -

I011Y-U

SSM (SPECIAL SERVICE MATERIALS)

08833-00030 Three cement black or equivalent Windshield Moulding

Wind shield

Back Window Glass

08833-00070 Adhesiva 1324, Front Door

THREE BOND 1324 or equivalent

08850-00065 Butyl Tape Set Ouarter Window

• 08850-00070 Windshield

No.15
glass

or equivalent
adhesiva set Windshield

(0-15 º C o r 32-59 ºF)

08850-00080 Windshield glass adhesiva set Windshield

No.35 or equivalent (15-35 ºCor 59-95 ºF)

08850-00090 Windshield glass adhesiva set Windshield

No.45 or equivalent (35-45 º C o r 9 5 - 1 1 3 ºF)

IOtQI-OI

1. C H O O S E SUITABLE ADHESIVE SET

Ambient
Part No. Part Nama Use an adhesiva set suitable for the a m b i e n t temper­
temperatura

Wind1hleld
atura.
O - 16ºC
08860-00070 gl111 adhesiva
(32 - 69ºFI
set No. 16

Windahield
16 - 35ºC
08860-00080 glaH adhesiva
(59 - 96ºF)
Ht No. 36

• 36

196
-

-
46ºC

113ºF)
08860-00090
Windshield

gl11a

set
adhesiva

No. 46

V00'250
B0-6
BODY - P R E P A R A T I O N , FRONT B U M P E R

2. C H E C K ADHESIVE USABLE TIME

(min.)

Windshield Glass Adhesive After mixing m a i n and h a r d e n i n g agents, f i n i s h glass

1 1 1 1 1
90 "' installation within the specified time as shown.

60

30
r\-'No'.15 \No.35\ '""No.45-

...
.,
'\.
,.._,.
-- ,---
....
'· ✓
....
__ ..,
"-

•-
.,.
........

-
Example: For glass installation in a n a m b i e n t tempera­

tura of 25 º C (77 º F), apply adhesiva set No. 35 within

45 minutes.
•
O 10 20 30 40 (ºCI

Ambient Temperature
800119

(min.l 3. C H E C K ADHESIVE H A R D E N I N G T I M E

1
After m a i n and hardening agents are mixed, leak tests
No.15
.! 600
� should be made only after the hardening time has
\No.3
... ..
\ elapsed.
g> ' \ No. 45- -
I"-.
Example: The h a r d e n i n g t i m e for adhosive set No. 35
'�
1300 ', � .....
' with an ambient temperatura of 25 º C (77 º F ) is 2 and
--- �--
r--.; ..... - - .. ..... ,.__
! --
-- 1 / 2 hours.

NOTICE: Do not drive the vehicle until a1t least double the
10 20 30 40 (ºCI

Ambient Temperature hardening time has elapsed.

800 1 2 0

FRONT BUMPER
IOtLY-OI

COMPONENTS

•
Front Wheel

Arch Moulding

,
',
,, '
,, '

,, '
,, ,
Front Fender Linar ,, ,
FrontWheel
, , '

, ' ' Arch Moulding

,,;�f,',

d'd", l_gj,"'
{j �
cf Mudguard
Front Fender Linar ffí (!'i,!1 ·•·•!

/�,et , , 1

, ,' , , 1

: : )

I ,' ,f

,-ffef

cf�•:'lLJ--Mudguard
Turn Signa! Light

d'
�

Front Bumper
✓-
_)c:_;$.-.--rurn Signal Light

✓
/ •
N15849
i 1
 B0-7
BODY - H O O D

HOOD
l0111-0I

HOOD ADJUSTMENT

• Q
HINT: Since the centering bolt is usad as

h i n g e set bolt, the hood cannot be adjusted with it o n .

Substituta the bolt with the washer for the c e n t e r i n g

the hood

bolt.

Centering Bolt Standard Bolt

tm433

1. ADJUST HOOD IN FORWARD/ REARWARD ANO

LEFT / RIGHT DIRECTIONS

1 •-®(
Adjust the hood by loosening the hood side hinge

�-
1
bolts.

Torque:

@: 1 3 N - m ( 1 3 0 kgf-cm, 1 O ft-lbf)

@: 1 8 N - m ( 1 8 0 kgf-cm, 1 3 ft-lbf)

N14050

2. ADJUST FRONT E D G E OF H O O D IN V E R T I C A L D1-

RECTION

Adjust the hood by t u rn i n g the c u s h i o n s .

B03211

3. ADJUST H O O D L O C K

Adjust the lock by loosening the bolts.

Torque: 8 N - m (82 kgf-cm, 71 in.-lbf)

N14051
B0-8
BODY - F R O N T D O O R

FRONT DOOR
to1T0-02

COMPONENTS

•
{i�����--Glass Aun

w/ Power Door Lock Outer Weatherstrip

Outside Handle

�kCylinde�

�-t,, ......--.\r---Door Glass

Control

Link lnner Cover �

Loc��ir ���� ---+4----., tt��b-::-:- \�

...<�
;;.
.� Outer RearVlew Mirror

Striker �• * '1 ���

(Equalizar Arm) "G> df
df \ Front Lower Frame

Window Regulator 1-
-«,
' _

.,
1 �-
.

W DoorHinge
�

-��� � -
Qt>
_, _, -
,,,,
� Door Checker

��-�, cVJ . 8.;f-cr,

•
.....,�:§��--..,-----Door Hinge

lnner We <V'
J')1--------Door lnside Handle

Clip

DoorTrim

,.,, "c-------Service Hole Cover

Armrest · ,1:1

e _, ✓ ,., •
1)

L--�'>� w/ Remote Control

"--�d
,,.
�"°'./,"'' Grommet

� Pla ,,. J

1 ..,,, Snap Ring " Jj

� � Door Speaker
Regulator Handle
,,
* Precoated part

w/ Power Wlndow _p w/ Power Wlndow

__,,. ,,. G'P ,..,,.
Armrest Panel
.,,,, ; .,,,, ., ...,....

Armrest and 'A

�
Panel
, ,,. ·------,"--:=-Clip
,,.

DoorTrim

Nl6119
 B0-9
BODY - FRONT DOOR

I01'C-M

FRONT DOOR ADJUSTMENT

1. ADJUST DOOR IN FORWARD/ REARWARD ANO

• VERTICAL D I R E C T I O N S

U s i n g SST, adjust the door by loosening the body sida

hinge bolts.

SST 0 9 8 1 2 - 0 0 0 1 O

Torque: 23 N•m (230 kgf,cm, 1 7 ft-lbf)

B00256 B2164 207820

2. ADJUST DOOR IN LEFT / RIGHT ANO VERTICAL

DIRECTIONS

Loosen the door sida hinge bolts to adjust.

HINT: Substituta the standard bolt for the c e n t e r i n g

bolts. (See paga B 0 - 7)

Torque: 23 N • m (230 kgf,cm, 1 7 ft-lbf)

B00257 B2185 207821

3. ADJUST D O O R LOCK STRIKER

(a) Check that the door fit and door lock linkages are

adjusted correctly.

(b) Adjust the striker position by slightly loosening the

striker m o u n t i n g screws, and hitting the striker with a

• (c)
hammer.

Tighten the striker m o u n t i n g screws a g a i n .

Torque: 1 2 N • m ( 1 2 0 kgf,cm, 9.0 ft,lbf)

802668

IOMY-01

FRONT DOOR DISASSEMBLY

1. w/o Power Window:

REMOVE REGULATOR HANDLE

Pull off the snap ring with a cloth and remove the

regulator h a n d l e and plata.

ASSEMBLY HINT: With door window fully closed,

install the plata and regulator handle with the snap

B00020
ring.

2. REMOVE D O O R I N S I D E HANDLE

(a) Remove the screw and slide the handle forward.

(b) Disconnect the handle from the control link and

remove the h a n d l e .

3. REMOVE ARMREST

w/o Power Window, w/o Wide Armrest:

Remove the 2 screws a n d door t r i m .

• 4. REMOVE I N N E R COVER

Using a screwdriver, remove the i n n e r cover.

B01994 B02456 200436

H I N T : Tape the screwdriver tip before use.
B0-10
BODY - FRONT DOOR

5. REMOVE DOOR TRIM

w/o Power Window
w/ Wide Armrest Wide Armrest Only w/o Power Window:

(a) Remove the clip.

e,.,,,,,
�
-�__ ,,

w/o Wide Armrest

--� (b)

(c)
w/ Wide Armrest:

Remove the 2 caps and 2 screws frorn the armrest.

lnsert a screwdriver between the retainer and door

•
,,
trim to pry it loase.
,,... ' -
. ;

.,- (d) Remove the 1 2 clips a n d door trim .

(e) w/ Wide Armrest:

Remove the 5 screws a n d armrest.

w/ Power Window
H I N T : Tape the screwdriver tip bsfors use.

w/ Power Window:

(a) Remove the c l i p .

(b) Remove the armrest panel by p u lli n g upward, then

disconnect the connectors.

(e) Remove the 2 caps and 2 screws.

(d) lnsert a screwdriver between the retainer and door

trim to pry it loase.

N13922
(e) Remove the 1 2 clips and door trim.

(f) Remove the 5 screws and armrest.

HINT: Tape the screwdriver tip befare use.

Panel 6. REMOVE DOOR SPEAKER

(a) Disconnect the connector.

(b) Remove the 5 screws and speaker.

Cotton

•
7. REMOVE SERVICE HOLE COVER
Tape
Cover
(a) Remove the 2 grommets.

(b) Remove the service hole cover.

ASSEMBLY HINT: Bring out the link and connector

B02465
through the service hola cover.

8. REMOVE THESE PARTS:

(a) Outer rear view mirror

(b) Outer weatherstrip

(e) Glass run

(d) Front lower frame

(e) Door glass

(f) Rear lower frame

9. REMOVE W I N D O W REGULATOR

(a) w/o Power Window:

Remove the 5 bolts and regulator.

Torque: 4.9 N-m (50 kgf,cm, 43 in.-lbf)

w/ Power Window:

•
Remove the 6 bolts and regulator.

Torque: 4.9 N-m (50 kgf,cm, 43 ln.,lbf)

(b) Disconnect the connector.

Power Window

N13924
 80-11
BODY - FRONT DOOR

ASSEMBL Y HINT: Apply MP grease to the window

regulator rollers.

w/o Power Wlndow

w/ Power Wlndow

� ♦

o o

o o

N13934

1 O. REMO VE DOOR LOCK

(a) Disconnect the 2 l i n k s from the outside h a n d l e .

(b) w/ Power Door Lock:

Disconnect the connector .

•
(e) Remove the 3 screws and door lock.

A S S E M B L Y H I N T : Apply adhesiva to the 3 screws.

Part No.08833-00070, THREE BOND 1324 or equiva­

lent.

Apply MP grease to the sliding and rotating parts of the

door lock.

1 1 . REMOVE O U T S I D E H A N D L E

(a) Remove the 2 bolts.

Torque: 5.0 N-m (50 kgf,cm, 43 ln.-lbf).

(b) Remove the lock cylinder.

w/o Power Door Lock

w/ Power Ooor Lock

N13935

10241-01

FRONT DOOR ASSEMBLY

Assembly is in the reverse order of disassembly.

B0-12
BODY - WIPER A N O WASHER

WIPER A N D WASHER
IOOJU-0&

COMPONENTS

'
'
:
1 ' 1

¡. '

� � '

�
"�
�
, ,
'1

� :

.--Cowl Louver

� � ' Wiper Link

'- .. . :, \

,, '

Wiper Motor
•

N14278

Z165'Xl

I01Tt-o:a

WIPER AND WASHER REMOVAL

1. REMOVE THESE PARTS:

(a) Wiper arms

Torque: 20 N - m (205 kgf•cm, 1 5 ft•lbf)

•
(b) Cowl louver

INSTALLATION H I N T : Adjust the i n s t a ll a t i o n , position

of the wiper arms to the positions, as shown.

N14274
@Approx. 25 mm (5.90 in.)
, , '
 B0-13
BODY - W I P E R ANO WASHER

3. REMOVE THESE PARTS:

(a) Wiper motor

Torque: 5.6 N•m (55 kgf•cm, 47 in.-lbf)

• (b)

(c)
Wiper l i n k

Torque: 5.6 N-m (66 kgf-cm, 47 ln.-lbf)

Window washer nozzle

10,n-u

WASHER NOZZLE A D J U S T M E N T

1. INSPECT WASHER NOZZLE

(a) W h i l e operating the washer, check w h e t h e r the u p p e r

point where the washer fluid hits the w i n d s h i e l d and

ths surge area are within the ranga indicated by the

hatched l i n e .

@ Approx. 1 5 0 m m (5.90 i n . )

® Approx. 50 mm ( 1. 9 7 in.)

© Approx. 1 2 0 m m (4.72 in.)

(O) Approx. 65 mm (2.55 i n . )

� Approx. 1 0 5 mm ( 4 . 1 3 i n . )

® Approx. 1 6 2 mm (6.37 in.)

© Approx. 1 5 6 m m ( 6 . 1 4 in.)

•
8 Approx. 287.7 m m ( 1 1 . 3 2 i n . )

CD Approx. 2 1 1 . 4 mm (8.32 i n . )

Q) Approx. 238.6 mm (9.39 in.)

® Approx. 1 8 9 mm (7.44 in.)

o;:) Approx. 1 0 2 . 5 mm (4.03 in.)

� Approx. O - 50 mm (0 - 1 . 9 6 in.)

(b) Check if the lower point where the washer fluid hits
2 - 2 . 5 mm
(0.079 - 0.098 in.)
the w i n d s h i e l d is within the ranga of the w i p i n g pat­

tern the area of the glass which is wiped by the wiper

blades.

2. ADJUST WASHER NOZZLE

Using a tool like that shown in the figure, c h a n g a t h e

direction of the nozzle hole to adjust the p o i n t where

0.7 - 0.75 mm
washer fluid strikes the w i n d s h i e l d .
(0.028 - 0.030 in.)

IE3367

IOZI0-01

WIPER AND WASHER INSTALLATION

lnstallation is in the reverse order of removal .

•
B0-14
BODY - W I N D S H I E L D M O U L D I N G

WINDSHIELD MOULDING
10211-01

COMPONENTS

•
(See page 80-16)

I01TI-OI

WINDSHIELD OUTSIDE UPPER MOULDING

REMOVAL

1. REMOVE THESE PARTS:

(a) Wiper a r m s

(b) Cowl louver, weatherstrip and protector

2. REMOVE WINDSHIELD OUTSIDE UPPER MOULD-

ING

N14037
U s i n g a knife, cut off the m o u l d i n g , as s h o w n .

NOTICE: Do not damage the body with the knife.

aon•-oa

W I N D S H I E L D O U T S I D E UPPER M O U L D I N G

I N S T ALLA T I O N

1. CUT ADHESIVE AT MOULDING INSTALLATION

•
AREA

Using a knife, cut off the old adhesiva around the

moulding installation area.

NOTICE: Do not damage the body with the knife.

803671 2. APPL Y ADHESIVE AT M O U L D I N G INSTALLA T I O N

AREA

3. INSTALL WINDSHIELD OUTSIDE UPPER MOULD-

ING

Place the moulding into the body and tap it by h a n d .

4. INSTALL THESE PARTS:

(a) Protector, weatherstrip a n d cowl louver

(b) Wiper arms

Torque: 20 N•m (205 kgf,cm, 1 5 ft•lbf)

Nl4038

•
 B0-15
BODY - W H E E L ARCH M O U L D I N G

WHEEL A R C H M O U L D I N G IOHL-N

COMPONENTS

Front Wheel

Arch Moulding

Rear Wheel Arch Moulding

• ----Mudguard

N16120

900KI-N

W H E E L ARCH M O U L D I N G REMOVAL

1. REMOVE FRONT W H E E L ARCH M O U L D I N G

(a) Remove the 7 screws.

(b) Using a screwdriver, pry up the wheel arch m o u l d i n g ,

and remove it.

H I N T : Tape the screwdriver tip before use.

2. REMOVE REAR WHEEL ARCH M O U L D I N G

(a) Remove the 8 screws.

(b) U s i n g a screwdriver, pry up the wheel arch m o u l d i n g ,

and remove it.

H I N T : Tape the screwdriver tip before use .

IOJ:U-01

•
WHEEL ARCH M O U L D I N G INSTALLATION

lnstallatlon is In the reverse order of removal.

80-16
BODY - W I N D S H I E L D

WINDSHIELD
IOIU-M

COMPONENTS

lnner Rear View Mirror

•
Holder

Windshield Glass
r-
--=-
� E��Viso�
=::
nuS

♦ Windshield Outside

Upper Moulding

-r---- ✓

Assist Grip

Front Pillar Garnish

Prot�

Weatherstrip
WiperArm

•
♦ Non-reusable part Cowl Louver
Nl4039

acnn-u

W I N D S H I E L D REMOVAL

1. REMOVE THESE PARTS:

(a) l n n e r rear view mirror

(b) Sun visors and holders

(e) Assist grips

(d) Front pillar garnishes

2. REMOVE WINDSHIELD OUTSIDE UPPER MOULD­

ING

(See page B 0 - 1 4 )

3. REMOVE WINDSHIELD GLASS

(a) Push piano wire through between the body and glass

from the interior.

(b) Tie both wire ends to a wooden block or similar

object. •

HINT: Apply adhesiva tape to the outer surface to

keep the surface from being scratched.

806232
 B0-17
BODY - W I N D S H I E L D

NOTICE: When separating the glass, take care not to

damage the paint and Interior and exterior ornamenta. To

prevent scratching the safety pad when removing the

• (e)
windshield, place a plaatic sheet between the piano wire

and safety pad.

Cut the adhesive by pulling the piano wire around it.

(d) Remove the glass.

NOTICE: Leave as much of the adhesive on the body as

8011189
possible when cutting off the glass.

I01TI-U

W I N D S H I E L D INST ALLATION

1. CLEAN ANO SHAPE CONTACT S U R F A C E OF BODY

(a) U s i n g a knife, cut away any rough areas on the body.

..
H I N T : Leave as m u c h of the adhesive on the body as

possible.

(b) C l e a n the cutting surface of the adhesive with a piece

of shop rag saturated in cleaner.

B0442O H I N T : Even if a ll the adhesive has been removed. c l e a n

the body.

2. C L E A N REMOVED GLASS

(a) U s i n g a scraper. remove the adhesiva sticking to the

glass.

1
(b) Clean the glass with cleaner.

•
!

--:t•
¡j N O T I C E : Do not touch the glass after cleaning it.

'I
�-

Ell5231

3. POSITION GLAS$

(a) Place the glass in correct position.

a
(b) Check that all contacting parts of the glass rim are
a
perfectly even and do not make contact with the

spacers.

(e) Place reference marks between the glass a n d body.

a
(d) Remove the glass.
a

1()5557

4. CLEAN CONTACT SURFACE OF GLASS

Using a cleaner, clean the contact surface black­

colored area around the entire glass rim.

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

•
804421
B0-20
B O D Y - QUARTE R W I N D O W GLASS

QUARTER W I N D O W GLASS

COMPONENTS

•
Quarter Window Glass
Lock Handle

; ;- - - - - - - - - - - - - � o - - - r - - � - - - - - ..i
,1 _, , ---�Coat Hook
1

• - ¡ ---- -iL{ér-_:-:--{l--- _ .e: " � �-= -�� Sacie Panel Upper Gamlsh

r • � � - r: : : - l - - J t�. ,•�J �=- BackPanelTrim

Retalner Htnge � .. � �
,., =�=:���-5.5]
(
1

Weatherstrip �

Scuff Plate

¡ !
i :
1 1

:�

\j�_---------1 Seat Belt

" .,,.---- Back Panel Lower Garnish

Quarter Window Trim d!JII> ... - .... _ ,. ,,,, .... �

�--
fJ",,

Rear Seat Cushion

N14043

ao,n-oa

O U A R T E R W I N D O W GLASS R E M O V A L

1. REMOVE D O O R S C U F F PLATE

Remove the 4 screws and plate.

2. REMOVE BACK PANEL UPPER GARNISH AND

BACK PANEL TRIM

(a) Using a screwdriver, remove the g a rn i s h .

(b) Remove the 3 bolts and t r i m .

H I N T : Tape the screwdriver tip before use.

3. REMOVE BACK PANEL LOWER G A R N I S H

O : 1 0 Clips
Using a screwdriver, remove the g a rn i s h .

---=- H I N T : Tape the screwdriver tip before use.

4. REMOVE REAR SEAT C U S H I O N

Remove the 4 bolts a n d rear seat c u s h i o n s .

5.

•
REMOVE SEA T BEL T

Remove the 4 bolts, seat belt anchor and belt g u i d a .

Torque: 43 N•m (440 kgf-cm, 32 ft•lbf)

 80-21
BODY - OUARtER W I N D O W G L A S S

6. REMOVE LOCK HANDLE

(a) Using a screwdriver. remove the cover.

(b) Remove the 2 screws and lock handle.

• ('I,

-��
te: '
,.,...; '
H I N T : Tape the screwdriver tip before use.

u N13927

7. REMOVE COAT H O O K

Remove the screw and coat hook.

8. REMOVE QUARTER TRIM

Remove the 1 3 clips a n d quarter t r i m .

N13928

9. REMOVE QUARTER WINDOW GLASS

Remove the 4 nuts and quarter window glass.

[
•
'

N13929

aotaw-u

Q U A R T E R W I N D O W GLASS

REPLACEMENT

REMOVE THESE PARTS:

(a) Lock handle

(b) Hinge

N13930

IIOlll-01

QUARTER WINDOW GLASS

I N S T ALLA T I O N

lnstallation is in the reverse order of removal .

•
80-22
BODY - BACK W I N D O W GLASS

BACK W I N D O W GLASS
IOOKI-OI

COMPONENTS

•
Back Window Assembly (Slide Type)

Fix Frame

,�
1 ti
Weatherstrip

Weatherstrip

Glass C h a n n a l
Back Window

•
Z1439J

IOOIC.t-OI

B A C K W I N D O W GLASS R E M O V A L
Weatherstrip

REMOVE BACK WINDOW GLASS WITH WINDOW

FRAME

(a) Using a screwdriver, loosen the weatherstrip from the

body.

NOTICE: Be careful not to damage the body paint.

803301

(b) Pry the lip of the weatherstrip outward from t h e inte­

rior part of the body flange.

(e) Pull the glass outwards, and remove it with the weath­

erstrip.

•
M1590
204539
 80-23
BODY - BACK W I N D O W GLASS

IOOl<A-07

BACK WINDOW GLASS DISASSEMBL Y

S li d e g l a s s type:

1. REMOVE THESE PARTS:

(a) Stopper

, (b) Fix trames

0:-
;

800048 800049 204533

2. REMOVE S LI D E GLASS

Pull apart the c h a n n e l s and remove the 2 s l i d e glass

panes at the center area of the glass c h a n n e l.

3. REMOVE N O N - S L I D E GLASS

(a) Pull apart the c h a n n e l s and remove the 2 fix trames,

1

as shown.
·1

, ¡ .

N14334

(b) Pull apart the c h a n n e l s and remove the 2 non-slide

glass panes, as shown.

A S S E M B L Y H I N T : Apply soapy water to the contact

surface of the weatherstrip a n d glass c h a n n e l f l a n g e .

I02M-01

BACK W I N D O W GLASS A S S E M B LY

Assembly is in the reverse order of disassembly .

•
B0-24
BODY - BACK W I N D O W GLASS

B A C K W I N D O W G L A S S INSTALLATIONIOOKC-Ol

1. INSTALL BACK WINDOW GLASS WITH WINDOW

(a)
FRAME

lnstall the working cord to the trame, as shown. •

(b) Apply soapy water to the contact surface of the body

and the weatherstrip lip,

:b,. ¡ 1 a :nm �0.31 in.)

� LJ;;1 2 mm (0.08 J,J

N14336

(e) Hold the glass in position on the body.

(d) lnstall the glass by pulling the cord from the room

side, w h i l e pushing on the outside of the weatherstrip

with your open hand.

•
Nt4338

(e) To make the glass fit in place, tap from the outside

with your open h a n d .

2. INSPECT FOR LEAKS AND REPAIR

(a) Perform a leak test after the h a r d e n i n g time has ela­

0 0
psed.

i� (b) Seal any leak with sealant.

Part No. 08833-00030 or equivalent

t'i'.l5952

•
1 1
 B0-25
BODY - REMOVABLE ROOF

REMOVABLE ROOF
I0111-N

COMPONENTS

•
Removable Roof Glass

�-��e::-:::::-- Holder

--1
Wind Deflector
Panel ---...:�
-------�, ._ .
-- 1 '
L- - 1

Removable Roof lnner_...,_��-y ,!, :

Weatherstrip
' Lock Handle

t
1

Removable Roof

•
Auxiliary Catch

Removable Roof

Hinge Case

1
1
�·r
,,
, ,
,,

,,

�:
�Spacer
1

Removable Roof Lock Base ��� -

1

-¡ ·
.. .-- --1

.,,, .-- D
1 L- - - �

\--- Removable Roof Lock Garnish

1 1

.,
1 1

• '
Nlll053
B0-26
BODY - RE MOVABLE ROOF

IOHl-01

R E M O V A B L E ROOF R E M O V A L

Outward +- ... lnward

� 1. REMOVE REMOVABLE ROOF I N N E R WEATHERST­

2.
RIP

REMOVE REMOVABLE ROOF AUXILIARY CATCH •

Opening Trim

NJ4CY59

3. REMOVE WIND DEFLECTOR PANEL

(a) Remove the 2 outside deflector c l i p s on the left a n d

right sidas.

(b) Remove the 2 inside deflector clips on the left and

r i g h t side w h i l e prying it with a screwdriver.

H I N T : Tape the screwdriver tip before use.

4. REMOVE REMOVABLE ROOF LOCK GARNISH

800894 B00895
207831

5. REMOVEREMOVABLEROOFLOCKBASE

(a) Remove the 2 screws and lock base.

1

Torque: 6 N-m (60 kgf,cm, 52 ln.•lbf)

� / (b) Remove the lock base and spacer.

•
� Spacer 6. REMOVE REMOVABLE ROOF H I N G E CASE

Remove the 2 bolts and the h i n g e case.

Torque: 3.5 N•m (35 kgf,cm, 30 in.-lbf)

t N14060

7. REMOVE LOCK HANDLE AND HOLDER

Remove the lock h a n d l e a n d holder with 2 bolts.

Torque: 3 N,m (30 kgf,cm, 26 in.-lbf)

N14(61

aoau-or

REMOVABLE ROOF INSTALLATION

lnstallation is in the reverse order of removal .

•
1 '
 B0-27
BODY - INSTRUMENT PANEL

INSTRUMENT PANEL
tone-oz

COMPONENTS

Center Heater to Register Duct

Defroster Nozzle

strument Panel Reinforcement

�

No.1 Heater to

Register Duct

�@�No.2Heaterto
N o . 2 Braca
� Register Duct

No.1 Brace Side Bracket

@� Lower N o . 2 Finish Panel

Glove Compartment

Door Reinforcement

ti
• eter i•���up r•r ' G G 1

Cluster Finish P � 'pl �

Starter Switch Bezel :;.;: -- ve Compartment

® • C! & & oor

(j,ft Key Cylinder Lamp 111

@ c_e�ter Lower Cluster Heater Control Panel

K .
&

No.1 Register Fin1sh Panel

H c,:::::i Radto
Spare Switch Hole Cover ---tl @ d'oa:=Eº

. @ Stereo

� �-- A � A Opening Cover

Steering Column�. 1 @

� Cigar Lighter Ash Receptacle Retainer

Hole Bezel

Steering Column Cover Ash Receptacle Box

Steering Wheel

Steering

Wheel Pad

Combination Switch �

Q_ t Lower Center lnstrument Cover

• Fuse Box Opening Cover

Nl4C64
B0-28
BODY INSTRUMENT PANEL

C O N P O N E N T S (Cont'd)

•
► No.2 Reg;ster

N o . 4 Heater to

Reg;ste� N o . 5 Heater to

Register Duct

lnstrument Panel

@@---:No.2 Stay •
@.. �Center

� Bracket

Front Console Box

For AT

- � Spare Switch Hole Cover

� Rear Consola

Box

Front Console Box Q)�

U p p e r Console Box �

Mounting Bracket

Rear Console B o x ----'®

Mounting Bracket • ·
8
®

•
 B0-29
BODY - INSTRUMENT PANEL

HINT: Screws in the ill u s t r a t i o n on the previous page

are indicated using the code below for removal and

i n s t a ll a t i o n of instrument p a n e l.

• mm (in.)

Code Shape Size Code Shape Size Code Shape Size Code Shape Size

; = 5 ; = 6 ; = 6

(0.20) (0.24) (0.24)

-

-
® @ © @
L = 14 L = 18 L = 18
� � �
(0.55) (0.71) (0;71)

; = 8 , ; ;= 5.22 ; = 5 .

(0.31) (0.21) (0.20)

-

-
® ® L = 18
@
L = 1 6
® � L = 10
� � (0.71) (0.63) (0.39)

; = 6 ; = 6

(0.24) (0.24)
Q) (J)
L = 22 L = 16
�
(0.87) (0.63)
�

N14115
\!06400

IOITA-02

INSTRUMENT PANEL REMOVAL

1. REMOVE STEERING W H E E L

(See page S R - 1 6 )

•
2. R E M O V E T H E S E PARTS:

(a) Steering column cover

(b) Hood lockre�ase lever

(e) Combination switch

(d) Fuse box opening cover

3. REMOVE LOWER LH F I N I S H PANEL

ce Remove the 4 bolts, screw and lower LH fi n i s h p a n e l.

4. REMOVE THESE PARTS:

��
(a) Starter switch bezel
'"t>

(b) No. 2 heater to register duct

(c) Steering column (See page S R - 1 3 )

(d) Clock

N14044

5. REMOVE CENTER CLUSTER F I N I S H PANEL

(a) Remove the cup holder and heater c o n t ro l knobs.

�
(b) Using a screwdriver, remove the heater control p a n e l.

(c) Disconnect the hazard connector.

(d) Remove the 2 screws and center cluster finish p a n e l.

•
(e) Remove the heater c o n t r o l. ( S e e page A C - 4 1 )

(f) Remove the radio.

HINT: Tape the screwdriver tip before use.

I

Nl4045
B0-30
BODY - I N S T R U M E N T PANEL

6. REMOVE CLUSTER F I N I S H PANEL

(a) Remove the 3 screws.

(b) U s i n g a screwdriver, remove the panel.

7.

(a)
H I N T : Tape the screwdriver tip before use.

REMOVE C O M B I N A TION METER

Remove the 4 screws.

•
(b) Disconnect the speedometer cable.

(e) Disconnect the 4 connectors.

G: 3 Clips
N14046

8. REMOVE THESE PARTS:

1:l) J (a) No. 1 register

(b) No. 1 heater to register duct

9. REMOVEGLOVECOMPARTMENTDOOR

1 10.
Remov e th e 2 screws and glov e com p artm e nt door.

REMOVE GLOVE COMPARTMENT DOOR REIN-

FORCEMENT

R e mov e t he 2 screws, bolt and glo ve compartment

N14047
door r e inforc e m e nt.

11. REMOVE LOWER CENTER INSTRUMENT COVER

R e mov e th e 2 clips.

12. REMOVE LOWER NO. 2 F I N I S H PANEL

R e mo ve the 3 screws.

•
13. REMOVE THESE PARTS:

(a) Ash r e c e p t acl e box

(b) A s h r e c e ptacl e r e tain e r

14. REMOVE CENTER LOWER CLUSTER F I N I S H PANEL

(a) Remove the stereo o p e n i n g cover.

(b) Remove the screw.

(e) Disconnect the cigar lighter connector.

N14048

15. REMOVE INSTRUMENT PANEL

(a) Remove the side bracket.

(b) Remove the 2 nuts and instrument p a n e l.

16. REMOVE I N S T R U M E N T PANEL R E I N F O R C E M E N T

(a) Remove the No. 1 and No. 2 brace.

(b) Remove the center heater to register duct.

(e)

(d)
Remove the defroster nozzle.

Remove the 4 nuts, 3 bolts and reinforcement.

•
N14049
 B0-31
BODY - INSTRUMENT PANEL

IOOKP-N

INSTRUMENT PANEL DISASSEMBLY

REMOVE T H E S E PARTS:

(a) No. 4 heater to ragistar duct

(b) No. 5 heater to ragistar duct

(c) No. 2 ragistar

(d) Cantar brackat

(a) No. 2 stay

(f) Front consola box

(g) U p p a r consola box m o u n t i n g brackat

(h) Raar consola box

(i) Raar consola box mounting brackat

IOtt7-01

INSTRUMENT PANEL ASSEMBLY

Assembly is in the reverse order of dlsassembly.

IOlll-01

INSTRUMENT PANEL INSTALLATION

l n s t a ll a t i o n is in the reverse order of removal .

•
B0-32
BODY - O N E - T O U C H TAIL GATE

O N E - T O U C H T A I L GATE
10111-M

COMPONENTS

•
Tail Gate Lock Control

� "�(2-Piecas�

: ��� Tall Gata Lock Strike°;' <'k.:-_

't, -,.� \ ,,,___.., (Jl,ft�

',.: " �----- Tail Gata Lock

(e L-�
Clip

Tail Gate Lock Link

- <

�--- :□�. . "> •• � ••

------Tail Gata

W Tail Gata Cable-

_____,_.....J� _ , -��ilGateHinge

Service Hola Covar � ,,,

r-- (
-- . ., r
12-Piacas) ,¡
-- --
'
(l

. •
( 12-Piecas) �

N16121

IOIN-01

◊ o T A I L GATE R E M O V A L

1. REMOVE SERVICE HOLE COVER

Remove the 1 2 screws and service hole cover.

2. D I S C O N N E C T TALE GATE LOCK L I N K FROM TAIL

GATE LOCK CONTROL

N13931

3. REMOVE TAIL GATE CABLE

(a) Disconnect the tail gate c a b l e from the tail gate.

(b) Remove the bolt and tail gate cable from the body.

Torque: 1 4 N•m ( 1 4 0 kgf-cm, 1 0 ft-lbf)

4. REMOVE TAIL GATE LOCK FROM T AIL GATE

Remove the 2 screws and tail gate lock.

•
N16123

1 '
 B0-33
-BODY - O N E - T O U C H TAIL GATE

5. REMOVE THESE PARTS:

(a) Tail gate l o c k striker

Torque: 1 2 N,m ( 1 2 0 kgf,cm, 9 ft,lbf)

(b) Tail gate

(e) Tail gate hinge

Torque:

@: 31 N - m ( 3 1 0 kgf-cm, 22 ft·lbf)

®: 24 N • m (240 kgf-cm, 1 7 ft•lbf)

©: 28 N • m (290 kgf•cm, 1 9 ft•lbf)

I011C-CM

T A I L G A T E LOCK C O N T R O L R E M O V A L
◊---◊¡
1. REMOVE SERVICE HOLE COVER
- - ---- ----- ----

2. D I S C O N N E C T 2 TAIL GATE LOCK L I N K S

3. REMOVE TAIL GATE LOCK CONTROL

---- ----- ----

N13933

IOZIA-01

TAIL GATE LOCK CONTROL

I N S T ALLA T I O N

l n s t a ll a t i o n is in the reverse order of removal .

• TAIL GATE INSTALLATION

10211-01

l n s t a ll a t i o n is in the reverse order of removal .

•
B0-34

BODY - SEAT

SEAT
aon1-oa

COMPONENTS

Bench Seat

Seatback Frame

Outer Shield (LH)

Seatback Cover
•
--- Seat Cushion Cover

Y---Seat Cushion Pad

-,...__--Seat Cushion Frame

�:>::::��-----------7 Outer Track

'
1

•
1

♦ Non-reusable part ' N14056

·1 1
 80-35
BODY - SEAT

g,,ut Rench �eat and Separate Seat

Split Bench Se.at (LH) Headrest

Split Bench Seat {RHI
Separate Seat
�Headrest

Seatback Frame

Seatback Frame Seatback Pad

Seatback Pad l'f Headrest Support Seatback Cover

Seatback Cover

' V ♦ H o g Ring

Armrest �
r-
Assembly 1

L --�

�©�����

, ' � '

Hinge Cover� (!)°10 'C

�---- Seat Cushion Cover ' Hog Ring

-r---- Seat Cushion Pad

1
,__ Seat Cushion Frame-----t,v

·I·
1

_ / Reclining Adjuster Relea se Handle

Outer Shield

(l.�, b Outer Track lnner Shield

� Reclining Connecting Pipe lnside lnside

O. lnner Shield Outer Shield

, ... lnner Track

o.. �-..
<' �
•
o. � a

r _ �

Equalising Wire

Outer Shield
Seat Adjuster

Separata Seat Adjuster

(l.@ b
Cable Outer Track
"I � 1

"- : lnner Track

i

•
♦ Non-reusable part
Nl4057
B0-36
BODY - SEAT

Sport Seat

Headrest

•
Headrest Support -------<

-....,,.1-----Seatback Frame

♦ Hog Ring----

Lumber Support Lever --Iil

---Seatback Pad

A------ Seatback Cover

.......-:::�---- Seat Cushlon Cover

---- Seat Cushion Pad

•
"�----Seat Cushion Frame

Front Seat lnner Belt

\ - '

r-r1 ', 'I

� lnside lnner Shield

� ca.&"- lnside Outer Shield

Rec�ining Connecting Pipe

v ',� Outer Track

•
'"0
i1
lnner Track ---'�

Outer Shield

.., Seat Adjuster Knob

Equalising Wire

..../ �

Vc:2':
/ Reclining Adjuster

"9
Ralease Handle
•
♦ Non-reusable part
N14C68
,¡ '
 B0-37
BODY - SEAT

COMPONENTS (Cont'd)

Rear J u m p Seat

Rear Seat Cushion Cover

ar Seat Cushion

Hinge Upper Cover

Rear Seat Hinge

Rear Seat Cushion Pad

Rear Seat Cushion

Hinge Cover

Rear Seat Turn Table

•
N\4449
BQ.38
BODY - SEAT B E L T

SEAT B E L T
IOHF-61

COMPONENTS

FRONT:
•
Bench Seat and Spllt Bench Seat ( Outer Belt)
Separate Seat ( lnner Belt and Outer Belt)

Shoulder Belt

Anchor Adjuster
� · la 1

Anchor Adjuster : ¡'- ' Cap '--.

Front Seat---:---.------:-----,

Outer Belt 1

Seat Belt Anchor

1--

Cap

i----:---Front Seat

Outer Belt

�;r •
Front Seat Front Seat

lower Arm , lnner Belt RH

Bench Seat ( lnner Belt) Spllt Bench Seat ( lnner Belt)

Front Seat
•
lnner Belt LH

�d
'<í- � 1 ,: ,,, /
_
¼� ...-.---

___--:,�
V------ ..... <� , "'

•
� ., . • i,

Front Seat

Lower Arm
Front Seat

Center Belt
N14041

! 1
 B0-39
BODY - SEA T BEL T

C O M P O N E N T S (Cont'd)

REAR:

----Rear Seat

Outer Belt

� T- -
\
--oe... \

, ' Rear Seat

lnner Belt

Belt Holder

. ---
�
1

u V

•
N14042
80-40
BODY - SEA T BEL T

IQIIC-01

SEAT B E L T I N S P E C T I O N

CAUTION: Replace the seat belt assembly (outer belt,

inner belt, bolts or nuts and sill-bar) lf lt has been used In

a severa impact. The entire assembly should be replaced

even if damage Is not obvious.

•
Emergency Locking Retractar (ELR} type

800632 1. R U N N I N G TEST (IN SAFE AREA)

AII seat belts:

(a) Fasten the front seat belts.

(b) Orive the car at 1 O mph (16 km/h) and make a very

hard stop.

(c) Check that the belt is locked and cannot be extended

at this time.

H I N T : Conduct this test in a safe area. lf the belt does

not Iock, remove the belt mechanism assembly and

conduct the following static check. Also, whenever

i n s t a ll i n g a new belt assembly, verify the p r o p e r oper-

ation befare installation.

2. STATIC TEST
15°
AII seat belts:
45º
(a) Verify that the belt locks when p u ll e d out q u i c k l v .
e{ / ('

(b) Remove the locking retractor assembly.

,� (c)

(d)
Tilt the

Verify

degrees
retractar slowly.

that

or
the

less,
belt

and
can

cannot
be p u ll e d

be pulled
out at

out
a

at
tilt of

ovar 45
1 5 •
degrees of tilt.

800633
lf a problem is fo u n d , replace the a s s e m b l y .

Except for driver's seat belt and FR center passen-

ger

(e) Pull out the whole belt, ralease it s l i g h t l y a n d t h e n p u ll

it out again.

(f) Verify that the belt cannot be extended further.

lf a problem is fo u n d , replace the assembly.

M a n u a l Type

TESTING

(a) Adjust the belt to the proper length.

(b) Apply a firm load to the belt.

(c) Verify that the belt does not extend.

•
800635

' 1
 B0-41
BODY - S E R V I C E S P E C I F I C A T I O N S

SERVICE SPECIFICA TIONS 8011K-N

TORQUE SPECIFICATIONS

N-m kgf-cm ft•lbf

Part tightened

HOOD

Hood hinge x Hood 13 130 10

Hood hinge x Body 18 180 13

Hood lock x Body 8 82 71 in.•lbf

FRONT DOOR

Hinge set bolts 23 230 17

Door lock striker x Body 12 120 9

Window regulator x Body (w/ , w/o Power window) 5 50 43 in.•lbf

Outside handle x Front door 5 50 43 i n- t b f

WIPER AND WASHER

Wiper motor x Body 5.6 55 47 in..lbf

Wiper link x Body 5.6 55 47 in-lbf

Wiper arms x Wiper link 20 205 15

-
OUARTER WINDOW GLASS

i
Seat belt anchor x Body 43 440 32

REMOVABLE ROOF

Removable roof hinge case x Body 3.6 36 30 in.-lbf

Removable roof lock base x Body 6 60 52 in.,lbf

• Removable roof handle x Removable roof

ONE TOUCH TAIL GATE

Tail gate cable x Tail gate

3

14
30

140
26 in.,lbf

10

Tail gate lock striker x Body 12 120 9

Tail gate hinge x Body (@bolt) 31 310 22

(® bolt) 24 240 17

((C} bolt) 28 290 19

SEAT

Front Seat

Seat adjuster x Body 37 375 27

Rear Jump Seat (Extra Cab)

Back panel trim x Body 10 100 7

Seat cushion x Body 10 100 7

SEAT BELT

Front Seat Belt

Shoulder belt anchor adjuster x Body 42 420 30

Shoulder belt anchor adjuster x Front outer belt 42 420 30

Front seat inner belt x Body 42 420 30

Front seat lower arm x Front seat inner belt 42 420 30

ELR x Body 42 420 30

Center belt x Body (Split bench seat) 42 420 30

• Rear Seat Belt

Rear seat outer belt x Body

ELR x Body
42

42
420

420
30

30

Rear seat inner belt x Body 42 420 30