BODY EXTERIOR

7870-00/7880-01/6110-01/7930-01/6210-01/7120-01/
6310-01/7220-01/6410-01/7930-01/5720-04/7115-01/
6210-01/7210-01/7215-01/7220-01/7321-01/6410-01/
7310-01/7840-01
BODY EXTERIOR
OVERVIEW AND OPERATION
6110-01 HOOD ASSEMBLY ...................... 22
PROCESS 7930-01 SIDE SILMOLDING ..................... 26
1. COMPOSITION OF BODY EXTERIOR... 3 5720-04 FENDER PANEL ASSEMBLY ...... 28
7115-01 FRONT DOOR TRIM
(DRIVER SIDE) ............................ 31
CONFIGURATION AND FUNCTION 6210-01 FRONT DOOR
(DRIVER SIDE)............................. 33
7870-00 COMPONENT OF FRONT 7210-01 WINDOW REGULATOR
BUMPER ASSEMBLY.................. 5 (PASSENGER SIDE) .................. 34
7880-01 COMPONENTS OF REAR 7215-01 REAR DOOR TRIM ...................... 35
BUMPER ASSEMBLY.................. 6 6310-01 REAR DOOR ASSEMBLY............. 37
6110-01 COMPONENTS OF HOOD 6310-01 REAR DOOR MOLDING AND
ASSEMBLY ................................. 7 PANEL ........................................ 38
7930-01 COMPONENTS OF SIDE 7220-01 REAR WINDOW REGULATOR...... 39
SILMOLDING .............................. 8 7321-01 TAILGATE TRIM ......................... 42
6210-01 COMPONENTS OF FRONT 6410-01 TAILGATE ASSEMBLY................ 44
DOOR ASSEMBLY ...................... 9 7310-01 TAILGATE LATCH AND
7120-01 COMPONENTS OF FRONT ACTUATOR ................................. 46
WINDOW REGULATOR................ 10 7840-01 REAR QUARTER GLASS............. 48
6310-01 COMPONENTS OF REAR DOOR
ASSEMBLY ................................ 11
7220-01 COMPONENTS OF REAR
WINDOW REGULATOR ............... 12
6410-01 COMPONENTS OF TAILGATE
ASSEMBLY ................................. 13

REMOVAL AND INSTALLATION

7870-00 FRONT BUMPER ASSEMBLY.. 15
7880-01 REAR BUMPER ASSEMBLY ... 18
 7870-00 06-3

BODY EXTERIOR 7870-00

1. COMPOSITION OF BODY EXTERIOR

Hood Assembly Sunroof Assembly

Front Door Assembly

Front Fender
Assembly

Front Bumper Assembly

Cover - Front end

member, lower
Energy absorber -
Front bumper

Front bumper
fascia assembly

Headlamp
Front extension
cover

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06-4 7870-00

Rear Door Assembly Tailgate Assembly

Side sill garnish

Rear Bumper Assembly

Rear upper bracket

Rear bumper beam

Energy absorber
- Rear bumper

Rear bumper garnish

Rear bumper fascia

assembly

Dummy type
Fog light type Fog light type

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 7870-00 06-5

Front Bumper Assembly

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Rear Bumper

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06-10 7120-01

REGULATOR
1) Dual Rail with Regulator
▶ The dual rail with regulator is installed to this vehicle. Its advantages are as below:
Smooth operation
1) Safety operation 4) Reduced the length of glass run
2) Preventing the glass pinch 5) Increased durability of lifting mechanism (including
3) Preventing the glass tilting glass run)
6) No contamination due to grease (applied solid coating)

Components

Driver Side Window and Regulator

Window assembly

Anti-trap ECU window

motor (optional)

Window mounting bracket

Window mounting Window guide rail

bracket
Window cable

Passenger Side Window and Regulator

Windodw assembly

Window Window mounting

mounting bracket
bracket
Window motor

Window guide
rail
Window cable

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6310-01 06-11

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06-12 7220-01

REGULATOR
Components

Window assembly

Window motor

Window mounting
bracket

Guide rail

Window cable

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 6410-01 06-13

1) Layout

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06-14 6410-01

2) Operating Mechanism

Construction - Inside View Construction - Outside View

Tailgate Open Switch

Key
cylinder

Appearance Switch

Key cylinder
Tailgate open switch

Safety crank
assembly

Actuator

Latch assembly Latch assembly

BODY EXTERIOR
ACTYON 2008.07
 7870-00 06-15

Disconnect the negative battery cable and remove the headlamps.

Mounting bolt
(fender)

Mounting bolt
(body)

Scrivet
1. Remove the scrivets ( ) from the upper 2. Unscrew the mounting bolts with the
cover. headlamp removed.

Fog light

Connector

3. Unscrew the lower mounting bolts at 4. Disconnect the fog light connector.
both sides on the front bumper.

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06-16 7870-00

5. Unscrew the mounting screws from the wheelhouse to remove the front bumper assembly.

Screws (Upper)

Side fastener and scrivet Scrivet (Lower)

Lower section of wheel house

6. Remove the front bumper

assembly.

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 7870-00 06-17

7. Remove the energy absorber from the front end member lower cover.

Composition of Front Bumper Assembly

Cover - Front end

member, lower

Energy absorber -
Front bumper

Front bumper
fascia assembly
Fog light

Headlamp

Front extension
cover

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ACTYON 2008.07
06-18 7880-01

Disconnect the negative battery cable and remove the combination lamp
assembly at both sides.

1. Unscrew three mounting screws with the 2. Unscrew two upper mounting bolts.
rear combination lamp assembly
removed.
Rear Mounting Scrivet (4 EA)

Parking Aid
Sensor Connector

Rear Fog light License Plate

Rear Fog light
Connector Lamp Connector
Connector

Lower Lower
Mounting Bolt Mounting Bolt

3. Remove two lower mounting bolts at 4. Disconnect the connectors for parking aid
both sides. sensor, rear fog light and license plate
lamp.

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 7880-01 06-19

5. Unscrew seven mounting screws from the rear wheelhouse.

Mounting
Screw Lower Mounting Screw of Wheelhouse

Lower Mounting Screw

6. Remove the rear bumper fascia and the energy absorber.

Energy
Absorber

Rear Bumper Fascia

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06-20 7880-01

7. Remove the rear upper beam (A) and (B) according to the following procedure with the rear
bumper fascia removed.

(1)Unscrew four mounting nuts and remove (2)Disconnect the license plate lamp connector.
the rear upper beam assembly.

Mounting Nut

Rear Bumper Beam Rear Upper Beam Rear Bumper Beam

Mounting Point Mounting Point

License Plate
Rear Bumper Beam
Parking Aid Lamp Connector
Sensor

LH/RH PAS Connector Mounting Bolt (LH) Mounting Bolt (RH)

Tightening torque: Tightening torque:

Center PAS Connector 42 - 62 Nm 42 - 62 Nm

(3)Disconnect the main wiring (parking aid (4)Unscrew two mounting bolts from the
sensor) connector at rear side and rear bumper beam at both sides. (Do not
remove the connector fastener from remove the upper bolt completely.)
body.

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 7880-01 06-21

8. Install the rear bumper beam assembly in the reverse order of removal.

Composition of Rear Bumper Assembly

Rear upper beam

Rear bumper beam

Energy absorber -
Rear bumper

Rear bumper
garnish

Rear bumper
fascia assembly

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ACTYON 2008.07
06-22 6110-01

Cover the vehicle body and place the chocks under the tires.

1) Hood
Hood
assembly
Disconnect
the hose
Washer hose

Hood
hinge
1. Disconnect the washer fluid
Hood lever nozzle hose (A) from the
engine hood.
Hood hinge

Hood lever

2. Slacken two mounting bolts on the hood Unscrew two mounting bolts and remove
hinge (Do not remove the bolts). the hood lever.

Alignment
mark

Make an alignment mark on the hood and

hinge for installation.

3. Carefully remove the engine hood.

Pay particular attention to avoid vehicle

damage and personal injury.

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 6110-01 06-23

2) Hood Latch and Cable

Remove the front bumper assembly.

Hood Cable

Hood Latch

Cable Fastener

1. Remove the lower instrument panel at 2. Unscrew three bolts (10 mm), disconnect
driver side and disconnect the hood the hood release cable, and remove the
release lever cable. hood latch.
(Refer to "Body" section.)

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06-24 6110-01

3) Hood Garnish (Front)

Front

1. Lift the hood and unscrew six

mounting bolts from hood garnish.

Mounting nut

Rear

2. Remove the hood garnish while

pulling it forward.

▶ Hood Insulation Pad

Remove the fasteners and insulation pad. Once removed, the insulation pad should be
replaced with new one.

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 6110-01 06-25

4) Hood Adjustment

Hood Hinge

Hood height adjustment overslam

▶ Up/Down/Left/Right Adjustment ▶ Hood Height Adjustment

1. Up/Down/Left/Right 2. Hood height
: Slacken the hood hinge mounting bolts : To adjust the height of hood front end,
and adjust the hood position until it is rotate the overslam bumper.
placed to the desired location.

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06-26 7930-01

All side moldings can be removed/installed with a similar procedure.

1. Unscrew two mounting screws from the

front/rear wheelhouse.

2. Unscrew the lower mounting screws from

the side sill molding.
3. Carefully remove the side molding seal.

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06-28 5720-04

Disconnect the negative battery cable and remove the headlamps, front
bumper and cowl.

1. Remove the tires and wheelhouse cover.

2. Remove the quadrant cover.

Be careful not to damage the fasteners.

4. Disconnect the side repeater 3. Remove the insulator sponge from

connector and remove the lamp the fender.
assembly.

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 5720-04 06-29

5. Unscrew one mounting bolt in cowl. 6. Unscrew two quadrant cover bolts.

7. Unscrew the front mounting bolt from

the headlamp.
Mounting bolt in
headlamp

Mounting bolt in
wheelhouse

8. Unscrew two bolts and one screw

from the wheelhouse. Screw

Mounting bolt

Mounting bolt

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06-30 5720-04

9. Unscrew the lower bolts from the fender. 10.Unscrew the upper bolts from the fender.

11.Remove the fender panel from the vehicle.

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 7115-01 06-31

Disconnect the negative battery cable.

- Removal of fastener cover 1. Unscrew seven mounting screws from

the door trim and separate the fasteners
starting from bottom of the door trim to
remove it.

Location of Fasteners

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06-32 7115-01

2. Remove the door handle cable (A), door courtesy lamp connector (B), door tweeter speaker
connector (C) and power window switch connector (D) from the removed door trim.

A. Door handle connector

: Remove the cables from 1 to 4 as
C. Door tweeter speaker connector.
in order shown in figure below.

Door tweeter speaker

Door handle

Door courtesy lamp

Power window switch

B. Door courtesy lamp connector D. Power window switch connector

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 6210-01 06-33

Disconnect the negative battery cable.

1. Remove the main wiring harness cover

and disconnect the door main connector.

Door check link

Door hinge

Door Main Connector

Door main connector

2. Unscrew the mounting bolt from 3. Unscrew the upper and lower hinge
the door check link (vehicle side). bolts and remove the door assembly.

Upper Door Mounting Bracket

Lower Door Mounting Bracket

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06-34 7120-01

Disconnect the negative battery cable.

1. Lower the window until the window mounting bracket can be seen. Unscrew the nuts from
the window mounting bracket and remove the window.

2. Disconnect the window motor connector and unscrew the mounting bolts from the window
regulator.

Passenger Side Mounting Bolt

Window Motor

Driver Side Window Motor

3. Remove the window regulator from the door.

Driver Side Passenger Side

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 7215-01 06-35

Disconnect the negative battery cable.

1. Remove the inside panel from the

rear door.

2. Unscrew six mounting screws from the door

trim.

3. Separate the bottom of door trim and pull

it up to remove it.

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06-36 7215-01

Location of Fasteners

4. Remove the door handle cable (A) and the power window switch (B) to remove the door trim.

A. Door Handle Cable B. Power Window Switch Connector

Door handle

Power window switch

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 6310-01 06-37

Discon nect the negative battery cable.

1. Remove the lower B pillar and the front

seat belt and disconnect the rear door
main connector.

Door hinge

Door check link

Rear Door Main Connector
Rear door main
connector
Door hinge

2. Unscrew the mounting bolts from 3. Unscrew the upper and lower hinge
the door check link (vehicle side). bolts and remove the door assembly.

Upper Door Mounting Bracket

Lower Door Mounting Bracket

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ACTYON 2008.07
06-38 6310-01

Remove the inside panel (upper) from the rear door.

1. Door Outer Panel 2. Door Outer Window Molding

(1)Unscrew four mounting screws with the (2)Unscrew two mounting screws from the
inside panel removed. inner window molding.

(2)Remove the outer panel from the door. (2)Carefully remove the molding.

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ACTYON 2008.07
 7220-01 06-39

1. Disconnect the negative battery cable.

2. Remove the rear door trim assembly.
1. Lower the window until the window mounting bracket can be seen. Unscrew the nut on the
window mounting bracket to remove the window glass.

Window Mounting Bracket

Removal of Window Glass

Guide
channel

2. Lower the window and unscrew two 3. Remove the guide channel from the door.
mounting nuts from the guide channel.

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06-40 7220-01

4. Remove the window motor

connector and three mounting nuts.

Motor
mounting nut

5. Unscrew the mounting nuts from the window regulator (upper: 2 EA, lower: 2 EA).

Upper Mounting Nut Lower Mounting Nut

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 7220-01 06-41

6. Remove the window regulator from the door.

Removal of Window Regulator Installation Location of Window Regulator

Window Regulator Assembly

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06-42 7321-01

Disconnect the negative battery cable.

1. Unscrew the scrivets and the upper trim screws and remove the upper trim from the tailgate.

Mounting Upper
scrivet
Mounting
scrivet

Lower

Mounting Mounting
screw screw

Mounting
scrivet

Mounting Mounting
screw screw

2. Remove the lower trim from the tailgate (at A, C and D).
A: Upper Mounting Screw B: Lower Mounting Screw C: Lower mounting screws
of Lower Trim of Lower Trim of tailgate.

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 7321-01 06-43

3. Remove the tailgate trim while separating the fasteners starting from bottom. Then, remove
the vinyl cover.

Upper trim

Fastener Fastener

Lower trim

Location of
Fasteners

4. Close the tailgate and remove the wiper blade assembly.

- Open the cap and unscrew the

mounting bolt.

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ACTYON 2008.07
06-44 6410-01

1. Disconnect the negative battery cable.

2. Remove the tailgate trim assembly.

Pay particular attention to avoid vehicle

damage and personal injury.

1. Remove the mounting clips at both sides and remove the gas lifter.

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 6410-01 06-45

2. Disconnect the de-icer cable connector (1),

wiper motor connector (2), high-mounted stop
lamp connector (3), door actuator connector (4),
door switch (5) and ground. Then, remove the
harness assembly.

3. Unscrew two hinge bolts and remove

the tailgate assembly.

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ACTYON 2008.07
06-46 7310-01

1. Disconnect the negative battery cable.

2. Remove the trim assembly.

1. Disconnect the door actuator connector and the door switch connector.

Door actuator terminal

Door actuator
connector

Door switch connector

2. Separate the connecting rod from the key 3. Unscrew three mounting bolts and
cylinder. remove the latch assembly.

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 7310-01 06-47

4. Separate the connecting rod (A) and three mounting screws from the removed latch
assembly to remove the door actuator.

Mounting
screw

Door switch Door actuator

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06-48 7840-01

1) Removal
Remove the rear quarter trim.

1. Unscrew six mounting nuts from the rear

quarter glass.

3. Remove the quarter glass and remove the

2. Remove the rear quarter glass while butyl seal on the glass and frame using a
pushing it inside of the vehicle. knife or a special tool.

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 7840-01 06-49

2) Installation
1. Wipe out any foreign material on the
body frame.

2. Apply the butyl seal to the new quarter glass at regular interval.

Molding

Cylinder

3. Install the rear quarter glass to the body frame and tighten the mounting bolts to the
specified torque. (Tightening torque: 6.5 Nm)

Installation of Quarter Glass Tighten the Nut

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ACTYON 2008.07