Body

Workshop Manual
1996 - 2000
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Ebay User ID: reveleus1
FRONT BUMPER
COMPONENTS
Email: suzlever@gmail.com
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INSTALLATION
1. Installation is the reverse of the removal procedure.
REAR BUMPER
COMPONENTS
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REMOVAL
[SEDAN]
1. Remove the rear transverse trim and loosen the rear luggage trim.
2. Remove the rear mud guard.
3. Remove the rear bumper cover assembly.

4. Remove the rear bumper beam and bumper cover bracket.
[WAGON]
1. Remove the rear combination lamp.
2. Remove the rear wiper washer reservoir tank.

3. Remove the rear bumper side mounting bolt (2EA) and nut (1EA).
(Quarter panel inner lower side)
4. Remove the bumper side mounting screw (2EA) and bolt (1EA).
5. Remove the rear bumper rail mounting bolt (2EA).

6. Remove the rear bumper cover ass'y.

REMOVAL
1. Remove the front bumper upper guard.
2. Remove the turn signal lamp.
3. Remove the lower side front bumper cover.
4. Remove the front bumper cover assembly.

5. Remove the front bumper beam.

COMPONENTS


INSTALLATION
REMOVAL
1. Remove the console upper cover.
2. Remove the rheostat
3. Remove the center facia panel mounting screws.

4. Pull the center facia panel forward and then take out the console mounting screws.
5. Remove the console assembly.


COMPONENTS
INSTALLATION
1. Installation is the reverse of removal procedure.
2. Connect all of the connectors securely.
REMOVAL
1. Remove the steering wheel.
2. Remove the steering column lower and upper shroud.
3. Remove the multifunction switch.

Disconnect the connector.
4. Remove the cluster facia panel.

5. Remove the cluster assembly and disconnect the connectors.
6. Remove the side facia panel and disconnect the mirror control connector.
7. Remove the hood release handle mounting screws.

8. Remove the crash pad lower cover and bracket.
9. Remove the console upper cover.
10. Remove the rheostat.

11. Remove the heater control cable. (LH side)
12. Disconnect switch extension wire connector (white, 20 pin), air conditioning switch connector, blower switch
connector, vacuum connector, and cigarette lighter connector.
13. Remove the center facia panel assembly.
14. Remove the console.

15. Remove the audio mounting screws (4EA) and then remove the audio.
16. Remove the glove box mounting screws and then remove the glove box assembly.
17. Remove the glove box striker mounting screws and then remove the glove box upper cover.


18. Detach the defroster nozzle from the main crash pad.
19. Remove the speedometer cable adapter and instrument connector.
20. Remove the data link connector mounting screws.
21. Remove the main crash pad.

22. Remove the instrument connector and data link connector from the main crash pad.
23. Remove the ventilators from the main crash pad.
24. Remove the passenger air bag.


25. Remove the lower crash pad lower panel support bracket.
26. Remove the center facia panel support bracket.
27. Remove the glove box striker mounting bracket.

COMPONENTS
INSTALLATION
In order to prevent the fender mounting bolt area from forming rust, apply tape sealer between the fender and
the body panel.
Purchased
from Ebay seller
Reveleus1
Thank-you for purchasing from me, it

is much appreciated.
To contact me please email
suzlever@gmail.com
REMOVAL
1. Remove the turn signal lamp.
2. Remove the wheel guard.
3. Remove the fender mounting bolts.

Use care to avoid damaging the paint
COMPONENTS


DOOR POSITION ADJUSTMENT

Check for flush fit with the body, then check for the equal gap between the front and rear, top and bottom door
edges and the body. The door and body edges should also be parallel. Adjust at the hinge with the Special Tool
(09793-21000).
Attach protective tape to the fender edges near the place where the hinge is installed.
DOOR STRIKER ADJUSTMENT

Make sure the door is not loose, and latches securely without slamming. If it needs adjustment:
1. Draw a line around the striker plate for reference.
2. Loosen the striker screws, and move the striker IN or OUT to make the latch fit tighter or looser. Move the
striker UP or DOWN to align it with the latch opening. Then lightly tighten the screws and recheck.
Hold the outside handle out and push the door against the body to be sure the striker allows a flush fit.
GLASS ADJUSTMENT
If the glass does not fit evenly when closed, adjust the slant of the glass in the front-to-back direction.
INSIDE DOOR HANDLE ADJUSTMENT

Adjust the inside handle play by adjusting the mounting position in the IN-to-OUT direction.
INSTALLATION
2. If the door glass has been removed from the glass grip, be sure to install it in the correct position.
When installing the door trim seal, butyl type should not be placed over door trim fastener mounting area.
REMOVAL
1. Remove the door window regulator handle and then remove clip using a piece of cloth (Manual type only).
2. Remove the quadrant inner cover.

3. Remove the rear outside mirror mounting screws and then remove the outside mirror.
Disconnect the remote control connector (electric type only).
4. Remove the door inside handle.
5. Remove the screws from the door trim and bezel side cover.

6. Insert a screwdriver between the trim fasteners and door panel to pry it loose.
Disconnect the connector (Power window motor, Power window main switch, Door lock actuator).
7. Remove the door speaker and speaker mounting bracket.
8. Remove the door trim seal.

9. Remove the front door belt joint moulding and upper moulding.
10. Remove the front door belt outside weather-strip.
11. Remove the carrier plate bolts from the regulator channel.


12. Pull the door glass out through the window slot.
13. Remove the door regulator channel mounting bolts and then remove the door regulator assembly.
14. Remove the front door quadrant channel.
15. Remove the door inside handle rod from the door latch assembly and channel.

16. Remove the outside door handle mounting bolts.

Disconnect the outside door handle rod from the outside door handle at the position shown.
17. Remove the door latch and door lock actuator.

18. Remove the door checker.
19. Remove the door glass run.
20. Remove the front door frame garnish.


COMPONENTS


REMOVAL
1. Pull out front seat mounting cover and remove the bolts.
2. Remove the front seat assembly.
3. Remove the seat recliner control lever and seat cushion control knobs.
4. Remove the seat shield cover.
5. Release the zipper of front seat back cover and remove the 2 bolts (14mm), then remove the 1 bolt (10mm) in
the opposite side.

6. Remove the 4 bolts mounted under the seat to remove the front seat track.

SPECIAL TOOLS
Tool Illustration Use

(Number and name)
09793-21000 Adjustment, removal and

Door hinge adjusting installation of the door hinge
wrench
09800-21000 Trim removal

Ornament remover
09861-31100 Cutting the sealant for the

Sealant cut-out tool windshield glass (use with
09861-31200)
09861-31200 Cutting the sealant for the

Sealant cutting blade windshield glass (use with
09861-31100)


09861-31300 Application of the sealant to
Sealant gun the windshield glass
09681-31400 Removal and installation of

Glass holder the windshield glass
09681-31000 Removal of the windshield

Windshield glass glass moulding
moulding remover

SPECIFICATIONS
Hood
Type Rear hinged, front opening type
Front door
Construction Front hinged, full door construction
Regulator system Wire drum type
Rear door
Construction Front hinged, full door construction
Regulator system Wire drum type
Trunk lid
Type Torsion bar type
Tailgate (Wagon)
Type Inner hinged, gas lift type
Glass thickness mm (in.)
Windshield glass Laminated clear, tinted 5 (0.20)
Laminated tinted shade band 5 (0.20)
Door glass 3.2 (0.13)
Rear fixed glass 3.2 (0.13)
Rear window glass 4 (0.16)
Distance between door upper hinge and lower hinge Front door 325 mm (12.80 in.)
Rear door 334 mm (13.15 in.)
Seat
Front seat travel 225 mm (8.9 in.)
Seat belt
Driver seat 3 point type with E.L.R.


Front passenger and outboard rear seat 3 point type with C.L.R.
Rear center 2 point type with static
E.L.R. : Emergency Locking Retractor

C.L.R. : Combination Locking retractor

TIGHTENING TORQUE
Front and rear doors Nm kg.cm lb.ft

Door hinge to body 36-42 360-420 26-30
Door hinge to door 13-26 360-320 9-19
Trunk lid Nm kg.cm lb.ft

Trunk lid hinge to body 7-9 70-90 5-6.5
Trunk lid hinge to trunk lid 7-9 70-90 5-6.5
Trunk lid latch to trunk lid 7-9 70-90 5-6.5
Trunk lid striker to body 7-9 70-90 5-6.5
Tailgate Nm kg.cm lb.ft

Tailgate hinge to body 7-9 70-90 5-6.5
Tailgate hinge to trunk lid 7-9 70-90 5-6.5
Hood Nm kg.cm lb.ft

Hood hinge to body 22-27 220-270 16-19.5
Hood hinge to hood 22-27 220-270 16-19.5
Hood latch to body 7-9 70-90 5-6.5
Hood striker to hood 7-9 70-90 5-6.5
Seat Nm kg.cm lb.ft

Front seat to floor, Nut 24-36 240-360 17-26
Front seat to floor, Bolt 35-55 350-550 25-40
Rear seat back to floor, Bolt 17-26 170-260 12-19
Rear seat back tilting bracket 17-26 170-260 12-19
Seat belt
Nm kg.cm lb.ft


Front seat belt buckle 40-55 400-450 29-40
Front seat belt upper anchorage to body 40-55 400-450 29-40
Rear seat belt anchor attaching bolt 40-55 400-450 29-40

TROUBLESHOOTING
Symptom Probable cause Remedy

SunroofWater leaks Dust accumulated in drainage of Clear dust from inside drain
housing assembly pipe
Clogged drain pipe Blow air into drain pipe to

remove dust
Broken or dislocated drain pipe, Check pipe installation and

defective or cracked clip flange contact
Deteriorated roof lid weatherstrip Replace
Excessive roof lid-to-body clearance Adjust

and improperly fitted weatherstrip
Wind noise Loose or deformed deflector Retighten or replace
Roof lid makes noise when moved Foreign matter lodged in guide rail Check drive cable and guide
rails for foreign matter
Loose guide rails and lid Retighten
Motor runs but lid does not move or Foreign matter lodged in guide rail Check drive cable and guide
moves only halfway rails for foreign matter
Incorrect engagement of motor pinion Check for loose motor

with drive cable installation and damaged
pinion
Decrease in clutch slipping force of Adjust

motor
Increased lid sliding resistance or Adjust or replace

interference of lid with drive cables,
weatherstrip, etc. due to maladjustment
of lid
Noise in motor (Clutch slipping noise Incorrect engagement of motor pinion Check pinion installation and
made in motor when lid is fully with drive cable retighten motor
opened or closed is not an unusual
noise.)
Worn or damaged motor pinion bearing Replace motor assembly
Worn or deformed drive cable Replace


Door glass fails to operate up and Incorrect window glass installation Adjust position
down
Damaged or faulty regulator arm or Correct or replace

regulator
Door does not open or close Incorrect door installation Adjust position
completely
Defective door check Correct or replace
Door hinge required grease Apply grease
Hood does not open or close Striker and latch not properly aligned Adjust
completely
Incorrect installed hood Adjust
Incorrect hood bumper height Adjust
Door hard to open Incorrect latch or striker adjustment Adjust
Water leak through windshield and Defective seal Fill with sealant
rear window
Defective body flange Correct
Wind noise around door Weatherstrip not holding firmly Adjust fit of door
Improperly installed weatherstrip or Repair or replace

setting of weatherstrip
Improperly closed door Adjust
Improperly fit door Adjust
Improper clearance between door Adjust

glass and division channel
Deformed door Repair or replace

ADJUSTMENT
Hood Hinge
1. Loosen the hood hinge mounting bolt.
2. Adjust the longitudinal and lateral positions of the hood by utilizing the oblong holes in the hinge.
3. Adjust front edge of hood in vertical direction by adjusting the hood stop adjusting bumpers.
Hood Latch
1. Loosen the hood lock mounting bolts.
2. Adjust the alignment of the hood latch by adjusting the vertical and lateral position of the lock and by adjusting
the height of the hood.
COMPONENTS


REMOVAL
1. Remove the hood mounting bolts, and then remove the hood.
Protect the front body area with a cloth so as not to cause damage with the hood.
2. Remove the hood lock.

3. Remove the hood cable by opening the clip.
4. Loosen the cable holder screws.
5. Pull the cable nut to the cab side.
COMPONENTS


REMOVAL
Front pillar Trim
1. To remove the front pillar trim, first remove the following parts:
(1)Remove the front seat belt upper mounting bolt.
(2)Remove the center pillar lower trim.
(3)Remove the center pillar upper trim.
(4)Using a (-) screwdriver remove the front pillar trim.
*Clip direction*
-1 2 3: to Front pillar
- 4 5: to Roof panel
Door Scuff Trim

1. Remove the trim mounting plug from the door scuff trim.
Center Pillar Trim

1. Remove the front seat belt upper mounting bolt.
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2. Remove the center pillar lower trim.
3. Remove the center pillar upper trim.

*Clip direction*
-1 2: to Roof panel
Cowl Side Trim

1. Remove the three screws from the cowl side trim.

Rear Wheel House Trim

[SEDAN]
1. Pull the rear seat mounting clip and remove the mounting bolts.
2. Loosen the rear seat back side cover mounting bolt and remove the rear seat back side cover from hook while
lifting the rear seat back side cover.
3. Remove the trim mounting plug from the rear wheel house trim.

[WAGON]
1. Remove the rear seat cushion.
2. Remove the rear seat back main mounting bolts from the rear seat back.
3. Remove the trim mounting plug and mounting screw.

Rear End Trim

1. To remove the rear end trim, first remove the following parts:
(1)Remove the cargo security screen.
(2)Remove the rear speaker grill.
(3)Remove the luggage side trim.
(4)Remove the cargo security screen holder.
(5)Remove the rear seat belt extension bar mounting bolt.
(6)Using a (-) screwdriver remove the rear end trim.
*Clip direction*
-1 2: to Roof panel
-3 4 5: to Quarter panel
Rear Package Tray Trim

1. Remove the rear seat cushion.

2. Untighten the rear seat back side cover mounting bolt and remove the rear seat back side cover from hook
while lifting the rear seat back side cover.
3. Remove the high mount stop lamp.


4. Remove the rear seat belt lower mounting bolt.
5. Remove the rear partition cover and rear package tray trim.
Rear pillar Trim

[SEDAN]
1. To remove the rear pillar trim, first remove the following parts:
(4)Using a (-) screwdriver remove the rear pillar trim.
*Clip direction*
-1 2: to Roof panel
-3, 4, 5, 6, 7, 8: to Quarter panel

[WAGON]
1. To remove the rear pillar trim, first remove the following parts:
(3)Remove the rear wheel house trim.
(4)Remove the luggage side trim.
(6)Remove the end trim.
(7)Using a (-) screwdriver remove the rear pillar trim.
*Clip direction*
-1 3: to Roof panel
2, 4, 5, 6: to Quarter panel
Rear Transverse Trim

[SEDAN]
1. Remove the trim mounting plug from the rear transverse trim.

[WAGON]
1. Remove the trim mounting screw (4EA) from the rear transverse trim.
Luggage Side Trim

[SEDAN]
1. Remove the screws and plugs from the luggage side trim.
[WAGON]


1. To remove the luggage side trim, first remove the following parts:
(3)Remove the rear wheel house trim.
(4)Remove the rear transverse trim
(5)Remove the luggage side trim
Head Lining
[SEDAN]
1. To remove the head lining, first remove the following parts:

(4)Remove the front pillar and rear pillar trim.
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2. Remove the sunvisor and retainer.
3. Detach the lens from the room lamp.

4. Remove the room lamp.
5. Remove the roof assist handle.


6. Remove the head lining.
[WAGON]
1. To remove the head lining and roof rack, first remove the following parts:
(4)Remove the front pillar trim.
(5)Remove the cargo security screen and rear speaker grill.
(6)Remove the rear wheel house trim and luggage side trim.
(8)Remove the rear end trim and rear pillar trim.
2. Remove the sunvisor and retainer.

3. Detach the lens from the map lamp, room lamp and luggage lamp.
4. Remove the map lamp, room lamp and luggage lamp.
5. Remove the roof assist handle and head lining mounting plug.

7. Remove the roof rack mounting nut (3EA).
8. Remove the roof rack assembly.

COMPONENTS
INSTALLATION
1. Clean the quarter fixed glass moulding assembly with gauze.
2. Apply a primer to the glass and the glass moulding assembly.
3. Apply the sealant to the entire circumference of the glass.

Install the glass to the body within five minutes.
4. To install the quarter fixed glass, tighten the glass moulding installing screw after setting it to the quarter fixed
glass hole.


REMOVAL
1. Remove the cargo security screen.
2. Remove the rear speaker grill.
3. Remove the rear wheel house trim.
4. Remove the luggage side trim and rear seat belt webbing guide mounting screw.

5. Remove the rear seat belt extension bar mounting bolt.
6. Remove the cargo security screen holder and rear end trim.
7. Remove the front seat belt upper mounting bolts.

10. Remove the rear pillar trim.

11. Remove the quarter fixed glass mounting screw.
12. After removing quarter fixed glass moulding, cut the sealant using the special tool.
13. Remove the quarter fixed glass.


COMPONENTS
INSTALLATION
2. If the door glass has been removed from the glass grip, be sure to install it in the correct position.
When installing the door trim seal, butyl tape should not be placed over door trim fastener mounting area.
REMOVAL
1. Remove the rear window regulator handle and then remove the clip using a piece of cloth (Manual type only).
Remove the door pull handle.
2. Remove the door inside handle.

Disconnect the inside handle rod clip.
3. Remove the rear door trim mounting screws.

4. Remove the door trim fasteners.
5. Remove the door trim seal and power window switch mounting bracket.
6. Remove the rear door frame upper moulding and joint moulding.

7. Remove the rear door outside belt weather strip.
8. Remove the carrier plate bolts from the regulator channel.
9. Loosen the division channel and remove the door glass.


10. Remove the fixing screw and the bolts of the division channel.
Remove the division channel.
11. Remove the fixed glass.
12. Remove the rear door glass run.
13. Remove the rear door frame garnish.

14. Remove the rear door regulator channel mounting bolts and then remove the door regulator assembly.
15. Remove the door inside handle rod from the door latch assembly.
16. Remove the outside door handle mounting bolts.

Disconnect the outside door handle rod from the outside door handle at the position shown.

17. Remove the door latch and door lock actuator.
18. Remove the door checker.

Purchased
from Ebay seller
Reveleus1
Thank-you for purchasing from me, it

is much appreciated.
To contact me please email
suzlever@gmail.com
COMPONENTS
COMPONENTS
REMOVAL
[SEDAN]
1. Pull the rear seat mounting clip and remove the mounting bolts.
2. Loosen the rear seat back side cover mounting bolt and remove the rear seat back side cover from hook while
lifting the rear seat back side cover.
3. Remove the rear seat back mounting bolts from the rear seat back.
4. Remove the rear seat back side bracket and tilting bracket.

[WAGON]
1. Remove the rear seat cushion mounting bolts from the rear seat cushion.
2. Remove the rear seat back mounting bolts from the rear seat back.
3. Remove the rear seat back bracket and tilting bracket.


COMPONENTS
INSTALLATION
[SEDAN]
1. Install the rear window glass moulding to the rear window glass.
2. Apply a light coat of glass primer to the outside of the dam.

a.Do not apply body primer to the glass
b.Never touch the primed surfaces with your hand.
If you do, the adhesive may not bond to the glass properly, causing a leak after the windshield is installed.
c.Keep water, dust, and abrasive materials away from the primed surface.
3. Apply a light coat of body primer to the original sealant remaining around the window opening flange. The
glass should be installed 10 minutes after you apply the primer.


4. Thoroughly mix all the sealant and hardener together on a glass or metal plate with a putty knife.
a.Clean the plate with a sponge and alcohol or wax or grease remover before mixing.
b.Follow the instructions that come with the sealant.
5. Pack adhesive into the cartridge (avoid air pockets), to ensure continuous delivery. Put the cartridge in a
caulking gun or Sealant Gun, and run a bead of adhesive around the edge of the glass as shown.
Apply the adhesive within 5 minutes after applying the glass primer.
Using the special tool, install the rear window glass.
[WAGON]
1. Install the rear window glass moulding to the rear window glass.


a.Do not apply body primer to the glass.
b.Never touch the primed surfaces with your hand.
If you do, the adhesive may not bond to the glass properly, causing a leak after the windshield is installed.
a.Clean the plate with a sponge and alcohol or wax or grease remover before mixing.

5. Pack adhesive into the cartridge (avoid air pockets), to ensure continuous delivery. Put the cartridge in a
caulking gun or Sealant Gun, and run a bead of adhesive around the edge of the glass as shown.
Using the special tool, install the rear window glass.

REMOVAL
[SEDAN]
1. Remove the defogger wire connector and then remove the rear pillar trim.
2. Remove the high mounted stop lamp.
3. Remove the rear seat back side cover and rear seat cushion.
4. Remove the partition cover and rear package tray trim.

5. Remove the rear window glass assembly.
[WAGON]
1. Remove the high mounted stop lamp.
2. Remove the tailgate frame upper and side trim.
3. Remove the tailgate trim panel ass'y.

4. Remove the tailgate latch and key cylinder.
5. Remove the rear wiper arm and rear wiper motor.
6. Remove the defogger wire connector.

7. Remove the rear window glass assembly.

COMPONENTS
REMOVAL
Front Seat Belt
1. Remove the door scuff trim.
3. Remove the front seat belt upper mounting bolt (14mm), lower mounting bolt (17mm).
4. Remove the seat belt assembly.
Front Seat Belt Height Adjust


6. Remove the front seat belt height adjuster.

ADJUSTMENT
1. Adjust the height of the glass panel. (A-A cross section)
Adjust the difference in height between the glass panel and the roof panel to no more than 5.8 mm (0.23 in.)
(Procedures to adjust B-B cross section)

(1)Loosen mounting screws 1 and 2.
When adjusting no more than 2 mm (0.08 in.), it may be better not to move screw 1.
(2)Adjust by turning the adjust screw.
clockwise Up
counterclockwise Down
(3)Tighten mounting screws 1 and 2.
(Procedures to adjust C-C cross section) Loosen the mounting and adjusting screws. For easy adjustment, do
not loosen the mounting screws too much. Adjust by moving the glass panel from inside or outside. Tighten
the adjusting screw and the mounting screws in that order.


COMPONENTS


INSTALLATION
Glass panel
1. Insert the guide of the sunroof glass panel into the guide rail.
2. After completely pushing back the sunroof glass panel, push the guide into the guide rail and then push the
glass panel so that the cable comes out of the tube drive.
OPERATING CONDITION CHECK

1. If the panel movement is difficult, check and adjust.
(1)Make sure the battery voltage is normal.
(2)Make sure that the sunroof sliding unit is free of foreign material.
(3)Make sure that, when the glass panel opens, the rear position of panel does not interfere excessively with
the roof panel. If interference occurs, fully open the glass panel and move the stopper forward.
If the stopper is moved forward too far, it may cause malfunction or leaks. Make sure the gap between the
glass panel and roof panel is not more then 5.8 mm (0.28 in.).
(4)Measure the driving force of the motor, and adjust it to 15-25 kg (33.1-55.7 lb) with the torque adjustment
nut on the motor.
(5)To measure, use the deep hole in the center of the lid lower panel.


REMOVAL
1. To remove the sunroof, first remove the following parts:
(1)Remove the over head console lamp, sunvisor, and roof assist handle.
(4)Remove the front pillar trim and rear pillar trim.
3. Disconnect the sunroof motor connectors.
4. Remove the front and rear drain hoses from the sunroof.
5. Remove the sunroof mounting bolts and nuts.


6. Remove the sunroof motor assembly.
7. Remove the sunroof tube drive guide mounting screws.
8. Remove the sunroof motor mounting screws.

9. Remove the sunroof motor mounting bracket.

10. Push the sunroof glass panel backward as shown in the illustration.
11. Remove the sunroof guide rail cover.
12. Pull the sunroof glass panel forward slowly so the guide will not come off the sunroof guide rail. Then, remove
the glass panel by pulling the guide upward through the groove on the front of the rail.

13. Remove the sunroof decoration cover.
14. Remove the lower lid panel.
15. Remove the sunroof deflector assembly.

16. Remove the sunroof guide rail and cover.

ADJUSTMENT
1. Adjust the striker frontward or rearward and rightward or leftward until the trunk lid is flush with the rear edge of
the body.
2. Adjust trunk hinges upward or downward and rightward or leftward as necessary to equalize the gap between
the lid and the body.
3. Turn the trunk lid bumpers either clockwise or counterclockwise to adjust the height of the trunk lid.
ADJUSTMENT
1. Adjust the striker frontward or rearward and rightward or leftward until the tailgate is flush with the rear edge of
the body.
2. Adjust the tailgate hinges upward or downward and rightward or leftward as necessary to equalize the gap
between the tailgate and body.
REMOVAL
1. Remove the trunk lid hinge mounting bolts and then remove the trunk lid.
2. Remove the torsion bar.
3. Remove the trunk lid latch and trunk lid lock.


4. To remove the trunk lid hinge, first remove the following parts:
a.Remove the defogger wire connector and then remove the rear pillar trim.
b.Remove the high mounted stop lamp.
c.Remove the rear seat cushion and seat back side cover.
d.Remove the partition cover and rear package tray trim.

TAILGATE
COMPONENTS
TRUNK LID
COMPONENTS
COMPONENTS
INSTALLATION
1. Using a cutter knife or the special tool, scrape the oil sealant smoothly to a thickness of about 2 mm on the
bonding surface around the entire windshield flange.
Be careful not to remove more adhesive than necessary, and also not to damage the paint work on the body
surface with the knife. If the paint work is damaged, repair the damaged area with touch-up paint.
2. Clean the body bonding surface with a sponge dampened in alcohol or wax and grease remover.
3. Install the cowl top cover mounting screws at the locations as shown in illustration.
4. Center a new windshield in the opening.

Mark the location by scribing lines across the glass and body with a grease pencil at the four points as shown.

5. Glue the rubber dam to the inside surface of the windshield around the entire edge as shown, to contain the
sealant during installation.

a.Do not apply body primer to the glass.
b.Never touch the primed surfaces with your hand. If you do, the adhesive may not bond to the glass
properly, causing a leak after the windshield is installed.

a.Clean the plate with a sponge and alcohol before mixing.
9. Pack adhesive into the cartridge, avoiding air pockets, to ensure continuous delivery. Put the cartridge in a
caulking gun or sealant gun, and run a bead of adhesive around the edge of the glass as shown.
10. Using suction cups or special tool (09861-31300), lower the glass over the opening, align it with the marks
made in step 4, and set it down on the sealant. Insert two lower spacers to prevent the windshield from
moving downward.
11. Scrape or wipe excess adhesive off with putty knife or gauze. Fill all cavities around the windshield.

12. Perform the water-test for the windshield. Use a cold water spray, being careful not to direct a powerful
stream of water on the new adhesive material. Allow water to spill over the edges of the glass.
13. If there are leaks, apply sealant at the leak points.


14. Install the cowl top cover.
Reinstall the front pillar trims and wiper arms.
Make sure the sealant has set sufficiently before putting the vehicle back into operation.

REMOVAL
1. Pry out the clips by hand.
2. Remove the front pillar trim.
3. To remove the windshield, first remove the following parts:

(1)Wiper arms.
(2)Cowl top cover.
4. Use the special tool (09861-31100) to cut through the windshield sealant.
5. Make mating marks on the glass and body if the glass is to be reinstalled.
Use chalk or equivalent to make mating marks on the glass and body.
6. Take out the windshield glass with special tool, Glass Holder.


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Workshop Manual

Ebay User ID: reveleus1

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2. Remove the rear mud guard.

3. Remove the rear bumper cover assembly.

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4. Remove the rear bumper beam and bumper cover bracket.

2. Remove the rear wiper washer reservoir tank.

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5. Remove the rear bumper rail mounting bolt (2EA).

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6. Remove the rear bumper cover ass'y.

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2. Remove the turn signal lamp.

3. Remove the lower side front bumper cover.

4. Remove the front bumper cover assembly.

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5. Remove the front bumper beam.

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2. Remove the rheostat

3. Remove the center facia panel mounting screws.

5. Remove the console assembly.

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Ebay User ID: reveleus1

Ebay User ID: reveleus1

Ebay User ID: reveleus1

2. Remove the steering column lower and upper shroud.

3. Remove the multifunction switch.

4. Remove the cluster facia panel.

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5. Remove the cluster assembly and disconnect the connectors.

7. Remove the hood release handle mounting screws.

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8. Remove the crash pad lower cover and bracket.

9. Remove the console upper cover.

10. Remove the rheostat.

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11. Remove the heater control cable. (LH side)

14. Remove the console.

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