BO5

FRONT DOOR
COMPONENTS
DISASSEMBLY
1. Removal of regulator handle (Front door without driving
motor)
(1) Remove the spring with cloth. Remove the regulator
handle and plate.
2. Removal of inside handle and pull handle
(1) Remove the inside handle and pull handle from the
door trim panel by removing the set screws.

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1 Door glass run
2 Door glass
3 Door locking button
4Door lock cylinder
5 Lock cylinder retainer
6 Door lock
7 Door glass inner weatherstrip
8 Control motor
9 Service hole cover
! Inside handle
" Pull handle
# Door trim
$ Garnish
% Door glass outer weatherstrip
& Front lower frame
( Front door window regulator
) Regulator handle (W/O power window)
~Power window regulator motor
+ Door trim bracket No. 1
, Outside handle
- Door weatherstrip
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LBO00018-00016
LBO00017-00015
LBO00019-00017
(1002-ED1)
BO(01-10) 10/9/02, 18:15 5
BO6
3. Removal of door locking button
(1) Remove the locking button.
5. Removal of door trim panel
(1) Remove the trim panel from the door panel by pulling
the door trim panel.
(2) Disconnect the power window switch connector.
6. Removal of Bracket, Door Trim No. 1.
(1) Remove the bracket from the door panel by removing
the two screws.
7. Removal of service hole cover
NOTE:
Be very careful not to allow the butyl tape to stick to
other parts during the removal.
4. Removal of outer rear-view mirror (Front door without
driving motor)
(1) Remove the garnish.
(2) Remove the mirror by removing the three set nuts.
LBO00020-00018
LBO00021-00019
LBO00022-00020
LBO00023-00021
LBO00024-00022
(1002-ED1)
BO(01-10) 10/9/02, 18:15 6
BO11
8. Installation of door mirror (motor driven type)
(1) Pass the mirror harness through the door panel.
(2) Install the mirror to the door panel with the three set
nuts.
9. Installation of door harness
(1) Insert the harness clamp through the clamp hole of
the door panel.
(2) Connect wiring for the power lock and door mirror
connector.
10. Installation of outer weatherstrip
(1) Insert the clip to the clip hole securely.
11. Installation of door glass
(1) Using the regulator handle or the power window
switch, turn the regulator in such a way that the glass
set bolt may come to the service hole position.
(2) Install the glass to the regulator with the two set bolts.
Tightening Torque: 5.88 - 8.82 Nm
NOTE:
Move the glass up and down several times to ensure
that the glass moves smoothly.
Make sure that the regulator and glass will not inter-
fere with the wire harness or connector.
12. Installation of service hole cover
(1) Affix butyl tape along the groove of the door panel.
(2) Push lightly the entire periphery of the service hole
cover so that the service hole cover may contact with
the butyl tape without any gap.
NOTE:
When affixing the butyl tape, never stretch it.
Never reuse the service hole cover if it has ruptured.
Be sure to affix the butyl tape in such a way that water
flows into the drain without fail.
When affixing the tape, be careful not to make
wrinkles.
LBO00045-00043
LBO00046-00044
LBO00047-00045
LBO00048-00046
LBO00049-00047
BO(11-20) 10/9/02, 18:16 11
BO12
Front
45
13. Installation of inside handle and door trim No. 1 bracket
(1) Connect the inside handle with the door opening
control link.
(2) Install the door trim No. 1 bracket with the two
screws.
14. Installation of door trim
(1) Connect wiring at the connector of the power window
switch.
(2) Securely insert the retainer of the door trim into the
door panel.
15. Installation of inside handle and pull handle.
(1) Install the inside handle and pull handle with the
screws.
16. Installation of door lock button
(1) Install the lock button to the open control link.
17. Installation of regulator handle
(1) Fully close the door glass.
(2) Install the handle at an angle shown in the right fig-
ure. Insert the snap ring.
LBO00050-00048
LBO00051-00049
LBO00052-00050
LBO00053-00051
LBO00054-00052
(1002-ED1)
BO(11-20) 10/9/02, 18:16 12
BO13

1. Door gap adjustment

(1) Loosen the hinge bolt at the body side (front pillar
side) and perform the adjustment.
1 Fender front door
Specified Value of Gap: 4.71(3.7-5.7) mm
2 Side outer panel door frame
Specified Value of Gap: 5.31(4.3-6.3) mm
FRONT DOOR ADJUSTMENT
2. Door lock striker adjustment
(1) Check to see if the door installation and lock linkage
adjustment have been performed correctly.
(2) Lightly loosen the striker attaching bolt.
(3) Adjust the striker position with a plastic hammer.
NOTE:
Affix protective tape to the paint surface to protect the
surface from being scratched.
LBO00055-00053
LBO00056-00054
LBO00057-00055
BO(11-20) 10/9/02, 18:16 13
BO14

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1 Rear door glass
2 Quarter window glass
3 Quarter window weatherstrip
4 Division bar
5 Control motor
6 Door locking button
7 Outside handle
8 Door lock
9 Service hole cover
! Door glass inner weatherstrip
" Pull handle
#Inside handle
$Door trim board
%Door glass filler
&Door glass channel
(Door glass run
) Door glass outer weatherstrip
~Door glass filler
+ Rear door regulator
,Regulator handle (W/O power window)
-Door weatherstrip
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REAR DOOR
COMPONENTS
DISASSEMBLY
1. Removal of regulator handle
(1) Remove the snap ring with cloth.
2. Removal of inside handle and pull handle
(1) Remove the inside handle and pull handle by remov-
ing the screws.
LBO00058-00056
LBO00059-00057
LBO00060-00058
(1002-ED1)
BO(11-20) 10/9/02, 18:17 14
BO15
3. Removal of locking button
(1) Remove the locking button from the control link.
4. Removal of door trim
(1) Pull the door trim panel.
(2) Disconnect the power window switch connector (if so
equipped).
5. Removal of service hole cover
NOTE:
Be very careful not to allow the butyl tape to stick to
other parts during the removal.
LBO00062-00060
LBO00061-00059
LBO00064-00062
6. Removal of door glass
(1) Using the regulator handle (or the power switch) turn
the regulator in such a way that the rail section may
come to the service hole position.
(2) Remove door glass run.
(3) Remove the devision bar attaching bolt and screw.
LBO00065-00000
7. Removal of regulator
(1) Lowered the regulator to the lowest position and
remove the four regulator set bolts.
(2) Remove the regulator assembly by removing the
roller from the rail section of the door glass channel.
LBO00066-00063
(1002-ED1)
BO(11-20) 10/9/02, 18:17 15
BO16
8. Removal of quarter window glass
(1) Pull out the glass run from the door frame and loosen
the division bar.
(2) Remove the division bar attaching bolt and screw.
(3) Remove the quarter window with the strip.
9. Removal of door glass
(1) Take out the door glass upward.
LBO00067-00065
LBO00068-00066
LBO00069-00067
LBO00070-00068
10. Removal of door lock
(1) Remove the door open control link from the outside
handle.
(2) Remove the door open control link from the door
lock.
(3) Remove the door lock from the door panel by remov-
ing the three set screws.
LBO00071-00069
BO(11-20) 10/9/02, 18:17 16
BO21
!1
w
e
!2
y
o
i
r
t
1 Back door glass
2 Door lock cylinder
3 Lock cylinder retainer
4 Back door stay
5 Door lock
6 Back door lock striker
7 Back door service hole cover
8 Grommet
9 Back door glass lower moulding
! Tapping screw
" Back door garnish
# Open control link
!0
q
u
BACK DOOR
COMPONENTS
DISASSEMBLY
1. Removal of wiper arm
(1) Remove the wiper arm with blade by removing the
set nut.
2. Removal of high mount stop lamp (if so equipped)
(1) Remove the stop lamp by removing the three set
screws.
(2) Disconnect the stop lamp harness connector.
LBO00094-00092
LBO00095-00093
LBO00093-00091
(1002-ED1)
BO(21-30) 10/9/02, 18:19 21
BO22
3. Removal of back door service cover hole
(1) Remove the inner panel by removing the eight set
screws and two grommets.
NOTE:
Remove the two retainers in a state as they are in-
stalled to the inner panel.
6. Removal of back door garnish
(1) Remove the two clips and four nuts.
(2) Disconnect the connector of the license plate lamp.
5. Removal of wire harness
(1) Remove the grommet and earth cable. Remove the
wire harness from the door panel.
4. Removal of wiper motor
(1) Remove the three set bolts.
(2) Disconnect the motor connector.
LBO00096-00094
LBO00097-00095
LBO00098-00096
LBO00099-00097
7. Removal of license plate lamp
(1) Pry out and push the license plate lamp clip from
back door garnish.
(2) Disconnnect the connector of the license plate lamp
by push out the clip.
LP8 EPS
LBO00220-00205
BO(21-30) 10/9/02, 18:19 22
BO23
9. Removal of back door stay
(1) Detach the clip of the quarter trim.
(2) Remove the door stay by removing the two set bolts
at the body side.
10. Removal of door lock
(1) Remove the two set bolts.
(2) Remove the door open control link. Remove the door
lock from the panel.
LBO00102-00100
LBO00101-00099
8. Removal of lock cylinder
(1) Remove the door open control link from the lock cyl-
inder.
(2) Remove the retainer. Remove the lock cylinder from
the door panel.
LBO00100-00098
(2) Remove the license plate lamp lens from the housing
by pushing out the clips.
LBO00221-00206
LBO00222-00207
INSTALLATION
(1) Reverse the removal procedure to perform installation
(1002-ED1)
BO(21-30) 10/9/02, 18:19 23
BO24
ASSEMBLY
Reverse the disassembling procedure to perform the assem-
bly.
1. Apply MP grease to the moving sections of the door lock.
2. Installation of back door stays (right and left position)
(1) After installing the stays, clip the quarter trim to the
panel securely.
Tightening Torque: 4.0 - 6.0 Nm
3. Installation of wire harness
(1) Install the wire harness grommet and earth cable se-
curely.
LBO00103-00101
LBO00104-00102
LBO00105-00103
4. Installation of wiper motor
(1) Connect wiring securely at the connector of the mo-
tor.
5. Installation of lock cylinder
(1) Securely insert the retainer into the groove section of
the lock cylinder.
(2) Securely install the open control link.
LBO00106-00104
BO(21-30) 10/9/02, 18:19 24
BO25
2. Lock striker adjustment
(1) Adjust the lock striker by loosening the bolts.
Tightening Torque: 4.0 - 6.0 Nm
LBO00108-00106
LBO00109-00107
LBO00110-00108
6. Installation of license plate lamp, high-mount stop lamp
and wiper motor harness
(1) Perform clamping securely. Also securely connect
wiring at the connector.
CAUTION:
Be very careful not to allow foreign matters to get to
the rod of the door stay to be reused. Also care must
be exercised not to scratch the rod.
Before disposing of the door stay, make sure to re-
lease the sealed gas completely by making a hole at
the bottom of the cylinder.
BACK DOOR ADJUSTMENT
1. Adjustment of gaps with roof panel and side outer panel
(1) Lightly loosen the two hinge set bolts (at the right and
left) and adjust the installation position.
Tightening Torque: 10 - 15 Nm
(1002-ED1)
BO(21-30) 10/9/02, 18:19 25
BO26
Service hole
FRONT BUMPER & REAR BUMPER
FRONT BUMPER
REMOVAL
1. Removal of signal lamp.
(1) Look for the service hole behind the bumper and un-
derneath the lamp (use a flashlight if necessary).
Insert a screwdriver through the hole and use it to
push and pry the lamp out.
(2) Disconnect the connector of signal by turn it
anticlock wise.
REAR BUMPER
REMOVAL
1. Removal of rear mud guard (if so equipped)
(1) Remove the mud guard from the rear bumper cover
by removing the four clips.
2. Removal of rear bumper cover
(1) Remove the bumper cover from the body back panel
by removing the five set bolts and two screws.
LBO00111-00109
LBO00112-00110
LBO00113-00111
LBO00114-00112
LBO00115-00113
2. Removal of bumper
(1) Remove the bumper by removing the seven set bolts
and two screws.
INSTALLATION
Reverse the removal procedure to perform the installation.
NOTE:
During the installation, care must be exercised so that
the bumper-to-fender gap and the bumper-to-hood
gap may be uniformed.
Do not scratch the FR bumper.
(1002-ED1)
BO(21-30) 10/9/02, 18:19 26
BO41
5. Removal of cowl top ventilator louver
(1) Remove the ventilator louver by detaching the eleven
clips.
LBO00165-00157
BO00096-99999
BO00098-99999
BO00099-99999
5. Removal of front window door glass
Push the lip section of the weatherstrip outward from the
body flange, using a common screwdriver or a bamboo
spatula. This operation is performed from the vehicle
interior.
NOTE:
Be very careful not to scratch the body paint finish
surface. Remove the front door glass weatherstrip
from the front door glass.
INSPECTION AND CLEANING
Clean the adhesion sections of the glass and body, using a
solvent such as alcohol or white gasoline.
(2) Soap water application
Apply soap water to the body flange contact sections
of the weatherstrip. Also, apply soap water to the
body flange.
INSTALLATION
1. Install the front door glass, as follows:
(1) Set an operation rope to the weatherstrip.
NOTE:
Never reuse any weatherstrip which exhibits
deterioration. Failure to observe this instruction will
cause water leakage.
Operation rope
(1002-ED1)
BO(41-50) 10/9/02, 18:21 41
BO42
BO00101-99999
BO00100-99999
BO00102-99999
2. Install the inner rear-view mirror assembly with two bolts.
3. Install the cowl top ventilator louver and hood-to-cowl top
weatherstrip.
(6) Apply non-drying window sealer to those contact
surface between the weatherstrip and the body.
Glass x Weatherstrip:
Periphery (dotted line section)
Weatherstrip x Body (real line section)
(3) Fit the windshield glass in such a way that the center
part of the weatherstrip section may be fitted into the
body flange.
(4) Hold the one end of the rope that is suspending in the
vehicle interior. Pull the rope in such an angle that
allows the weatherstrip to cross over the flange. While
so doing, pound the surface of the glass at points
adjacent to the weatherstrip using ones palm from
the outside of the vehicle in order that the windshield
may be installed into position.
(5) Furthermore, pound the surface of the glass using
ones palm from the outside of the vehicle so that the
windshield may be settle in place.
NOTE:
To prevent glass breakage do not excert too much.
(1002-ED1)
BO(41-50) 10/9/02, 18:21 42
BO43
BO00103-99999
4. Installation of windshield wiper arm assembly
(1) Operate the wiper motor, until it assumes the
automatic stopping position.
(2) Set the wiper arms at the positions indicated in the
right figure.
(3) Tighten the nut and attach the front wiper arm cover.
5. Water leakage check and repairs
(1) Perform the water leakage check after the adhesive
agent has hardened. If the water leakage exists, dry
the leaky point. Then, repair the leaky point by pack-
ing the sealer.
6. Install the following parts given below.
(1) Cowl louver
(2) Wiper arm
(3) Front pillar garnish
(4) Inner rear-view mirror & room lamp
(5) Sun visor & assist grip
(6) Instrument panel
LBO00180-00000
LBO00181-00000
(1002-ED1)
BO(41-50) 10/9/02, 18:21 43
BO44
A
A
B
B
5
3
Butting position of dam
A
A
Butting position of clip
A B
B B
BACK DOOR WINDOW
INSTALLATION
NOTE:
Perform the preparation for applying the adhesive
agent in the same procedure as with the windshield
installation. (Refer to the section under Front Wind-
shield.)
1. Installation of locating clips
(1) Insert the spacer and lower moulding into the
backdoor window.
(2) Insert the clip into the clip hole of the body.
(3) Peel off the adhesive seal of the clip.
(4) Push the glass onto the clips, while keeping the
positional relationship shown in the right figure.
(5) Remove the glass with the clips attached.
4. Water leakage check
(1) Perform the water leakage check after the adhesive
agent has hardened. If the water leakage exists, re-
pair the leaky point by packing the sealer.
3. Installation of glass
(1) Apply adhesive agent to the glass. (Refer to the right
figure.)
(2) Insert the clip section of the glass into the clip hole of
the body.
(3) Have the adhesive agent fully contacted by pushing
the entire glass lightly.
2. Application of primer
(1) Affix the spacer and molding.
NOTE:
(The molding should be butted at the marking section
at the center/lower edge of the glass.)
(2) Apply the primer M to the body; primer G to the
glass. (Refer to the section under Front Windshield.)
LBO00187-00000
LBO00188-00177
LBO00189-00178
LBO00190-00179
LBO00191-00000
(1002-ED1)
BO(41-50) 10/9/02, 18:21 44
BO47
BO000112-99999
REMOVAL
Main points of removal
1, 2 Roof drip molding
1. Insert a common screwdriver between the roof drip
center molding and the body (at around the central
portion of the roof drip center molding). Then, lift up
the roof drip molding.
NOTE:
Be sure to affix protection tape to the body so that
no damage may be made to the body when you pry
out the molding with the common screwdriver.
2. As for the front and rear ends of the molding, remove
the adhesive agent layers formed between the roof
drip molding and the body, using a knife or the like.
NOTE:
1. When removing the adhesive agent layer, be sure
to leave a layer of about 1 mm thickness.
2. Be sure to affix protection tapes to the body in
advance so that no damage may be made to the
body.
ROOF DRIP MOLDING
Tolls, grease and others
BO000110-99999
BO000111-99999
COMPONENTS
Shape and item Use
Sealer gun Adhesive agent application
Tools
Wooden round bar Diameter: 6 mm
Length: The bar must be long enough for it to be
held by one hand. About 20 cm
For pressing roof drip finish center molding
Tape Protection of body surface
Alcohol and white gasoline Cleaning of installation surface of roof drip molding
Beta seal 552 (Urethane sealant) Application of roof drip finish molding
Grease and
others
BO(41-50) 10/9/02, 18:21 47
BO48
BO00113-99999
3. After the adhesive agent has been applied, within three
minutes affix the molding. This attachment must be
performed by aligning the molding with the affixing
reference lines at the front and rear ends. Then, press the
molding, using fingers or tolls.
4. Push the center molding into the rear end of the front
molding. (Overlapping length: about 10 mm)
5. Push the entire parts of the molding into the roof groove
so as to secure the, molding.
Handling instructions on Beta seal 552
1. Stock the Beta seal 552 in a cold, dark and dry place.
(This instruction is important owing to the Beta seals
properties of quick curing.)
2. The Beta seal 552 cures within two or three days after the
opening of the tube (cutting of the nozzle). Therefore,
open the tube immediately before the use.
BO00114-00000
BO00117-00000
(1002-ED1)
BO(41-50) 10/9/02, 18:21 48
BO61
BO00151-99999
BO(61-70) 10/9/02, 18:23 61
BO62
BO00152-99999
BODY SECTIONAL CONSTRUCTION
The following is the main section at various sections of the body. This construction assures adequate
rigidity with light weight.
P
M
O
L
A Section
B Section C Section D Section
A
B
D
C
E
F
G
K
H
U
N
J
I
J
(1002-ED1)
BO(61-70) 10/9/02, 18:23 62
BO67
A section
(For hood seal) (For front
window)
E, F section
B section C section
H section I section J section
C
E
F
D
B
A
Adhesive
All round
All round
Glass, Back door
1
0
2
0
J
I
H
BO00157-99999
WHETHER STRIPS
The front whether strip employees with the hollowed type so that the water-proof and the reducing of
wind noise have been improved as indicated.
BO(61-70) 10/9/02, 18:23 67
BO68
BO00197-99999
FLOOR CARPET
COMPONENTS
BO00195-99999
REMOVAL
1. Remove the front seat assembly (driver and
passenger) by removing the eight bolts.
2. Remove the rear seat cushion by removing the two
bolts.
3. Remove the shift lever knob.
4. Remove the door opening trims. (see page BO61.)
BO00196-00000
BO00198-99999
5. Remove the two clips attaching the luggage carpet.
6. Remove the front floor carpet by detaching the carpet
welt sections.
7. Remove the two clips attaching the front floor carpet.
8. Remove the brace, dash panel to cowl at the bottom
side by removing the bolts.
BO(61-70) 10/9/02, 18:23 68