Body.pdf

BodyGENERAL

EXTERIORFRONT DOORFOLDING DOORFOLDING DOOR ENGINE ASSEMBLYSWING DOORSWING DOOR CONTROL ASSEMBLYFRONT BUMPERREAR BUMPERREAR LUGGAGE FLAPGARNISH

INTERIOR

HEADLININGINSTRUMENT PANELFRONT WINDOWDRIVER’S WINDOWFOLDING DOOR GLASSSWING DOOR GLASSSIDE GLASS RH NO.1SIDE SAFETY GLASSSIDE SLIDING WINDOWSIDE FIXING WINDOWREAR WINDOWDRIVER’S SEATPASSENGER SEATSEAT BELT

BD -2 BODY

GENERAL

SPECIFICATION E946E71E

Item Specifications

Construction Front hinged, Full door construction

Regulator system Wire drum typeDoor

Locking system Pin - fork type

Windshield glass 6.76(0.27)

Door glass 5.0(0.2)Glass Thickness mm(in.)

Rear glass 5.0(0.2)

Seat belt E.L.R type

E.L.R : Emergency Locking Retractor

TIGHTENING TORQUE

Tightening TorqueItem

Nm Kgf.m Ib - ft

Door hinge to body 20~29 2.0~3.0 14.4~21.6Door

Door hinge to door 20~29 2.0~3.0 14.4~21.6

Upper anchor mounting bolt 39~54 4.0~5.5 28.9~39.7

Seat belt height adjustermounting bolt

39~54 4.0~5.5 28.9~39.7

Retractor mounting bolt 39~54 4.0~5.5 28.9~39.7

Seat belt

Buckle mounting 39~54 4.0~5.5 28.9~39.7

Bolt 34~54 3.5~5.5 25.3~39.7Seat

Nut 37.3~68.6 3.8~7.0 27.5~50.6

GENERAL BD -3

GENERAL SAFETY INFORMATION EBFA6531

PRECAUTIONS FOR ELECTRIC WELDING

WARNING

When electric-welding the electronic parts whichare con nected directly to the battery, current inthe welding machine can flow through the ground-ing circuit to these parts, thus damaging them.Follow below procedures surely.

1. Turn off all of the electric switches in vehicle.

2. Remove the (-) Battery.

3. Disconnect all of grounding circuits earthed in vehicle,insulate the current using rubber and etc.

NOTERefer the Electrical Troubleshooting Manual in rela-tion position of ground terminal.

4. Disconnect all ECU and controller connector.Engine control system : ECU or ECMBrake control system : ABS ECUThe other system : ETACS

NOTE

Refer the Electrical Troubleshooting Manual in rela-tion position of ground terminal.

5. Do not earth grounding circuit in the welding machineto the fuel tank.

6. The welding spark should be contacted to the fueltank.

7. When tightening ground terminal to the body, cleanthe neighborhood of body and tighten it with specifiedtorque.

Tightening torque.Item Outer Diameter of

bolt(mm) Nm kgf·m lb-ft

Battery (+) cable tightening M8 8.83~13.73 0.9~1.4 6.51~10.13

Battery (+) terminal M8 8.83~13.73 0.9~1.4 6.51~10.13

Battery (-) cable tightening M10 18.63~27.46 1.9~2.8 13.74~20.25

Battery (-) terminal M6 3.92~5.88 0.4~0.6 2.89~4.34

Starter motor M8 9.81~11.77 1.0~1.2 7.23~8.68

Alternator "B" terminal M8 8.83~13.73 0.9~1.4 6.51~10.13

Engine grounding strap M10 18.63~27.46 1.9~2.8 13.74~20.25

Main Fuse box M8 8.83~13.73 0.9~1.4 6.51~10.13

BD -4 BODY

EXTERIOR

FRONT DOOR

COMPONENTS E852DA41

2

1

4

3

5

6

7

1. Front door outside handle2. Door latch3. Front door inside handle4. Front door lower trim flange5. Full handle6. Front door inside handle bezel7. Front door trim

ECOBD5001A

EXTERIOR BD -5

REMOVAL EC5BE638

1. Remove the front door inside handle housing(A).

A

KCOBD5502A

2. Revove the cap using a sharp screwdriver.

3. Remove door pull handle.

KCOBD5503A

4. Remove the front door lower trim flange(A).

NOTEWhen using with a flat tip screwdriver, wrap it with ashop towel to prevent damage in the paint.

A

KCOBD5504A

5. Loosen the door trim panel screws and by using thetrim panel remover, remove the door trim panel(A).

A

KCOBD5505A

BD -6 BODY

6. Remove the door outside handle

1) Remove the 2 links.

2) Remove the 2 bolts.

3) Using a screwdriver wrapped with protectivetape, remove the outside handle.

KCOBD5506A

7. Remove the door key cylinder (A) after removing thehandle mounting bolt.

A

KCOBD5507A

8. Remove the door inside handle.

1) Remove the tapping screw.

2) After removing the 2 links and loosening the 2screws, remove the door inside handle.

KCOBD5508A

9. Remove the door latch assembly.After removing the 3 screws, remove the door latchassembly(A).

A

KCOBD5509A

EXTERIOR BD -7

INSTALLATION E0C7DDD0

1. Grease applicationApply grease to each protrusion part of the door latchassembly.

2. Front door key cylinder assemblyInstall the door key cylinder(A) to the front door out-side handle.

A

KCOBD5507A

3. Front door outside handle installation

1) Push the front door outside from the door paneloutside until it fits in mesh.

2) Engage the front door outside handle togetherwith the key cylinder.

3) Install the front door outside handle with 2 bolts.

KCOBD5506A

4. Installation of front door latch assembly

1) Install the front door latch assembly(A) withscrews.

2) Install the 2 links.

A

KCOBD5509A

5. Front door inside handle installation

1) Install the 2 links.

KCOBD5510A

BD -8 BODY

2) Install the front door inside handle(A) withscrews.

KCOBD5508A

6. Front door trim installation

1) Install the front door trim(A) by tapping 12 clipportions until they fit in mesh.

2) Install screws.

A

KCOBD5505A

7. Install the front front door trim lower flange(A).

A

KCOBD5504A

8. Pull handle installation

1) Install the pull handle with 2 screws.

2) Install the cap.

KCOBD5503A

9. Install the front front door inside handle vessel(A).

A

KCOBD5502A

EXTERIOR BD -9

FOLDING DOOR

COMPONENTS E027B1FC

1. Inside full handle2. Folding door front molding upper3. Door hinge4. Folding door rear molding upper5. Rubber bumper

6. Folding door insertion rubber7. Folding door insertion rubber8. Plate & lower sealing weather strip9. Stopper bracket

1

2

4

3

9

8

3

9

5

7

6

3

ECOBD5002A

BD -10 BODY

REMOVAL EADFCF93

1. Remove the snap pin(A) and link pin(B) from thebracket connected to the auto folding engine assem-bly.

A

B

KCOBD5512A

2. Remove the center door hand-rail assembly(A) withremoving a screw.

A

KCOBD5513A

3. Remove the folding door front molding upper.

4. Remove the folding door rear molding upper.

5. Remove the stopper bracket(A) with removing thescrew.

A

KCOBD5514A

6. Remove the lower sealing weather strip and plate.

KCOBD5515A

7. Remove the folding door hinge(A) with removing ascrew.

A A

KCOBD5516A

EXTERIOR BD -11

8. Remove the door insertion rubbers.

KCOBD5517A

INSTALLATION E6D3B9E3

1. Apply body grease to each protrusion part.

2. Folding door insertion rubber installation

1) Take care that any part of the door insertion rub-ber does not come out of the door flange.

2) Align both upper and lower ends of the door in-sertion rubber with the door flange ends.

KCOBD5517A

3. Install the folding door hinge.

4. Install the folding door lower sealing weatherstrip.

5. Install the folding door stopper bracket.

CAUTIONAfter applying bond to the surface of rubberbumper and door stopper bracket, let them dryfor 4 minutes and attach the rubber bumper tothe door stopper bracket.(Take care not to con-taminate the adhesive portion.)

A

KCOBD5514A

6. Installation of folding door inside handrail assem-bly(A).

CAUTION

After connecting the handrail assembly, makesure that the handrail is not moving by rotatingit with hand.

NOTEApply the specific grease to all rotating and contactsurfaces.

A

KCOBD5513A

7. Install the auto folding engine assembly to the doorbody.

8. After installation, check operation of folding door.

BD -12 BODY

FOLDING DOOR ENGINEASSEMBLY

COMPONENTS E5DB72EB

2

1

3

4

5

67

8

10

1112

23

9

14

15

16

1718

19

20

21 22

13

1. Auto and manual lever2. Cap nut3. Cover 4. Time relay assembly5. Motor assembly6. Micro box7. Micro switch8. Close switch cam

9. Connector (MG 640333 SWP-4M)10. Open switch cam11. Base-A12. Operation lamp13. Door bracket14. Base plate15. Base-B

16. Buzzer assembly17. Circuit breaker18. Close stopper switch19. Open stopper switch20. Arm-A21. Arm-C22. Stroke bolt23. Arm-B

ECOBD5006A

EXTERIOR BD -13

DISASSEMBLY COMPONENTS

12 15

18

1920

21

222324

25

26

27

28

29

2

4039

37

38

3

44

47

43

45

41

4651

50

1

52

5

49

48

42

4

31

30

36

35

33

34

32

18

1716

20

19

13

14

1110

9

8

7

8

6

1. Cover2. Control lever3. Base plate4. Base-B5. Base-A6. Motor7. Motor bracket8. Coupling9. C-ring10. Bearing11. Worm gear12. Gear box-A13. Special bolt

14. Plate spring15. Control shaft16. Bolt17. Adjust plate18. Power spring nut19. Power spring-A20. Guide taper21.Rack gear22. Bearing23. Worm wheel24. Gear cover25. Internal gear26. Small gear

27. Drive shaft28. Bearing29. Gear box-B30. Time relay31. Buzzer32. Switch cam No. 1 (Close)33. Switch cam No. 2 (Open)34. Cam shaft35. Micro switch36. Bush37. Shaft38. Connection bar39. Stopper switch-A (Close)

40. Stopper switch-B (Open)41. Operation lamp42. Circuit breaker43. Arm link44. Taper pin45. Link pin46. Connection pin47. Arm-A48. Space ring49. Arm-B50. Arm-C51. Link pin52. Stroke bolt

ECOBD5007A

BD -14 BODY

REPLACEMENT ECE8681A

1. Remove the folding engine assembly arm(A) from thebracket connected to folding door body.

A

ECOBD5512A

2. Remove the 4 bolts connected to floor.

KCOBD5518A

3. The installation is the reverse of removal.

SPECIFICATION EF3519E4

Items Specifications

Rated voltage DC 24V

Circuit brake capacity 10A

Operating voltage DC 22V ~ DC 30V

Rate of rotation 5000 ~ 6000 RPM

INSPECTION EDC17FAE

INSPECTION OF COMPONENTS

1. MotorConnect the motor terminals directly to the batteryand check that the motor operates smoothly. Next,reverse the polarity and check that the motor operatessmoothly in the reverse direction. If the operation isabnormal, replace the motor.

ECOBD5008A

2. BuzzerConnect the buzzer terminals directly to the batteryand check the buzzer sounds.(Red terminal : + terminal, Black terminal : - terminal)

BlackRed

ECOBD5009A

EXTERIOR BD -15

3. Stopper switchCheck for continuity between the terminals andbracket."A" direction : ∞"B" direction : 0 Ω

<Close>

Stopper Switch

<Open>

A

B

A

B

ECOBD5010A

4. Micro switchOpen the door by halves and check for continuity be-tween the terminals.

Open micro switch/Close micro switch

Switch depressedTerminal COM and N.O : 0Terminal COM and N.C : ∞

Switch released Terminal COM and N.O : ∞Terminal COM and N.O : 0

N.O : Normally openN.C : Normally closeCOM : Common

Close microswitch

Open microswitch

COM

N.O

N.C

ECOBD5011A

DOOR CAM ADJUSTMENT

Set the control lever in manual position.

1. Close cam adjustment.

1) Close the door at the door positioned parallel ofthe body.

2) Loosen the cam mounting screws (A,C) and ad-just the close cam micro switch (Upper) for theswitch lever depressing.

3) Tighten the cam mounting screws (A,C) when theoperating lamp is on if the cam positioned prop-erly.

Close micro switch

A

C

ECOBD5012A

BD -16 BODY

2. Open cam adjustment.

1) Open the door at the door positioned a right angleof the body.

2) Loosen the cam mounting screws (A,B) and ad-just the open cam micro switch (Lower) for theswitch lever depressing.

3) Tighten the cam mounting screws (A,B) when theoperating lamp is on if the cam positioned prop-erly.Install the removed parts after adjustment and setthe control lever in auto position.

A

B

Open micro switch

ECOBD5013A

NOTEFor the safety, be care of below description.1. Not for battery discharged, operate the door

when engine is running.2. If battery voltage is below 22V, the driving force

of motor is weakened and the door may not beoperated.

3. For the door normally operate, the door controlswitch fully operate.

4. Be care not catch in the door when the door isoperating.

5. Be care not spatter water in the door engine.6. To avoid troubles, do not change wiring or

switches in the door engine.7. If the circuit breaker operates, repair as neces-

sary and reset the circuit breaker.8. Regularly check the door operation and operating

lamp. If improper operation of the door adjust thedoor cam position.

9. Uncertainty of the trouble, does not disassembleat your disposal and see service center.

EXTERIOR BD -17

TROUBLESHOOTING E43919CC

Symptom Probable cause Remedy

Door does not operateFuse blownDoor control switch faultyWiring or ground faulty

Replace fuse and repair as necessaryReplace door control switchRepair as necessary

Buzzer sounds, but doordoes not operate

Time relay faultyMicro switch faultyImproper stopper switch ground positionWiring or ground faulty

Replace time relayReplace micro switchTighten stopper switch groundRepair as necessary

Door operates but buzzerdoes not sound

Buzzer faulty Replace buzzer

Frequently main fuse blown orcircuit breaker operates

Micro switch faultyImproper switch cam position

Motor ground shortImproper door operationWiring or ground faulty

Replace micro switchAdjust switch cam and reset thecircuit breakerRepair as necessaryCheck and repair as necessaryRepair as necessary

Motor is on when the doorfully open or close

Defect motor wiringDefect micro switch wiringImproper switch cam position

RepairRepairAdjust switch cam

Buzzer is normal, but dooroperates only one direction

Time relay faultyMicro switch faultyImproper stopper switch ground positionWiring or ground faulty

Replace time relayReplace micro switchTighten stopper switchRepair as necessary

BD -18 BODY

SWING DOOR

COMPONENTS EEBC1A70

1. Swing door rear latch2. Swing door center link3. Safety knob4. Swing door service hole cover5. Door inside handle6. Inside handle link

7. Swing door front latch8. Swing door upper trim9. Swing door lower trim10. Retainer11. Key cylinder12. Swing door checker

4

3

2

1

10

11

12

9

8

7

6

5

ECOBD5014A

EXTERIOR BD -19

REPLACEMENT EB1BBBBF

1. Remove the door inside handle(A) with removing ascrew

A

KCOBD5002A

2. Remove the swing door upper trim by using a trimpanel remover.

Clip

ECOBD5524A

3. Remove the lower arm(A) from swing door.

A

KCOBD5526A

4. Remove the swing door check assembly and pipemounting from the swing door body.

KCOBD5527A

5. Remove the upper and lower pipe(A) from the swingdoor body.

A

KCOBD5528A


CAUTIONApply the general LATCH grease to all rotationgand contact surfaces.

BD -20 BODY

DISASSEMBLY E6AFC19A

1. Remove the door inside handle(A).

A

KCOBD5040A

2. Remove the swing door upper trim by using a trimpanel remover.

Clip

ECOBD5524A

3. Remove the swing door lower trim by using a trimpanel remover.

4. Remove the door checker with removing bolts andpins.

KCOBD5527A

5. Detach the door key cylinder(A).

A

KCOBD5529A

6. Remove the door outside handle.

A

KCOBD5003A

EXTERIOR BD -21

7. Remove the door inside handle link.

KCOBD5530A

8. Remove the door front latch.

KCOBD5531A

9. Detect the door center link.

KCOBD5532A

10. Remove the door rear latch.

KCOBD5533A

BD -22 BODY

REASSEMBLY EF0C912E

1. Apply body grease to each protrusion part of theswing door center assembly and door latch assembly.

2. Install the rear latch assembly with bolts.

KCOBD5533A

3. Install the door center assembly.

KCOBD5532A

4. Install the front door latch assembly with screws.

KCOBD5531A

5. Installation of swing door outside handle assembly

A

KCOBD5003A

1) Engage the key cylinder together with the outsidehandle.

2) Install the outside handle with 4 screws.

3) Install the link.

6. Engage the swing door key cylinder(A) together withthe outside handle.

A

KCOBD5529A

EXTERIOR BD -23

7. Installation of swing door inside handle link assembly.

KCOBD5530A

1) Install the inside handle with bolts.

2) Install the knob.

3) Install the link.

8. Installation of swing door checker assembly

KCOBD5527A

1) Install the door checker with bolts.

2) Install the pin.

9. Swing door upper trim installationInstall the door trim by tapping the clips until they fit inmesh.

Clip

ECOBD5524A

10. Swing door inside handle installationInstall the door trim by tapping the clips until they fit inmesh.

11. Install the swing door inside handle (A).

A

KCOBD5002A

BD -24 BODY

SWING DOOR CONTROLASSEMBLY

COMPONENTS E7612AE3

1

2

3

4

87

6

5

30

29

28 2725

2624

23

2221

20

1914

14

15

16 1718

1312

11

10

9

1. Switch adjust cover2. Cover3. Mounting bracket4. Body5. PCB assembly6. Buzzer assembly7. Open stopper switch8. Relay and bracket assembly9. Close stopper switch10. Open stopper switch cam

11. Close stopper switch cam12. Servo motor assembly13. Base mounting bracket assembly14. Lever15. Photo sensor16. Photo sensor switch17. Circuit breaker18. Connect19. Push lever assembly20. Gear box-A

21. Gear box-B22. Switch board assembly23. Close micro switch24. Hi speed micro switch25. Hi speed and close switch cam26. Open micro switch27. Driver shaft28. Open switch cam29. Cable assembly30. Driver shaft boot

ECOBD5015A

EXTERIOR BD -25

DISASSEMBLY COMPONENTS

1. Body and cover2. Driver shaft boot2-1. Boot3. Switch adjust cover4. Mounting bracket5. Bolt6. Buzzer7. Relay and bracket8. P.C.B assembly9. Grommet10. Base mounting bracket11. Bolt12. Cable13. Key14. C-ring

15. Cam body15-1. Spacer16. Switch board17. Switch stopper18. Bearing19. Drive shaft20. Gear box-B21. C-ring22. Screw cap23. Cable holder24. Nut25. Washer26. Rack gear sub assembly26-1. Rack gear26-2. Nut

27. Spring guide28. Spring housing29. Rack gear stopper30. Push lever30-1. Cable roller cover30-2. Wire pulley31. Planetary reducer and gear housing assembly32. Gear box-A33. Push lever stopper34. Bush cap 35. Bush 36. Spring 37. Ball guide pin 38. Ball

39. Servo motor39-1. Worm40. Servo cover41. Control lever42. C-ring43. Handle44. Worm wheel45. Worm wheel46. Bearing47. Gear cover48. Bolt49. Washer50. Photo sensor switch51. Circuit breaker

12

1722

23

25

27

39-1

39

30

2430-1

26-1

2930-2

1

1314

15

16

19

20

21

31

32

44, 45

46

4748

10

50

49

51

8

7

40

28

26-226

34, 3536, 37, 38 33

41

42

43

6

9

11

49

18

15-1

32

4

5

2-1

ECOBD5016A

BD -26 BODY

REPLACEMENT E142EA90

1. Remove the retainer ring(A) , washer and mountingbolt(B) from the pipe connected to swing door.

A

B

KCOBD5525A

2. Remove the connector connected to swing door con-trol assembly.

3. Remove the mounting bolt connected to floor.

KCOBD5501A


CAUTION

After installation, check the operation of door.

SPECIFICATION EA66DCAF

Items Specifications

Rated voltage DC 24V

Door open angle 149˚ ~159˚

Circuit brake capacity 15A

Operating voltage DC22V-DC32V

INSPECTION OF COMPONENTS E1CB959C

1. MOTOR

a. Connect No. 1 inspectionConnect the motor terminals directly to the batteryand check that the motor operates smoothly. Next,reverse the polarity and check that the motor operatessmoothly in the reverse direction. If the operation isabnormal, replace the motor.

b. Connector No. 2 inspectionCheck the terminals for continuity when motor shaftoperate manually. If the continuity is repeatedly, it isnormal.

Connector No.1

Connector No. 2

ECOBD5017A

2. RELAY

Check for continuity between terminal by using an ohm-meter. Connect the each battery terminal to 85 and 86terminal. And the check to continuity 30 and 87 terminal .Continuity is normal. If the continuity is abnormal, replacethe relay.

8630 87

85

85

30

86

87

ECOBD5018A

EXTERIOR BD -27

3. BUZZER

Connect the buzzer terminals directly to the battery andcheck the buzzer sounds.(Red terminal : + terminal, Black terminal : - terminal)

BlackRed

ECOBD5009A

4. SWITCH BOARD

1. High speed micro switch2. Close micro switch3. Open switch cam4. Open micro switch5. Close stopper switch

6. Open stopper switch7. Close switch cam8. Close stopper switch cam9. Open stopper switch cam

1

2

3

4

5

6

98

7

Strong ward

Strong ward

ECOBD5019A

BD -28 BODY

Check for the continuity between the terminals.

Open micro switch Close micro switch High speed micro switch

Switch depressedTerminal 1 and 2:

Not continuityTerminal 1 and 4:

Not continuityTerminal 1 and 3:

Not continuity

Switch released Terminal 1 and 2:Continuity Terminal 1 and 4:Continuity Terminal 1 and 3:Continuity

5. PHOTO CELL

Check for the continuity of the photo cell

Condition Emitter cell Receiver cell

1 Terminal : +, 2 Terminal : - 100 Ω ~ 150 Ω 15 kΩ ~ 25 kΩ

1 Terminal : - , 2 Terminal : + ∞ ∞

If the continuity is abnormal replace the photo cell.

Receiver cell

Emitter cell

ECOBD5020A

NOTEFor the safety, be care of below description.1. Look all around of the vehicle when door oper-

ates.2. Does not open the door when the vehicle is mov-

ing.You should operate the door when the vehicle isstopped.

3. Not for battery discharge, operated the doorwhen engine is running.

4. If battery voltage is below 22V, the driving forceof motor is weakened and the door may not beoperated.

5. For the door normally operate, the door controlswitch fully operate.

6. Improve of the durability of motor, as possiblydoes not operate the door in the inclination.

7. Be care, not catch in the door when the door isoperating.

8. Be care, not spatter water in the door engine.9. To avoid troubles, does not change wiring or

switch in the door engine.10. If the circuit braker operates, repair as necessary

and reset the circuit braker.11. Uncertainty of trouble, does not assemble at your

disposal and see service center.

EXTERIOR BD -29

TROUBLESHOOTING E14A3ABD

Symptom Probable cause Remedy

Door does not operate Fuse blownDoor control switch faultyWiring or ground faulty

Replace fuse and repair as necessaryReplace door control switchRepair as necessary

Buzzer sounds, but doordoes not operate

Circuit breaker operates

Micro switch faultyRelay faulty

Repair as necessary and reset the circuitbreakerReplace micro switchReplace relay

Door operates but buzzerdoes not sound

Buzzer faulty Replace buzzer

Frequently main fuse blownor circuit breaker operates

Improper switch cam position

Micro switch faultyMotor wiring is shortRelay faultyImproper door operationImproper door catch operationWiring faulty

Adjust switch cam and reset the circuitbreakerReplace micro switchReplace motor and reset the circuit breakerReplace relay and reset the circuit breakerCheck and repair as necessaryCheck and repair door catchRepair as necessary

Motor is on when the doorfully open or close

Micro switch faultyImproper switch cam position

Replace micro switchAdjust switch cam

Buzzer is normal, but dooroperates only one direction

Relay faultyMicro switch faultyWiring faulty

Replace relayReplace micro switchRepair as necessary

Buzzer sound continuouslyand only door open

Improper photo cell positionPhoto cell faulty

Adjust photo cell positionReplace photo cell

Power is cutted, when dooroperating

Overload of the door and fuse cuttedDoes not fully close the doorin the inclinationStop the door in the fullyopened position

Repair as necessary and replace the fuseSetting the close stopper switch tothe strong wardSetting the open stopper switch tothe strong ward

Door does not locking Door catch device faultyImproper door positionImproper stopper switch cam position

Replace door catch deviceAdjust door positionAdjust switch cam position

Does not operate catchwhen door opening

Improper catch operationImproper cable positionCable faulty

Check or replace catchCheck or adjust cableReplace cable

Door operating speedis irregular

Motor shaft magnetic faultyShort or cut of motor servocover wiring

Check or replace motorReplace servo cover

BD -30 BODY

FRONT BUMPER

REPLACEMENT EE473AEB

NOTE• Using a screw driver or remover for removing

work, wind a protection tape on it.• Wear gloves for protect your hands.• Be careful that the trim and panel are not dam-

aged.

1. Disassemble the connector (A) of the both fog lamp.

A

ECOBD5021A

2. After taking off the bolt, remove the bumper (A).

A

ECOBD5311A

3. The installation is performed in the reverse order ofthe removal.

NOTE- Be ensured that the connector is firmly tightened.- The gap of the bumper and front end panel :

2.5 ~ 3.5 mm- The gap of the bumper and side panel :

4.6 ~ 5.1 mm

EXTERIOR BD -31

REAR BUMPER

REPLACEMENT EDCD2F0D

NOTE• Using a screw driver or remover for removing

work, wind a protection tape on it.• Wear gloves for protect your hands.• Be careful that the trim and panel are not dam-

aged.

1. Remove the bolt and bumper.

ECOBD5023A


NOTE

- Be ensured that the connector is firmly tightened.- The gap of the bumper and front end panel : 3.5

~ 4.5 mm

BD -32 BODY

REAR LUGGAGE FLAP

COMPONENTS EE879AB5

1. Luggage door trim2. Lifter assembly3. Garnish assembly4. Retainer5. Trunk lead key cylinder6. Luggage door latch assembly

3

6

5

4

1

2

ECOBD5408A

REMOVAL E67564AF

1. Remove the luggage flap trim.

KCOBD5534A

EXTERIOR BD -33

2. Remove the screw and the luggage flap latch.

KCOBD5535A

3. Remove the key cylinder.

KCOBD5536A

4. Remove the garnish and disconnect the connector.

A

ECOBD5508A

5. Remove the gas lifter.

KCOBD5009A

INSTALLATION EA3EBE1E

1. Installation is the reverse of removal procedure.The opening gap of luggage flap and rear body : 5.5~ 6.1 mm

NOTEApply the specific grease to all rotating and contactsurface.

CAUTION- Do not disassemble or throw the gaslifter into

fire.- Punch a hole in the gaslifter before disposal

to release the gas inside.

BD -34 BODY

GARNISH

REPLACEMENT E1A52E3A

FRONT UPPER GARNISH

1. Remove the fastener and front upper garnish (A).

A

KCOBD5538A

2. If the fastener is damaged, replace the new one.

NOTETo prevent the leakage of water, apply the sealant inthe fastener hole and install the upper garnish. Se-curely fasten the garnish in the body.

Position of fastener

ECOBD5022A

REAR GARNISH REPLACEMENT

1. Remove the fastener and front rear garnish (A).

A

KCOBD5611A

2. If the fastener is damaged, replace the new one.

NOTETo prevent the leakage of water, apply the sealant inthe fastener hole and install the rear garnish. Se-curely fasten the garnish in the body.

KCOBD5612A

INTERIOR BD -35

INTERIOR

HEADLINING

COMPONENTS E63AB4F4

1. Sunvisor2. Front-rear headlining3. Air con grill4. Speaker5. Front-front headlining6. Clock

7. Inside rear view mirror8. Sunvisor9. Room lamp10. Air con rubber11. Air con double rubber12. Ceiling No. 1 panel

13. Ceiling No. 2 panel14. Rear headlining15. Ceiling molding16. Booster ventilator17. Room lamp lens18. Room lamp

1

7

2

53

4 6

11

108

9

14

13

12

15

16

4

17

18

[Short body]

ECOBD5415A

BD -36 BODY

1. Sunvisor2. Front-front headlining3. Air conditioner radiator grill4. Speaker5. Front-rear headlining6. Clock

7. Inside rear view mirror8. Sunvisor9. Interior lamp10. Air conditioner rubber11. Air conditioner double rubber

[Long body]

56

1

2

3

11

8710

9

4

ECOBD5024A

INTERIOR BD -37

1. Ceiling No. 1 panel2. Speaker3. Speaker grill4. Ceiling molding5. Ceiling No. 2 panel

6. Room lamp7. Room lamp lens8. Booster ventilator9. Ceiling molding10. Roof headlining

11. Speaker12. Room lamp13. Room lamp lens14. Ceiling No. 4 panel15. Shelf

[Long body]

1

10

14

15

23

8

6

7

11

12

13

54

9

ECOBD5416A

BD -38 BODY

REPLACEMENT E136DFBB

FRONT HEADLINING REMOVAL

1. Remove the air conditioning grill(A).

A

KCOBD5570A

2. Remove the curtain rail.

KCOBD5574A

3. Remove the air conditioning rubbers.

ECOBD5038A

4. Remove the roof ceiling molding.

5. Remove the front-rear headlining.

KCOBD5571A

6. Remove the rear view inside mirror(A).

A

KCOBD5572A

7. Remove bolts and sunvisor assembly(A).

A

KCOBD5573A

8. Remove the front front-headlining.

INTERIOR BD -39

ROOF CEILING REMOVAL

1. Remove the room lamp(A).

A

KCOBD5575A

2. Remove the shelf(A) (If installed).

A

ECOBD5575A

3. Remove the speaker(A).

A

KCOBD5576A

4. Remove the roof ceiling No.1.

NOTEDo not bent the roof ceiling.

KCOBD5577A

5. Remove the roof vent (A), room lamp (B), speaker(C)and roof ceiling molding.

A

C

CB

KCOBD5579A

BD -40 BODY

6. Remove the rear headlining.

KCOBD5580A

7. Installation is the reverse of removal.

CAUTIONInstall the cap screw to the roof headlining.

INTERIOR BD -41

INSTRUMENT PANEL

COMPONENTS ED43972C

1. Air vent bezel2. Air vent duct3. Crash pad lower panel4. Column cover5. Ashtray6. Instrument crash pad7. Glove box8. Crash pad lower panel9. Air vent duct10. Side panel cover

1

2

3

4

5

8

9

10

7

6

ECOBD5025A

REPLACEMENT EE7EBE78

1. Remove the steering wheel. (Refer to the "SteeringSystem Group")

2. Taking off the assistant’s seat crash pad lower panelscrew (A), remove the lower panel (B).

CAUTIONUsing a screw driver or remover for removingwork, apply a tape on it to protect the parts.

A

B

ECOBD5026A

BD -42 BODY

3. Remove the tightening screw (A) for instrument faciapanel.

A

A

A

ECOBD5027A

4. Disassemble the emergency lamp connector, the foglamp connector, the heater mirror connector, cigarlight connector and the heater & air-con control con-nector.

5. Disassemble the temperature controlling switch cable(B) from the instrument facia panel (A).

NOTE

When removing the temperature controlling switch ca-ble, release the locking by pressing the cable fixingbracket (C) and lay down the cable (B) to downward.

B

A

C

ECOBD5028A

6. Taking off the cluster tightening screw (A) and disas-sembling the connector, remove the cluster (B).

A

AB

ECOBD5029B

7. Taking off the screw (A) installing the audio, disas-semble the antenna jack and the audio connector.Remove the audio unit (B).

B

A

ECOBD5030A

8. Taking off the tightening screw (A) for glove box link-age, remove the glove box out lead (B).

B

A

ECOBD5031A

INTERIOR BD -43

9. Taking off the tightening screw (A) of the glove box,remove the glove box (B).

B

A

ECOBD5032A

10. Remove the Front crash pad lower panel (A).

A

ECOBD5033A

11. Remove the fuse box cover (A).

A

ECOBD5034A

12. Remove the ventilator switch (A) and the door operat-ing switch (B).

A

ECOBD5035A

B

KCOBD5613A

13. Remove the driver’s seat side cover panel screw.

: Bolt : Screw

Fastener Locations

ECOBD5036A

BD -44 BODY

14. Remove the assistant’s seat side cover panel screwand the crash pad tightening bolt and screw.

: Bolt : Screw

Fastener Locations

ECOBD5037A

15. Remove the instrument crash pad.


INTERIOR BD -45

FRONT WINDOW

WINDSHIELD GLASS EAA0CCAA

COMPONENTS

1. Inside mirror2. Windshield weather strip3. Windshield glass4. Wiper arm5. Wiper arm head cover6. Wiper arm7. Sunvisor

2

3

1

4

5 6

7

ECOBD5409A

BD -46 BODY

REMOVAL E149282E

WINDSHIELD GLASS REMOVAL

1. Removal of wiper arm and blade.

2. Removal of right outside rear view mirror assembly.

3. Removal of inside rear view mirror assembly.

4. Removal of sunvisor assemblies (Left and right sides).

WINDSHIELD GLASS REMOVAL

1. When reusing the weatherstrip

1) Using a screwdriver wrapped with protectivetape, push the weatherstrip lip portion from theinside to the body flange outside.

2) Push the glass outward with an equal force anddisconnect the glass together with the weather-strip.

KCOBD5539A

2. When replacing the weatherstrip

1) Cut the weatherstip from the outward using aknife or equivalent.

2) After removing the glass with an equal force, dis-connect the weatherstrip by pulling it.

KCOBD5540A

WINDSHIELD GLASS INSTALLATION

1. Cleaning of windshield glass installation portionClean the glass and body installation portion withgasoline.

2. Windshield weatherstrip installationAlign the mating marks on the glass and weatherstripand install the weatherstrip.

Mating Marks

ECOBD5039A

CAUTION

Replace the weatherstrip.If the weaterstrip is worn, do not reuse it.

INTERIOR BD -47

3. Windshield glass installation

1) Set around a string in the weatherstrip groove.Make certain that the string overlaps each otherat each end.

String

ECOBD5040A

2) Apply soap solution to entire surface of the flangeand weatherstrip lip portion.

4. As shown in figure, pull one end of the strip hang-ing in the room side to the both side with maintaininghigher angle than the flange. At the same time, tapthe weather strip portion of the glass from the outsidein order to install to the glass.

CAUTIONPull the strip from the both ends of the wind shieldto the center portion and press from the outsideof the glass.

G7BD025D

1

2

3 4

5

A

B

G7BD025E

5. Inspection for leaks

6. Apply adhesive.

CAUTIONApply adhesive to where are leaks inspected.

1) Attach protective tape to the glass and body sur-faces.

2) Apply a sealer between the weatherstrip andglass, and weatherstrip and body from the out-side

3) Scrape the rough and uneven sealer smooth to-gether with protective tape.

CAUTIONLet the adhesive and sealed portion dry for about1 hour.

4) Inspect leaks.

7. Left and right sunvisor assemblies installation

8. Inside rear view mirror assembly installation

9. Outside rear view mirror assembly installation

10. Wiper arm and blade installation

BD -48 BODY

DRIVER’S WINDOW

FRONT DOOR GLASS ECF2BE8E

COMPONENTS

1. Front door glass2. Adhesive3. Front door window rear glass4. Window lock knob5. Front door window center sash cap6. Front door window glass dam

7. Front door window No. 1 piece8. Front door glass clip cap9. Front door glass clip10. Pin11. Front door window center frame12. Front door window front glass

13. Retainer14. Packing15. Front door window outer frame16. Clip

1

2

3

4

5

6

7

8

9

10

11

12

1314

4

15

16

14 13

ECOBD5410A

INTERIOR BD -49

REPLACEMENT E56645FC

FRONT DOOR WINDOW GLASS

1. Remove the clip cap and front door trim flange.

KCOBD5541A

2. Remove the clip.

KCOBD5542A

3. Using a cutter, cut the butyl tape and remove the frontdoor window frame.

KCOBD5543A

DISASSEMBLY OF FRONT DOOR WINDOW

1. Loosen the center seal mounting screw and removethe front door glass.

KCOBD5544A

2. Disassemble the front door window frame.

KCOBD5017A

FRONT DOOR FIXED GLASS

1. Remove the clip cap and front door upper trim flange(A).

A

KCOBD5020A

BD -50 BODY

2. Make hole in the fixed glass adhesive and pass thepiano wire from the inside of the vehicle through thehole. Pull the piano wire alternately from the insideand outside along the fixed glass to cut the adhesive.

KCOBD5547A

CAUTIONDo not let the piano wire touch the edge of thefixed glass

3. Remove the fixed glass by detaching the glass fas-tener.

KCOBD5021A

INSTALLATION EE893BB8

FRONT DOOR WINDOW GLASS

1. Using a cutter knife or special tool, remove the butyltape on the bonding surface. Clean the window frameand door panel bonding surface with cleaner. Applythe butyl tape in the door window frame.

2. Install the window frame to door panel and clip anddoor trim flange and clip cap.

KCOBD5542A

FRONT DOOR FIXED GLASS

1. Using a cutter knife or special, remove the adhesiveon the bonding surface. Clean the door fixed glassand door panel bonding surface with cleaner.

2. Remove the adhesive on the fixed glass if fixed glassreused.

Adhesive

ECOBD5566B

INTERIOR BD -51

3. Install male fastener on the fixed glass and femalefastener on the door frame.

KCOBD5022A

4. Apply the adhesive in the fixed and glass cleaner inthe inside of adhesive.

13.5mm

KCOBD5023A

5. Apply the sealant in the fixed glass higher than adhe-sive and install fixed glass.

12mm

KCOBD5024A

6. Install the removed parts.

10mm

8mm

KCOBD5548A

NOTELet the car stand for at least four hours after fixedglass installation.If the car has to be used with in the first 8 hours, itmust be driven slowly.

BD -52 BODY

FOLDING DOOR GLASS

COMPONENTS E1F5FB07

1. Center door glass2. Center door glass inner weatherstrip3. Center door inside pull handle

1

3

2

ECOBD5549A

REMOVAL E92DCB06

FOLDING DOOR GLASS REMOVAL

1. Disconnect the folding door inside pull handle.

2. Disconnect the folding door glass weatherstrip.

A

KCOBD5513A

INTERIOR BD -53

3. Remove the folding door glass.＜When reusing the weatherstrip＞

1) Using a screwdriver wrapped with protectivetape, push the weatherstrip lip portion towardthe body flange outside.

2) (Up and both lateral sides)Push the glass outward with an equal force anddisconnect the glass together with the weather-strip.＊ The glass together with the weatherstrip

KCOBD5550A

3) Cut the weatherstip from the outward using aknife or equivalent.

4) Remove the glass by pushing its surface withan equal force from the inside and remove theweatherstrip by pulling it.

INSTALLATION EF855DE7

FOLDING DOOR GLASS INSTALLATION

1. Preparation prior to folding door glass installationClean the glass and body installation portion withgasoline.

CAUTION

For a new glass, clean it.

2. Install the weatherstrip to the glass.

CAUTIONReplace the weatherstrip.If the weaterstrip is worn, never reuse it.

3. Folding door glass installation



3) Place the weatherstrip lateral portion to the wind-shield flange.

KCOBD5552A

BD -54 BODY

4) To install the glass, with the aid of an assistantto tap the glass around the weatherstrip from theoutside and pull strings in the inside (one stringhigher than the flange).

KCOBD5551A

5) Lightly tap the glass by hand from the outside toseat it completely.


5. Apply adhesive.

CAUTIONApply adhesive to where are leaks inspected.


2) Apply a sealer between the weatherstrip andglass and weatherstrip and body from the out-side


6. Folding door inside full handle installation

INTERIOR BD -55

SWING DOOR GLASS

COMPONENTS EA48DC2C

1. Swing door glass molding2. Swing door glass3. Pin4. Swing door glass clip

1

23

4

ECOBD5411A

BD -56 BODY

REMOVAL EABEB731

1. Remove the swing door glass clip cap, and flangetrim.

KCOBD5553A

2. Make hole in the swing door glass adhesive and passthe piano wire from the inside of the vehicle throughthe hole.Pull the piano wire alternatively from the inside andoutside along the swing door glass to cut the adhe-sive.

CAUTIONDo not let the piano wire touch the edge of theswing door glass.

Protect�tape

Adhesive�portion

ECOBD5555A

3. Remove the swing door glass by detaching the glassfastener.

Pin

ECOBD5554A

INTERIOR BD -57

INSTALLATION E1DE7ADE

1. Using a cutter knife or special tool , remove the ad-hesive on the bonding surface. Clean the door glassand door panel bonding surface with cleaner.

Adhesive

ECOBD5566B

2. Remove the adhesive on the door glass if door glassreused.

3. Install the male fastener on the door glass and femalefastener on the door frame.

4. Apply the adhesive in the door glass and glass cleanerin the inside of adhesive.

Pin

ECOBD5554A

5. Apply the sealant in the door glass higher than adhe-sive and install door glass.


NOTELet the car stand for at least four hours after swingdoor glass installation.If the car has to be used with in the first 8 hours, itmust be driven slowly.

BD -58 BODY

SIDE GLASS RH NO.1

COMPONENTS E24467C9

1. Lock knob2. Side window glass3. Side window glass dam4. Clip5. Side window frame6. Protector

1

2

3

4

6

5

[Right side window]

ECOBD5556A

INTERIOR BD -59

INSTALLATION OF SIDE GLASS RIGHTSIDE NO.1 E4F475DD

1. Attach butyl tape all around the window chassis as-sembly.Note that butyl tape should be applied to the entirearound of chassis.

CAUTIONDon’s miss any portion. It can cause leaks.

KCOBD5026A

2. Fix the window chassis assembly to body

1) Keep an opening gap within 3±0.5mm betweenthe window chassis lower surface and waist railside panel.

2) Keep an opening gap within 3±0.5mm betweenthe window chassis end line and end of body Apillar and dream rail.

3) Align the window chassis end with the door pillarend as shown in the illustration.

3. Fix the window chassis assembly to the body withclips.

CAUTION

Securely engage clips not to get loose.

KCOBD5027A

4. Insert the protector to all around of the window as-sembly and body rail flange.

CAUTIONSecurely insert the protector (A) not to get loose.

A

KCOBD5557A

BD -60 BODY

SIDE SAFETY GLASS

COMPONENTS EDAF2A16

[Safety galss]

ECOBD5041A

SIDE SAFETY GLASS REMOVAL E5E64B85

CAUTIONBe careful of the pin installed to the glass asshown in the illustration.

Pin

Adhesiveportion

ECOBD5558A

INTERIOR BD -61

1. Apply protective tape along the edge of the side safetyglass and body.

Protecttape

Adhesiveportion

Piano wire

ECOBD5559A

2. Push the piano wire through the hole between theglass and body from the inside and wrap each endaround a piece of wood.

3. Pull the piano wire in the inside and cut the adhesive.

CAUTION• Carefully cut through the adhesive around the

glass edge to prevent damage.• For the pin portion, unwrap the piano wire

from the wood in the outside, pass throughthe gap between the pin and adhesive, andthen wrap the piano wire again around thewood.

4. Hold the glass in the outside, disengage the pin, andthen remove the side safety glass.

SIDE SAFETY GLASSINSTALLATION E9EFB70B

1. Clean the body bonding (SIKA SF250PC) surfaceand glass edge (Ceramic coating portion) withcleaner (SIKA CLEANER No.1).

12mm

Spacer

Cleanerapplication arear

ECOBD5558B

CAUTION

• Apply cleaner enough.• After applying cleaner, let it dry for 5-10 min-

utes.(After cleaning, keep foreign material, espe-cially finger print getting on the surface)

2. Using a sealant gun, apply adhesive (SIKA SF250PC)to the glass.

BD -62 BODY

3. Adhesive bead figureConstantly apply adhesive to a height of 20-30mm tothe connecting portion to continue the application.

10mm

8mm

KCOBD5548A

CAUTIONAdhesive is so quickly hardening that the glassattaching procedure should be finished within 8minutes since its application to the body.

4. Safety glass attachment

1) Keep a gap to 3±1.0mm between the side paneland its all around .

KCOBD5029A

2) Press all around of the glass surface to securelyseat with butyl tape. (If not, it can cause leaks.)

3) Take care not to come sealer out, if it comes out,wipe off immediately with cleaner.

4) When attaching the safety glass, using a fastenerserved to glass, set the position from the lower toupper portion and insert the glass by pressing.

CAUTION

• Check the adhesive between the body andglass for secure adhesion.

• The glass attached should not move until theadhesive hardens completely.

5) When attaching the safety glass, keep a gapwithin 3±0.5mm between the body side paneland opening through all around.

5. Safety noticeAdhesive is poisonous, always wear mask while work-ing, especially protect your eyes, if it splashes into theeyes, wash them with clean water, and then see a doc-tor if its condition becomes serious.

INTERIOR BD -63

SIDE SLIDING WINDOW

COMPONENTS ED8C1F10

1. Side trim2. Side trim3. Protector4. Window sash5. Clip6. Lock knob7. Packing8. Side window glass9. Retainer

[Side window]

C

D

C

A

4

6

7

9

8

2

13

5

B

ECOBD5412A

BD -64 BODY

REMOVAL E42BFB7D

1. Remove the side trims and protectors.

KCOBD5030A

2. Remove the clips in the window frame.

KCOBD5560A

3. Using a cutter knife, cut the butyl tape.

4. Remove the side window frame.

ECOBD5561A

INSTALLATION E5B93E97

1. Using a cutter knife remove the butyl tape on thewindow frame and body flange. Clean the bondingsurface with cleaner on the window frame and bodyflange. Apply the butyl tape around the window frame.

2. Install the window frame on the body and clips.

KCOBD5560A

3. Install the protectors and side trims.

INTERIOR BD -65

SIDE FIXING WINDOW

COMPONENTS EDA56BF5

1. Garnish upper2. Side window garnish3. Spacer4. Window glass5. Fastener

[Fixed glass]

1

2

3

4

5

ECOBD5563A

BD -66 BODY

1. Side window garnish upper2. Side window garnish3. Spacer4. Side window garnish lower5. Quarter bench letter lopper6. Side rear glass

[Side rear window]

1

2

3

5

6

4

2

ECOBD5413A

INTERIOR BD -67

REMOVAL E8B4B683

1. Remove the clips and garnish.

KCOBD5564A

2. Apply the protect tape around the glass on the bodypanel.Make a hole in the glass adhesive and pass thepiano wire from the inside of the vehicle through thehole. Pull the piano wire alternatively from the insideand outside along the glass to cut the adhesive.

KCOBD5565A

CAUTIONDo not let the piano wire touch the edge of theglass.

3. Remove the glass by detaching the glass fastener.

[REAR SIDE WINDOW]

SIDE WINDOW REMOVAL

1. Using a flat tip screwdriver wrapped with protectivetape, disengage the clips and remove the side windowgarnish.

KCOBD5564A

CAUTIONRemove the side window garnishes from the up-per and lower portions.

2. Side window glass disassembly

CAUTIONBe careful of the pin installed to the glass asshown in the illustration.

1) Apply protective tape along the body surface ofthe side window edge.

2) Push the piano wire through the hole between theglass and body from the outside and wrap eachend around a piece of wood.

KCOBD5565A

BD -68 BODY

3) Pull the piano wire in the inside and cut the ad-hesive

CAUTION

• Carefully cut through the adhesive around theglass edge to prevent damage.

• For the fastener portion, unwrap the pi-ano wire from the wood in the inside, passthrough the adhesive of fastener, and thenwrap the piano wire again around the wood.

4) Hold the glass in the outside, disengage the fas-tener, and remove the side window glass.

INSTALLATION E05CA67D

1. Using a cutter knife, remove the adhesive on thebonding surface. Clean the glass and body panelbonding surface with cleaner.

2. Remove the adhesive on the glass if door glassreused.

3. Install the male fastener on the glass and female fas-tener on the body frame.

Spacer

Spacer

ECOBD5567A

4. Apply the adhesive in the door glass and glass cleanerin the inside of adhesive.

5. Apply the sealant in the door glass higher than adhe-sive and install door glass.


NOTE

Let the car stand for at least four hours after swingdoor glass installation.If the car has to be used with in the first 8 hours, itmust be driven slowly.

REAR SIDE WINDOW ASSEMBLY

1. Preparation prior to body side assemblyIf the cut body side adhesive is obviously protruded,scrape the rough and uneven portion smooth using aknife or equivalent.

Adhesive

ECOBD5566A

CAUTION

Don’t forget to remain some amount of adhesiveas shown in the illustration.

2. Preparation prior to side window glass assembly(When reusing the glass)

1) Remove the adhesive and spacer remaining fromthe glass.

2) Remove the damaged fastener.

3) Clean the glass with SIKA CLEANER.

4) Attach the fastener to the place shown in the il-lustration.

5) Attach the spacer to the place shown in the illus-tration.

Spacer

Spacer

ECOBD5567A

INTERIOR BD -69

3. Side window glass assembly

1) Clean the body applied with the adhesive (SIKASF250PC) with SIKA CLEANER No.1.

CAUTION• Do not coat too thick.• Do not apply it to the adhesive.• Take care of the welding portion to apply.• After applying cleaner, let it dry for 5-10 min-

utes and attach the glass.• After cleaning, keep foreign material, espe-

cially finger print getting on the surface.

2) Clean the glass edge (Ceramic coating portion)with cleaner (SIKA CLEANER No.1).

CAUTION• Do not apply cleaner too thick.• After applying cleaner, let it dry for 5-10 min-

utes and apply adhesive.• After cleaning, keep foreign material, espe-

cially finger print getting on the surface.

Spacer

Spacer

ECOBD5567A

4. Using a sealant gun, apply adhesive (SIKA SF250PC)to the body. (Per each window sash)

1) Adhesive bead figureOverlap adhesive to a height of 20-30mm to theconnecting portion to continue the application.

2) Adhesive hardens so quickly that the glass at-taching procedure should be finished within 8minutes since its application to the body.

CAUTIONAdhesive is poisonous, always wear maskwhile working, especially protect your eyes, if itsplashes into your eyes, wash them with cleanwater, and then see a doctor if its conditionbecomes serious.

10mm

8mm

KCOBD5548A

3) Using the fastener served to the glass and body,adjust and attach the glass to the body.

4) Press all around of the glass edge to securelyseat the adhesive between the body and glass.

CAUTION

The glass attached should not move until the ad-hesive hardens completely.

5. Leak inspection and repair

1) After hardening the adhesive, check for leaks.

2) If there are leaks inspected, apply three cementblack.

6. Side window garnish assembly

BD -70 BODY

REAR WINDOW

COMPONENTS EB804BDD

1. Rear end seat2. Outer under rear view mirror3. Rear window glass weatherstrip4. Rear window glass5. Rear wiper arm6. Rear wiper arm cover

2

1

3

4

5

6

ECOBD5414A

INTERIOR BD -71

REAR WINDOW GLASSDISASSEMBLY EBDA21EE

1. Rear wiper arm (A) removal (For the vehicle with rearwiper)

A

B

KCOBD5037A

2. Outer under rear view mirror (B) removal (For the ve-hicle with outer under rear view mirror)

3. Rear window glass removal＜When reusing the weatherstrip＞

1) Using a flat tip screwdriver wrapped with protec-tive tape, remove the weatherstrip lip part fromthe body flange by prying the body flange edgesoff (Upper and both lateral sides).

2) Pull the glass by equally pushing its surface withan equal force from the outside and disassembleit together with weatherstrip.

KCOBD5568A

＜When replacing the weatherstrip＞

3) Cut around the weatherstrip using a knife orequivalent.

4) Remove the glass by pushing its surface withan equal force from the outside and remove theweatherstrip by pulling it.

REAR WINDOW GLASS ASSEMBLY E8B9F23B

1. Cleaning of rear window glass assembly portionClean the glass and body assembly portion with gaso-line.

2. Rear window weatherstrip assemblyAssemble the weatherstrip to the glass.

CAUTIONReplace the weatherstrip.If the weaterstrip is worn, never reuse it.

3. Rear window glass assembly



3) Place the weatherstrip lower portion to the win-dow flange.

KCOBD5569A

BD -72 BODY

4) To install the glass, with the aid of an assistantto tap the glass around the weatherstrip from theoutside and pull strings in the inside (one stringhigher than the flange).

5) Lightly tap the glass by hand from the outside toseat it completely.


5. Apply adhesive.

CAUTION

Apply adhesive to where are leaks inspected.


2) Apply a sealer between the weatherstrip andglass, and weatherstrip and body from the out-side


CAUTIONLet the adhesive and sealed portion dry for about1 hour.

4) Inspect leaks.

INTERIOR BD -73

DRIVER’S SEAT

COMPONENTS E0336FE0

1. Seat buckle belt2. Seat back cover3. Seat back pad4. Seat back frame5. Seat cushion cover6. Recycling adjuster7. Seat cushion pad

8. Seat cushion frame9. Seat track10. Seat equalizing wire11. Seat outside shield12. Lumber support lever13. Lumber support

1

2

6 13

3

4

12

5

8

9

10

11

7

ECOBD5417A

BD -74 BODY

REMOVAL E27CB8D6

1. Loosen the seat mounting bolts and disconnect theseat belt connector.

KCOBD5581A

2. Remove the front seat belt rest assembly.

3. Remove the front seat inner belt assembly.

KCOBD5582A

4. Remove the reclining adjust release handle and outside shield.

KCOBD5583A

5. Remove the screw and outside shield.

ECOBD5583A

6. Remove the seat back.

KCOBD5585A

7. Remove the reclining adjust assembly.

KCOBD5586A

INTERIOR BD -75

8. Remove the seat cushion.

KCOBD5587A

9. Remove the lumber support lever.

KCOBD5588A

10. Separation of lumber support assembly (For the vehi-cle with lumber support)Remove the 2 bolts and disconnect the lumber sup-port assembly from the front seat back frame.

KCOBD5589A

11. Separation of front seat cushion cover assembly

1) Separate the seat cushion frame in mesh of theseat cushion cover as shown in the illustration.

2) After detaching the hog ring, disconnect the frontseat cushion cover and seat cushion pad from theseat cushion frame.

KCOBD5590A

BD -76 BODY

FRONT SEAT ASSEMBLY ED2A1C0E


KCOBD5591A

CAUTION

Do not dirt or damage the seat cover while assem-bling.

2. Install the hog ring for seat cover using a hog ringprimer.

CAUTIONTake care not to make wrinkles while installing thehog ring if possible.

3. If there are wrinkles in the seat cover, smooth themout using a dryer or equivalent.After that, if the wrinkles are still existed, lightly sprayit with water and dry.

KCOBD5584A

4. When assembling the seat back cover strip band tothe frame, lightly tighten the hog ring using a hog ringprimer, and lightly tighten the band not to loose or notto be damaged.

CAUTIONAfter installation, put the sub seat outer belt Cassembly into the front seat back pocket.

KCOBD5592A

INTERIOR BD -77

PASSENGER SEAT

COMPONENTS EF1F2251

[First row, No.2 Passsenger seat]

Left support seat

ECOBD5593A

BD -78 BODY

1. Plug2. Handle3. Ashtray4. Seat back board5. Arm rest

6. Seat back frame7. Seat back pad8. Seat back cover9. Seat ommer be;t10. Seat cushion cover

11. Seat cushion pad12. Outer seat belt13. Seat cushion frame14. Seat leg15. Reclining shock absorber

[First row, Passsenger's seat]

1

23

4

5

14

13

15

7

8

6

9

10

11

ECOBD5418A

INTERIOR BD -79

1. Seat back frame2. Seat back frame3. Seat back cushion4. Seat back cover5. Seat back frame spacer6. Seat back frame guide

7. Bush8. Seat back lower frame9. Assist seat cover10. Seat cushion11. Cushion frame12. Nut

13. Assist seat cushion bracket14. Clip15. Pin16. Cover

[No.2 Passsenger's support seat]

1

3

4

2

3

4

9

10

11

13

14

715

7

5

67

7

8

1612

7

With slide

ECOBD5419A

BD -80 BODY

[No.3 Support seat]

Second row support seat

ECOBD5542A

INTERIOR BD -81

1. Handle2. Bush3. Ashtray4. Seat back board5. Seat back frame

6. Seat back pad7. Seat back cover8. Seat belt9. Seat outer belt10. Seat cushion cover

11. Seat cushion pad12. Seat leg13. Assist seat

[No.3 Support seat]

12

3

4

5

6

7

9

10

13

1212

11

8

ECOBD5420A

BD -82 BODY

1. Seat back frame2. Seat back cushion3. Seat back cover4. Support seat cover5. Seat cushion

6. Cushion frame7. Support seat cushion bracket8. Cover9. Seat back frame guide10. Seat back lower frame

[No.3 Support seat]

12

3 12

3

4

5

6

7

8

10

9

ECOBD5421A

INTERIOR BD -83

REPLACEMENT EC271A7E

SEPARATION LEFT SUB ASSEMBLY NO.2

1. Remove the 4 bolts and disconnect the left sub seatNo.2.

KCOBD5595A

2. Remove the 2 screws.

3. Separate the protrusion in mesh and detach the cush-ion panel as shown in the illustration.

KCOBD5596A

4. Sub seat cushion bracket separation

1) Remove the nut spring and washer and pull thepin.

KCOBD5597A

2) Disengage the 2 clips and 2 bushes.

3) Disengage the straight pin and detach the subseat cushion bracket from the sub seat assembly.

KCOBD5598A

5. Separation of sub seat back assemblyAfter removing the 2 bolts, 2 bushes, and 2 wavewashers, separate the sub seat back assembly.

KCOBD5599A

BD -84 BODY

6. Separation of sub seat back cover assemblyDisengage the hog ring, and detach the seat backcover and seat back pad.

7. Separate the sub seat back frame guides (RH andLH). (For the vehicle with double slide type seat back)


KCOBD5600A

2) Detach the 2 E rings and remove the 2 spacersand 2 pins.

3) Remove the seat back upper frame from thelower frame by pulling it.

KCOBD5601A

4) After removing the 2 screws, separate the 2 spac-ers of the sub seat back frame No.1

5) Separate the sub seat back frame guides (RHand LH).

ASSEMBLY OF LEFT SUB SEAT ASSEMBLY NO.2

1. Assembly is the reverse of disassembly

CAUTIONDo not dirt or damage the seat cover while assem-bling.

KCOBD5592A

2. Install the hog ring for seat cover using a hog ringprimer.

CAUTIONTake care not to fold while installing the hog ringif possible.

3. If there are wrinkles in the seat cover, smooth themout using a dryer or equivalent.After that, if the wrinkles are still existed, lightly steamand dry.

NO.3 SUPPORT SEAT ASSEMBLY REMOVAL

1. Remove the jump seat

KCOBD5594A

INTERIOR BD -85

2. Loosen the screw and remove the cushion panel.

KCOBD5596A

3. Remove the jump seat cushion bracket.

KCOBD5597A

KCOBD5598A

4. Remove the jump seat back.

5. Assembly is the reverse of disassembly.

KCOBD5599A

6. Separation of sub seat back cover assemblyDisengage the hog ring, and detach the seat backcover and seat back pad.

7. Separate the sub seat back frame guides (RH andLH). (For the vehicle with double slide type seat back)


KCOBD5600A

BD -86 BODY

2) Detach the 2 E rings and remove the 2 spacersand 2 pins.

3) Remove the seat back upper frame from thelower frame by pulling it.

KCOBD5601A

4) After removing the 2 screws, separate the 2 spac-ers of the sub seat back frame No.1.

5) Separate the sub seat back frame guides (RHand LH).

ASSEMBLY OF RIGHT SUB SEAT ASSEMBLY NO.3

1. Assembly is the reverse of disassembly

CAUTIONDo not dirt or damage the seat cover while assem-bling.

KCOBD5592A

2. Install the hog ring using a hog ring primer.

CAUTION

Take care not to make wrinkles while installing thehog ring if possible.

3. If the wrinkles are existed, smooth them out using adryer.

INTERIOR BD -87

SEAT BELT

COMPONENTS EDBC1FF7

1. Seat belt2. Passenger seat3. Seat inner belt4. Driver seat5. Seat belt6. Retractor cover

1

2

4

5

6

3

ECOBD5422A

BD -88 BODY

REMOVAL EEF1DC69

1. Remove the center pillar lower garnish.

ECOBD5602A

2. Remove the seat belt retractor cover.

ECOBD5603A

3. Remove the seat belt retractor.

ECOBD5604A

4. Remove the seat belt upper anchorage.

ECOBD5605A

LEFT SIDE 3 POINT TYPE

1. Separation of front seat belt retractor cover (LH)Remove the 4 screws and detach the front seat beltretractor cover (LH).

ECOBD5604A

2. Separation of front seat belt retractorRemove the 2 bolts mounting on the retractor anddetach the retractor assembly.

KCOBD5607A

INTERIOR BD -89

3. Separation of front seat outer belt floor anchor (LH)Remove the floor anchor bolt.

ECOBD5608A

4. Separation of front seat outer belt (LH)Using a thin screwdriver with protective tape, open theanchor cover, remove the bolt, and detach the frontseat outer belt (LH).

ECOBD5609A

RETRACTOR INSPECTION E8DBDB48

CAUTIONDo not disassemble the retractor.

1. ELR lock opening inclination angle inspectionWhen the retractor is rather inclined than the installedangle, check that the belt is locked at 45?or more, notwithin 15?to all around.

2. Inspection for ELR lockWith the vehicle assembled, check that the belt is fixedwhen the belt is rapidly pulled.

ECOBD5610A

FRONT SEAT OUTER BELT INSTALLATION

RIGHT SIDE

1. Front seat outer belt (RH) installation

1) Insert the retractor into the panel and install thefloor anchor bolt.

2) Install the retractor upper bolt.

3) Install the shoulder belt anchor bolt.

CAUTION• After tightening the anchor bolt, check the an-

chor for smooth operation.• With the belt installed, check the belt for

smooth operation.

Body.pdf

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