DocumentBD

Body (Interior andExterior)

GENERAL

EXTERIORFENDERHOODTAIL GATEFUEL FILL DOORFRONT DOORREAR DOORBODY SIDE MOLDINGSSUN ROOFMIRROR

INTERIORCONSOLE

CRASH PADROOF TRIMINTERIOR TRIMWINDSHIELD GLASSCOWL TOP COVER

BUMPERFRONT BUMPERREAR BUMPER

SEATFRONT SEATREAR SEATSEAT BELT

BD -2 BODY (INTERIOR AND EXTERIOR)GENERALSPECIFICATIONS E7DCBDA9

HOOD Type Rear hinged, gas lifter typeConstruction Front hinged, full door constructionRegulator system Wire drum typeFRONT DOORLocking system Pin-fork systemConstruction Front hinged, full door constructionRegulator system Wire drum typeREAR DOORLocking system Pin-fork system

TAIL GATE Type Inner hinged gas lifter typeWindshield glass 5mmFront door glass 4mmRear door glass 4mm

GLASSTHICKNES

Rear window glass 3.5mmFront 3 point type with Emergency Locking Retractor (E.L.R)

SEAT BELTSRear 3 point type with Emergency Locking Retractor (E.L.R)2 point type

GENERAL BD -3

TIGHTENING TORQUE E9D6066C

Items Nm kgfm LbfftDoor hinge to body 12.7 ~ 25.5 1.3 ~ 2.6 9.4 ~ 18.8Door hinge to door 9.8 ~ 19.6 1.0 ~ 2.0 7.2 ~ 14.5Foont and rear doorsStriker 6.9 ~ 10.8 0.7 ~ 1.1 5.1 ~ 8.0Tail gate hinge to body 21.6 ~ 26.5 2.2 ~ 2.7 15.9 ~ 19.5

Tail gateTail gate hinge tail gate 21.6 ~ 26.5 2.2 ~ 2.7 15.9 ~ 19.5Hood hinge to body 21.6 ~ 26.5 2.2 ~ 2.7 15.9 ~ 19.5Hoodl hinge to hood 21.6 ~ 26.5 2.2 ~ 2.7 15.9 ~ 19.5HoodHood latch to body 6.9 ~ 8.8 0.7 ~ 1.1 5.1 ~ 8.0Front seat mounting bolts 34.3 ~ 53.9 3.5 ~ 5.5 25.3 ~ 39.2Front seat mounting nut 34.3 ~ 53.9 3.5 ~ 5.5 34.3 ~ 53.9Rear seat mounting bolts 16.7 ~ 25.5 4.0 ~ 5.5 28.9 ~ 39.8

Seat

Rear seat frame mounting bolts 16.7 ~ 25.5 4.0 ~ 5.5 28.9 ~ 39.8Front seat belt height adjuster 39.2 ~ 53.9 4.0 ~ 5.5 28.9 ~ 39.8Front seat belt buckle mounting bolt 39.2 ~ 53.9 4.0 ~ 5.5 28.9 ~ 39.8Front seat belt anchor mounting bolt 39.2 ~ 53.9 4.0 ~ 5.5 28.9 ~ 39.8Front seat belt lower anchor 39.2 ~ 53.9 4.0 ~ 5.5 28.9 ~ 39.8Front seat belt upper anchor 39.2 ~ 53.9 4.0 ~ 5.5 28.9 ~ 39.8Rear seat belt anchor attaching bolt 39.2 ~ 53.9 4.0 ~ 5.5 28.9 ~ 39.8

Seat belt

Rear seat belt retractor mounting bolt 39.2 ~ 53.9 4.0 ~ 5.5 28.9 ~ 39.8

BD -4 BODY (INTERIOR AND EXTERIOR)SPECIAL TOOLS E21D049B

Tool (Number and name) Illustration Use

09793-2100Door hinge adjusting wrench

SSPBD00001

Adjustment, removal andinstallationOf the door hinge

09800-21000Ornament remover

SSPBD00002

Trim removal

09853-31000Headliner clip remover

SSPBD00003

Removal of the headliner clips

09861-31100Sealant cut-out tool

SSPBD00004

Cutting the sealant of the windshield(Use with 09861-31200)

09861-31200Sealant cutting blade

SSPBD00005

Cutting the sealant of the windshield(Use with 09861-31100)

09861-31300Sealant gun

SSPBD00006

Application of the sealant tothe windshield

GENERAL BD -5

Tool (Number and name) Illustration Use

09681-31400Glass holder

SSPBD00007

Removal and installation of thewindshield

09681-31000Windshield molding remover

SSPBD00008

Removal of the windshield molding

09880-4F000Hog ring clip installer

SSPBD00009

Installation of the hog ring clip

BD -6 BODY (INTERIOR AND EXTERIOR)TROUBLESHOOTING EDB4725D

Symptom Suspect Area Remedy (Refer to page)Dirt accumulated in drain tube Clear dirt inside of drainClogged drain tube Blow air into drain to remove dirtBroken or dislocated drain tube,defective or cracked clip

Check tube installation andflange contact

Deteriorated roof lid weatherstrip ReplaceWater leaks from sunroof

Excessive roof lid-to-body clearanceand improperly fitted weatherstrip Adjust

Wind noise around sunroof Loose or deformed deflector,gaps in body work Retighten adjust or replace

Foreign particles lodged in guide rail Check drive cable and guiderails for foreign particlesSunroof lid makes a noise when move

Loose guide rails and lid RetightenForeign particles lodged in guide railIncorrect engagement of motorpinion with drive cableDecrease in motors clutchslipping force

Motor runs but sunroof Does notmove or moves only partially

Increased sunroof sliding resistanceor interference of sunroof with drivecables, weatherstrip, etc. due tomaladjustment of sunroof

Adjust or replace

Incorrect engagement of motorpinion with drive cable

Check pinion installation andretighten motor

Worn out or damaged motorpinion bearing Replace motor assembly

Noise in motor (clutch slippingnoise from motor when sunroofIsfully opened or closed is notan unusual noise

Worn out or deformed drive cable ReplaceIncorrect window glass installation Adjust position

Door glass fails to operate upand down Damaged or faulty regulator

arm orregulator Correct or replace

Incorrect door installation Adjust positionDefective door check assembly Correct or replaceDoor does not open or close

completelyDoor hinge requires grease Apply greaseStriker and latch not properly aligned AdjustIncorrectly installed hood AdjustHood does not open or close

completelyIncorrect hood bumper height AdjustDefective seal Fill with sealantWater leak through windshield

end rear window Defective flange Correct

EXTERIOR BD -7

EXTERIORFENDER

REPLACEMENT E37F53AD

NOTE Take care not to damage the hood and body. When removing the clips, use a clip remover.

1. Remove the following items. Headlamp assembly. Front bumper (Refer to page BD-76). Side garnish (B), mud guide (C), cover (D)

2. After loosening the fender mounting bolts, then re-move the fender (A).

3. Installation is the reverse of removal.

A

B

C

Bolt Clip 1

11

1

Fastener Locations

SUNBD6050L

BD -8 BODY (INTERIOR AND EXTERIOR)HOOD

REPLACEMENT E74EAEB4

HOOD ASSEMBLY REPLACEMENT

NOTE When removing and installing the hood, an as-

sistant is necessary. Take care not to damage the hood and body. When removing the clips, use a clip remover.

1. Disconnect the windshield washer nozzle connectingtube.

2. After loosening the hood hinge (B) mountingbolts,then remove the hood (C).


NOTE Make sure the hood opens properly and locks

securely. Adjust the hood alignment (Refer to page BD-13).

C

B

Bolt locations, 421.6 ~ 26.5 N m(2.2 ~ 2.7 kgf.m, 15.9 ~ 19.5 lbf.ft)

SUNBD6056L

EXTERIOR BD -9

HOOD INSULATOR REPLACEMENT

1. Using a clip remover, detach the clips, and remove thehood insulator (A).

NOTETake care not to scratch the hood panel.

Clip locations, 15

A

SUNBD6057L


NOTEReplace any damaged clips.

HOOD SEAL WEATHERSTRIP REPLACEMENT

1. Detach the clips, then remove the hood weather-strip(A). Take care not to scratch the hood.Clip locations, 6

A

SUNBD6058L


NOTEReplace any damaged clips.

BD -10 BODY (INTERIOR AND EXTERIOR)HOOD RELEASE HANDLE REPLACEMENT

1. After loosening the mounting screw, then remove thehood release handle (A).

A

Screw locations

SUNBD6011L


NOTE Make sure the hood latch cable is connected

properly. Make sure the hood locks securely.

HOOD LATCH REPLACEMENT

1. Loosen the air duct (A) mounting bolts.

Bolt locations, 2

A

SUNBD6012L

2. Remove the under cover (A).

Clip locations, 11

A

SUNBD6006L

EXTERIOR BD -11

3. After loosening the mounting bolts, then remove thebracket (A).

Bolt locations, 2

A

SUNBD6010L

4. Detach the clips, then remove the hood latch cover(A).

Bolt locations, 2

A

SUNBD6013L

5. Remove the hood latch (A) mounting bolts.

Bolt, 26.9~10.8 N.m(0.7~1.1 kgf.m,5.1~8.0 lbf.ft)

Nut, 1

A

Fastener Locations

SUNBD6018L

6. Disconnect the hood latch cable (A) and remove thelatch (B).

A

B

SUNBD6021L


NOTE Make sure the hood latch cable is connected

properly. Make sure the hood locks securely.

BD -12 BODY (INTERIOR AND EXTERIOR)HOOD LATCH CABLE REPLACEMENT

1. Remove the following items. Hood latch (Refer to page BD-10). Hood release handle (Refer to page BD-10). Wheel guard (Refer to page BD-39).

NOTETake care not to bend the cable.

2. Disconnect the hood latch cable (A) and release cable(B).

3. Remove the hood latch cable (C).

C

B

A

SUNBD6054L


NOTE Make sure the hood latch is connected properly. Replace any damaged clips.

EXTERIOR BD -13

ADJUST HOOD E67C4E40

1. After loosening the hinge (A) mounting bolt, adjustthehood (D) by moving it up or down, or right or left.

2. Adjust the hood height by turning the hood overslambumpers (B).

3. After loosening the hood latch (C) mounting bolts,ad-just the latch by moving it up or down, or right or left.

C

A

D

B

BD

C

C

B

A

A

SUNBD6974D

BD -14 BODY (INTERIOR AND EXTERIOR)TAIL GATE

TAILGATE TRIM REPLACEMENT E3019040

NOTE When removing and installing the tailgate, an as-

sistant is necessary. Put on gloves to protect your hands.

1. Open the tailgate.

2. Remove the upper trim (A) and side trim (B).3. Remove the tailgate trim (C).4. Installation is the reverse of removal.

NOTEReplace and damaged clips.

A

B

B

C

Clip Screw Clip1

11

1

1

Fastener Locations

SUNBD6077L

EXTERIOR BD -15

LATCH ASSEMBLY REPLACEMENT

1. Remove the tailgate trim (Refer to page BD-14).2. Disconnect the connector (B).

B

SUNBD6086D

3. After loosening the mounting screws, then remove thelatch assembly (A).

A

Bolt locations, 2

6.9 ~ 10.8 N.m 0.7 ~ 1.1 kgf.m,

5.1 ~ 8.0 lbf.ft)

SUNBD6090L


NOTE Make sure the connector is connected properly

and the connecting rod is connected properly. Make sure the tailgate opens properly and locks

securely.

OUTSIDE HANDLE REPLACEMENT

1. Remove the tailgate trim (Refer to page BD-14).2. Remove the tailgate garnish (Refer to page BD-40).3. After loosening the mounting screws, then remove the

outside handle (A).

A

Screw locations, 2

SUNBD6107L


NOTEMake sure the tailgate opens properly and locks se-curely.

BD -16 BODY (INTERIOR AND EXTERIOR)TAILGATE WEATHERSTRIP REPLACEMENT

NOTEDo not apply sealant to the body.

1. Remove the tailgate weather strip (A).

A

SUNBD6986D


EXTERIOR BD -17

ADJUSTMENT EC1DF9B8

1. After loosening the tailgate hinge (A) mounting bolt,adjust the tailgate by moving it up or down, or right orleft.

2. Adjust the tailgate fit by turning the tailgate overslambumper (C) and side bumper (B).

3. Adjust the striker (D) by moving it up or down, or rightor left.

C

A

C

C

A

B

D

D

B

B

SUNBD6955D

BD -18 BODY (INTERIOR AND EXTERIOR)FUEL FILL DOOR

REPLACEMENT E1F1D55E

1. Remove the ring (A).

A

SUNBD6513D

2. Loosen the bolts, then remove the fuel filler door (A).

Bolt locations, 2

A

SUNBD6900L


NOTE Make sure the fuel fill door opens properly and

locks securely. Check that the fuel fill door (A) fit flush against

thebody. If necessary, adjust it.

Bolt locations, 2

A

SUNBD6514L

EXTERIOR BD -19

FRONT DOOR

COMPONENTS E320FDC2

7

6

5

3

1

4

2

8

1. Door trim2. Power window motor3. Module4. Door lach assembly

5. Door panel6. Door belt weatherstrip7. Glass8. Inside handle

SUNBD6172L

BD -20 BODY (INTERIOR AND EXTERIOR)REPLACEMENT EDBA5A2DOUT SIDE HANDLE REPLACEMENT

1. After loosening the mounting bolt, then remove thekey holder (A).

Bolt locations

A

7.8 ~ 11.8 N.m(0.8~1.2 Kgf.m,5.8 ~ 8.7 lbf.ft)

SUNBD6130L

2. Remove the outside handle (A) by sliding it rearward.

A

SUNBD6133D

3. Remove the outside handle pad.


NOTEMake sure the door locks and opens properly.

DOOR BELT WEATHERSTRIP REPLACEMENT

1. Loosen the mounting screw, then remove the doorbelt weatherstrip (A).

A

Screw locations, 2

SUNBD6515L


EXTERIOR BD -21

DOOR TRIM REPLACEMENT

NOTE Take care not to scratch the door trim and other

parts. Put on gloves to protect your hands.

1. After loosening the mounting screw, then remove theinside handle cover (A).

A

Screw locations, 1

SUNBD6120L

2. Loosen the door trim (E) mounting screws. Releasethe clips that hold the door trim, then remove the doortrim by pulling it upward. Disconnect the power win-dow switch connector (A), power mirror connector (B),and door courtesy lamp connector (C), trunk lid con-nector (D).

E

Screw Clip

AC

DB

Fastener Locations

SUNBD6117L


NOTE Make sure of connectors is plugged in properly

and each rod is connected securely. Make sure the door lock and opens properly.

BD -22 BODY (INTERIOR AND EXTERIOR)GLASS REPLACEMENT

1. Remove the front door trim (Refer to page BD-21).2. Remove the glass mounting hole plug (A).

NOTE Using the door switch to align the mounting hole

with the hole on the door glass. If it is impossible, align the hole with hands after

removing the motor. Take care not to drop to glass and scratch the

glass surface.

3. Carefully move the glass (B) until you can see the-bolts, then loosen them. Separate the glass from theglass run and carefully pull the glass out through thewindow slot.

B

A

Screw locations, 2

8.8 ~ 11.8 N.m(0.9 ~ 1.2 kgf.m,6.5 ~ 8.7 lbf.ft)

SUNBD6125L


NOTE Roll the glass up down to see if it move freely

without binding. Adjust the position of the glass as necessary (Re-

fer to page BD- 26).

INSIDE HANDLE REPLACEMENT

1. Remove the front door trim (Refer to page BD- 21).

2. Loosen the inside handle (A) mounting screw.Push the inside handle forward to disconnect from thedoor module.

Screw locations, 3

A

SUNBD6143L

3. Disconnect the lock cable and (A) inside handle con-nect cable (B).

A

B

SUNBD6137D

EXTERIOR BD -23

SPEAKER REPLACEMENT

1. Remove the door trim (Refer to page BD-21).2. Drill out the rivets to remove the speaker (B) from the

door module.

3. Disconnect the speaker connector (A).

B

A

SUNBD6200D

4. Installation is the reverse of removal.Use sheet metal screws to secure the speaker.

POWER WINDOW MOTOR REPLACEMENT

1. Remove the door trim (Refer to page BD-21).2. After disconnecting the connector (A), remove the

power window motor (B).

Screw locations, 3

B

A

SUNBD6147L


NOTERoll the glass up down to see if it move freely withoutbinding.

BD -24 BODY (INTERIOR AND EXTERIOR)DOOR MODULE ASSEMBLY REPLACEMENT

1. Remove the following parts. Door trim (Refer to page BD-21). Window glass (Refer to page BD-22). Outside handle (Refer to page BD-20).

2. Loosen the mounting screw (A).

Screw locations

A

SUNBD6220L

3. Loosen the door module mounting bolts, then removethe door module (A).

A

Screw : Bolt6.9~10.8 N.m(0.7~1.1 Kgf.m,5.1~8.0 lbf.ft)

6.9~10.8 N.m(0.7~1.1 Kgf.m,5.1~8.0 lbf.ft)

Fastener Locations

SUNBD6124L

4. Disconnect the connector (C).5. Disconnect the door module wiring harness (A), then

remove the module assembly (B).

C BA

SUNBD6502D


NOTE Make sure the connector is plugged in properly

and each rod is connected securely. Make sure the door locks and open properly.

EXTERIOR BD -25

LATCH ASSEMBLY REPLACEMENT

1. Remove the following parts. Door trim (Refer to page BD-21). Window glass (Refer to page BD-22). Out side handle (Refer to page BD-20).

2. Remove the module assembly (Refer to page BD-24).3. Disconnect the latch connector (A), then remove the

latch assembly (B).

CA

B

SHDBD6510D

4. Installation is the reverse the removal.

NOTEMake sure the door locks and opens properly.

DOOR WEATHERSTRIP REPLACEMENT

1. Loosen the checker mounting bolts.

2. Detach the clips, then remove the weatherstrip(A).

A

SUNBD6958D


BD -26 BODY (INTERIOR AND EXTERIOR)ADJUSTMENT EC3E4CE9GLASS ADJUSTMENT

NOTECheck the glass run channel for damage or deteriora-tion, and replace them necessary.

1. Remove the following parts. Door trim (Refer to page BD- 21).

2. Carefully move the glass (A) until you can see the-glass mounting bolts (B), then loosen them.

B

A

Screw locations, 2

8.8 ~ 11.8 N.m(0.9 ~ 1.2 kgf.m,6.5 ~ 8.7 lbf.ft)

SUNBD6125L

3. Check that the glass moves smoothly.

4. Raise the glass fully, and check for gaps.Check that the glass contacts the glass run channelevenly.

5. Check for water leaks. Run water over the roof andonthe sealing area as shown, and note these items:

Use a 12mm (1/2Iin.) diameter hose. Adjust the rate of water flow as shown. Do not use a nozzle. Hold the hose about 300mm(12in.) away from

the door.

12 mm (0.47 in.)

300 mm (12 i

n.)

0.5 m (18 in.)

A

A

B

ESKE003L

EXTERIOR BD -27

DOOR POSITION ADJUSTMENT

NOTEAfter installing the door, check for a flush fit withthe body, then check for equal gaps between thefront,Rear, and bottom, door edges and the body.Check that the door and body edges are parallel.Before adjusting, replace the mounting bolts.

1. Place the vehicle on a firm, level surface when adjust-ing the doors.

2. Adjust at the hinges (A):- Loosen the door mounting bolts slightly, and-

move the door IN or OUT until it aligns flushwiththe body.

- Loosen the hinge mounting bolts slightly, and-move the door BACKWARD or FORWARD, UPor DOWN as necessary to equalize the gaps.

- Place a shop towel on the jack to preventdamageto the door when adjusting the door.

A

A

12.7 ~ 25.5 N.m(1.3 ~ 2.6 kgf.m, 9.4 ~ 18.8 lbf.ft)

9.8 ~ 19.6 N.m(1.0 ~ 2.0 kgf.m,7.2 ~ 14.5 lbf.ft)

SUNBD6522L

3. Check that the door and body edges are parallel.

4. Grease the pivot portions of the hinges indicatedbythe arrows.

Grease

SUNBD6601L

5. Check for water leaks (Refer to page BD-26 ).

BD -28 BODY (INTERIOR AND EXTERIOR)DOOR STRIKER ADJUSTMENT

Make sure the door latches securely without slammingit.If necessary adjust the striker (A): The striker nuts arefixed.The striker can be fine adjusted up or down, and inor out.

1. Loosen the screws (B), then insert a shop towel be-tween the body and striker.

A

B6.9 ~ 10.8 N.m(0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lbf.ft)

SUNBD6602L

2. Lightly tighten the screws.

3. Wrap the striker with a shop towel, then adjust thestriker by tapping it with a plastic hammer.Do not tap the striker too hard.

4. Loosen the screws and remove the shop towel.


6. Hold the outer handle out, and push the door againstthe body to be sure the striker allows a flush fit. If thedoor latches properly, tighten the screws and recheck.

EXTERIOR BD -29

REAR DOOR

COMPONENTS E8641B64

4

56

7

8

3

10

9

2

1

11

SHDBD6151L

BD -30 BODY (INTERIOR AND EXTERIOR)REPLACEMENT ECBD0ACDOUT SIDE HANDLE REPLACEMENT

1. After loosening the mounting bolt, then remove thehandle cover (A).

A

Bolt locations7.8 ~ 10.8 N.m(0.8~1.1 Kgf.m,5.8 ~ 8.0 lbf.ft)

SUNBD6217L

2. Remove the outside handle (A) by sliding it rearward.

A

SUNBD6218D

3. Remove the outside handle pad.


DOOR BELT WEATHERSTRIP REPLACEMENT

1. Loosen the mounting screw, then remove the doorbelt weatherstrip (A).

A

Screw locations, 1

SUNBD6516L


EXTERIOR BD -31

DOOR TRIM REPLACEMENT

NOTE Take care not to scratch the door trim and other

parts. Put on gloves to protect your hands.

1. Remove the delta inner cover (A).

A

SHDBD6501D

2. After loosening the mounting screw, then remove theinside handle cover (A).

A

Screw locations

SUNBD6192L

3. Loosen the door trim (B) mounting screws. releasetheclips that hold the door trim, then remove the door trimby pulling it upward. disconnect the power windowswitch connector (A).

B

A

Screw locations

SUNBD6193L


NOTE Make sure of connectors is plugged in properly

and each rod is connected securely. Make sure the door lock and opens properly.

BD -32 BODY (INTERIOR AND EXTERIOR)GLASS REPLACEMENT

NOTEPut on gloves to protect your hands.

1. Remove the door trim (Refer to page BD- 31).2. Remove the door belt weatherstrip.

3. After loosening the mounting bolt and screw, then re-move the quarter glass assembly (A).

: Screw : Bolt

A

Fastener Locations

SUNBD6208L

4. Release the rear channel mounting bolt and nut.

CAUTIONTake care not to drop to glass and scratch theglass surface.

5. Carefully move the glass (A) until you can see the-bolts, then loosen them. Separate the glass from theglass run and carefully pull the glass out through thewindow slot.

B

A

SUNBD6210D


NOTE Roll the glass up down to see if it move freely-

without binding. Adjust the position of the glass as necessary(Re-

fer to page BD- 36).

EXTERIOR BD -33

INSIDE HANDLE REPLACEMENT

1. Remove the door trim (Refer to page BD- 31).2. Loosen the inside handle (A) mounting screw.

Push the inside handle forward to disconnect from thedoor module.

Screw locations

A

SUNBD6224L

3. Disconnect the lock cable and (A) inside handle con-nect cable (B).

A

B

SUNBD6137D

POWER WINDOW MOTOR REPLACEMENT

1. Remove the door trim (Refer to page BD- 31).2. After disconnecting the connector (A), remove thep-

ower window motor (B).

A

B

Bolt locations, 3

SUNBD6207L


NOTERoll the glass up down to see if it move freely withoutbinding.

BD -34 BODY (INTERIOR AND EXTERIOR)SPEAKER REPLACEMENT

1. Remove the door trim (Refer to page BD-31).2. Drill out the rivets to remove the speaker (B) from the

door module.

3. Disconnect the speaker connector (A).

B

A

SUNBD6200D

4. Installation is the reverse of removal.Use sheet metal screws to secure the speaker.

MODULE ASSEMBLY REPLACEMENT

1. Remove the following parts. Door trim (Refer to page BD-31). Window glass (Refer to page BD-32). Outside handle (Refer to page BD-30).

2. Remove the outside pad (A).3. Loosen the mounting screw.

Screw locations

A

SUNBD6220L

4. After loosening the door module mounting bolts, re-move the door module (A).

A

: Screw, 3 : Bolt, 8

6.9~10.8 N.m(0.7~1.1 Kgf.m,5.0~8.0 lbf.ft)

6.9~10.8 N.m(0.7~1.1 Kgf.m,5.0~8.0 lbf.ft)

Fastener Locations

SUNBD6204L

EXTERIOR BD -35

5. Disconnect the connector (B).6. Detach the clips, then remove the wiring harness(C).

CB

SUNBD6238D


NOTE Make sure the connector is plugged in properly

and each rod is connected securely. Make sure the door lock and open properly.

DOOR WEATHHERSTRIP REPLACEMENT

1. Loosen the checker mounting bolts.

2. Detach the clips, then remove the weatherstrip(A).

A

SUNBD6960D


BD -36 BODY (INTERIOR AND EXTERIOR)ADJUSTMENT E2B14C12GLASS ADJUSTMENT

NOTECheck the glass run channel for damage or deteriora-tion, and replace them necessary.

1. Remove the following parts. Door trim (Refer to page BD- 31).

2. Carefully move the glass (A) until you can see the-glass mounting bolts (B), then loosen them.

B

A

SUNBD6210D

3. Push the glass against the channel, thentighten theglass mounting bolts.

4. Check that the glass moves smoothly.

5. Raise the glass fully, and check for gaps.Check that the glass contacts the glass run chan-nelevenly.

6. Check for water leaks. Run water over the roof andonthe sealing area as shown, and note these items:- Use a 12mm (1/2Iin.) diameter hose.- Adjust the rate of water flow as shown.- Do not use a nozzle.- Hold the hose about 300mm(12in.) away fromthe

door.

DOOR POSITION ADJUSTMENT

NOTEAfter installing the door, check for a flush fit withtheBody, then check for equal gaps between thefront,Rear, and bottom, door edges and the body.CheckThat the door and body edges are parallel.BeforeAdjusting, replace the mounting bolts.

1. Place the vehicle on a firm, level surface when adjust-ing the doors.

2. Adjust at the hinges (A):- Loosen the door mounting bolts slightly, and-

move the door IN or OUT until it aligns flushwiththe body.

- Loosen the hinge mounting bolts slightly, and-move the door BACKWARD or FORWARD, UPor DOWN as necessary to equalize the gaps.

- Place a shop towel on the jack to preventdamageto the door when adjusting the door.

A

A

9.8 ~ 19.6 N.m(1.0 ~ 2.0 kgf.m,7.2 ~ 14.5 lbf.ft)

SUNBD6524L

EXTERIOR BD -37

3. Check that the door and body edges are parallel.

SHDBD6602D

4. Grease the pivot portions of the hinges indicated bythe arrows.

Grease

SUNBD6603L

5. Check for water leaks (Refer to page BD- 26).

DOOR STRIKER ADJUSTMENT

Make sure the door latches securely without slamming it.If necessary adjust the striker (A): The striker nuts arefixed.The striker can be fine adjusted up or down, and in or out.1. Loosen the screws (B), then insert a shop towel be-

tween the body and striker.

A

B6.9 ~ 10.8 N.m(0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lbf.ft)

SUNBD6602L


3. Wrap the striker with a shop towel, then adjust thestriker by tapping it with a plastic hammer.Do not tap the striker too hard.

4. Loosen the screws and remove the shop towel.


6. Hold the outer handle out, and push the door againstthe body to be sure the striker allows a flush fit. If thedoor latches properly, tighten the screws and recheck.

BD -38 BODY (INTERIOR AND EXTERIOR)BODY SIDE MOLDINGS

REPLACEMENT E60F3D61ROOF RACK REPLACEMENT

NOTE When prying with a flat-tipped screwdriver, wrap

itwith protective tape, and apply protective tapearound the related parts, to prevent damage.

Put on gloves to protect your hands. Take care not to scratch the body surface.

1. Remove the roof rack cover (A).2. After loosening the mounting nuts, then remove the

roof rack (B).3. Installation is the reverse of removal.

A

B

Nut locations

SUNBD6996L

EXTERIOR BD -39

MUD GUARD AND WHEEL GUARD REPLACEMENT

NOTE- When prying with a flat-tip screwdriver, wrap


- Put on gloves to protect your hands.

- Take care not to scratch the body surface.

1. Remove the wheel guard.


4

3

12

1. Front wheel guard2. Front mud guard

3. Rear wheel guard4. Rear mud guard

SUNBD6999L

BD -40 BODY (INTERIOR AND EXTERIOR)TAILGATE GARNISH REPLACEMENT

1. Remove the tailgate trim (Refer to page BD-14).2. Remove the tailgate garnish (A).

A

: Nut locations

SUNBD6109L


EXTERIOR BD -41

SUN ROOF

COMPONENTS E2D8B2CD

1. Guide assembly2. Glass3. Drip link4. Guide assembly5. Drip rail

6. Drain tube7. Drain tube8. Set bracket9. Frame10. Defector link

11. Motor12. Drive unit13. Defector14. Sunshade15. Decoration cover16. Drip link

1

2

3

4

5

6

7

89

1011

12

13

14

15

16

SUNBD6604L

BD -42 BODY (INTERIOR AND EXTERIOR)REPLACEMENT E0DE9642GLASS REPLACEMENT

NOTEPut on glove to protect your hands.

1. Remove both decoration cover (A).

A

ASIE071B

2. Remove the glass (A) by lifting it up.

NOTEDo not damage the roof panel.

Screw locations 6

A

SUNBD6517L


EXTERIOR BD -43

MOTOR REPLACEMENT

1. Remove the over head console (Refer to pageBD-63).

NOTEConfirm the position of guide whether it is closed ornot when you remove the motor.

2. Disconnect the motor connector (A), remove the-screws and then remove the motor (B).

A

Bcrew locations

SUNBD6905L


NOTEMake sure to initialize the motor.

DEFLECTOR REPLACEMENT

1. Open the glass fully.

2. Disconnect the deflector link (A) from the frame (B),and then remove the deflector (C).

A

A

C

B

SUNBD6912D


BD -44 BODY (INTERIOR AND EXTERIOR)SUNROOF ASSEMBLY REPLACEMENT

1. Remove the follows parts. Door scuff trim (Refer to page BD-66). Front pillar trim (Refer to page BD-66). Center pillar trim (Refer to page BD-67). Rear pillar trim (Refer to page BD-68). Headlining (Refer to page BD-64). Sunroof glass (Refer to page BD-42).

2. Disconnect the drain tubes (B).3. Remove the bracket (A).

4. After loosening the mounting bolts and nuts, removethe sunroof assembly (B).

NOTETake care not to scratch the interior trims and other-parts.


: Bolt, 6 Nut, 4

A

A

A

B

A

B

Fastener Locations

SUNBD6605L

EXTERIOR BD -45

SUNSHADE AND DRIP RAIL REPLACEMENT

1. Remove the sunroof assembly (Refer to page BD-44).2. Remove the drip link (A) and sunshade stopper (B).3. Remove the sunshade (C) and drip rail (D).

Screw locations, 1

B

C

A

D

SUNBD6519L


GUIDE ASSEMBLY REPLACEMENT

1. Remove the sunroof assembly (Refer to page BD-44).

2. Remove a guide assembly (A) after lowering a guide-thoroughly by pushing a slide (B) to rear.

A

B

ASIE090H

3. Remove the guide (A) and slide (B).

B

A

ASIE080I

BD -46 BODY (INTERIOR AND EXTERIOR)4. Installation is the reverse of removal.

NOTE- Make sure to align the slide with the center of"A"

and "B"- Make sure to initialize the motor.

A B

ASIE070K

ADJUSTMENT E7BC91E8HOW TO INITIALIZE

1. Check that the glass has been installed.- Finished height adjustment.

2. Push the up switch. (Keep on pushing the switch)- the slide moved 5mm forward after 15 seconds

- Before moving the slide -

- After moving the slide -

ESQE171M

3. After moving the slide 5mm forward, turn OFFtheswitch and push the UP switch (Keeping onpushingthe switch with continuous operation)- If the operation above is normal condition, the-

sunroof once and closes.

4. When the sunroof is closed completely, turn OFF theUP switch initialize the motor completely.

EXTERIOR BD -47

WHEN TO INITIALIZE THE MOTOR

1. First operation the vehicle after manufacture it.

2. Initial value is erased or damaged because of short-power electric discharge during operation

3. After using the manual handle.

OPERATING THE SUNROOF EMERGENCY HANDLE

1. Use the sunroof emergency handle to close and openthe sunroof manually for the following case only- To close the sunroof before driving a vehicle in

arainy day or on the highway if the sunroof can-not be closed due to failure of the sunroof motororcontroller.

2. Operating method- Remove the overhead console- Push the emergency handle up into the hexago-

naldrive (A) of the sunroof motor. You must pushhardenough to disengage the motor clutch; oth-erwise the emergency handle will slip due to in-complete fit in the motor.

- Carefully turn the emergency handle clockwise toclose the sunroof.

- After closing the sunroof, wiggle the handle backand forth as you remove the tool from the motor,toensure the motor clutch reengages.

- A 5mm hex socket may be used in place of theemergency handle, with a Speeder type han-dle.

CAUTIONDo not use power tools to operate the sun-roof.Damage to the components may occur.

A

ASIE070M

BD -48 BODY (INTERIOR AND EXTERIOR)MIRROR

RELPLACEMENT EAF6B60COUTSIDE REAR VIEW MIRROR RELPLACEMENT

NOTE- When prying with a flat-up screwdriver, wrap



1. Remove the cover (A)2. After loosening the mounting bolts, then remove the

outside rear view mirror (B).

B

A

Screw locations, 3

SUNBD6028L


INSIDE REAR VIEW MIRROR REPLACEMENT

1. Push the inside rear view mirror base (A) down tore-move to inside rear view mirror assembly (B).

Spring

A

B

A

SUNBD6606L


EXTERIOR BD -49

ECM MIRROR REPLACEMENT

1. Remove the ECM mirror cover (A).

A

KSBF183A

2. Remove the cover and connector (B).3. Push the ECM mirror base down to remove the ECM-

mirror assembly (A).

A

B

KSBF180E


BD -50 BODY (INTERIOR AND EXTERIOR)INTERIORCONSOLE

COMPONENTS EF12C8EA

2

1

5

4

3

SUNBD6169L

INTERIOR BD -51

REPLACEMENT E3A20D44FLOOR CONSOLE REPLACEMENT

NOTE When prying with a flat-tip screwdriver, wrap it

with protective tape, and apply protective tapearound the related parts, to prevent damage.

Put on gloves to protect your hands.

1. Remove the console rear cover (A).

A

SUNBD6626D

2. Remove the under cover (A).

A

SUNBD6646D

3. Disconnect the connector .

4. Remove the console storage box cover (A).

A

SUNBD6631D

5. After loosening the console mounting screws, thenremove the floor console assembly (A).

A

: Screw : BoltFastener Locations

SUNBD6642L

6. Disconnect the connector.

BD -52 BODY (INTERIOR AND EXTERIOR)7. After loosening the console mounting screws, then

remove the front console (A).

A

: Screw locations

SUNBD6643L


ARMREST REPLACEMENT

1. Remove the rear console cover (A).

A

SUNBD6626D

2. After loosening the armrest mounting screws, thenremove the armrest (A).

A

Screw locations, 2

SUNBD6628L


INTERIOR BD -53

CRASH PAD

COMPONENTS EBD3F29D

3

11 1

12

1314

10

9

87

4

2

6

5

SUNBD6170L

BD -54 BODY (INTERIOR AND EXTERIOR)REPLACEMENT E1EA0321CLUSTER FACIA REPLACEMENT

NOTE When prying with a screwdriver, wrap it with pro-

tective tape, and apply protective tape around therelated parts, to prevent damage.

Take care not to scratch the crash pad and re-lated parts.

1. Tilt the steering column down.

2. After disconnecting the trip sensor connector (A), re-move the cluster facia panel (B).

B

A

Screw locations, 2

SUNBD6673L

3. After loosening the mounting screws, then remove thecluster facia (A).

: Screw locations

A

SUNBD6731L


NOTEMake sure the connector is plugged in properly.

INTERIOR BD -55

CENTER FACIA PANEL REPLACEMENT

NOTE Make sure the connector is plugged in properly. Replace any damage clips.

1. Remove the front console upper cover (A).

A

SUNBD6669D

2. Disconnect the connector (A).

A

SUNBD6666D

3. After loosening the mounting screw, then remove thefacia panel (A).

: Screw locations, 2

A

SUNBD6694L


BD -56 BODY (INTERIOR AND EXTERIOR)LOWER PANEL REPLACEMENT

NOTE Take care not to scratch the crash pad and re-

lated parts.

1. Remove the crash pad side cover (A).

A

SUNBD6710D

2. After loosening the crash pad lower panel mountingscrews, then remove the lower panel (A).

3. Disconnecting the connector (B).

P

A

B

SUNBD6713D

4. After loosening the mounting bolts, then remove thereinforcing panel (A).

A

: Bolt locations, 4

SUNBD6740L


INTERIOR BD -57

HEATER CONTROL UNIT REPLACEMENT

1. Remove the center facia panel (Refer to page BD-55).2. After loosening the heater control mounting

screws,remove the heater control unit (A).

: Screw locations

A

SUNBD6739L


NOTEMake sure the connector is plugged in properly

AUDIO ASSENBLY REPLACEMENT

1. Remove the center facia panel (Refer to page BD-55).2. Loosen the audio (B) mounting screws.


B

SUNBD6699L

3. Disconnect the connector (A).

A

SUNBD6701D


NOTEMake sure the connector is plugged in properly.

BD -58 BODY (INTERIOR AND EXTERIOR)GLOVE BOX REPLACEMENT

1. Disconnect the damper (B) from the glove box (A).

A

B

SUNBD6675D

2. Remove the glove box (A) from the lift (B).

A B

SUNBD6689D

3. Disconnect the pine (A), then remove the glove box(B).

B

A

SUNBD6691D


INTERIOR BD -59

AIR VENT REPLACEMENT

NOTE- When prying with a screwdriver, wrap it with pro-



1. Remove the crash pad (Refer to page BD-61).2. Loosen the mounting screws, then remove the air vent

(A).

A

: Screw locations

SUNBD6807L


SHROUD REPLACEMENT

1. Loosen the screws.

2. Remove the shroud assembly (A).


A

SUNBD6738L


BD -60 BODY (INTERIOR AND EXTERIOR)COVER REPLACEMENT

NOTE When prying with a screwdriver, wrap it with pro-



1. Remove the crash pad side cover (A).

A

SUNBD6710D


CRASH PAD REPLACEMENT

NOTE When prying with a flat-up screwdriver, wrap it

with protective tape, and apply protective tapearound the related parts, to prevent damage.


1. Remove the following items. Front seat (Refer to page BD-80). Cluster facia panel, cluster (Refer to page

BD-54). Audio assembly (Refer to page BD57). Glove box (Refer to page BD-00). Crash pad side cover (Refer to page BD-58). Front pillar trim (Refer to page BD-66).

2. Remove the photo sensor (C).3. Disconnect the passengers air bag connector (A).

INTERIOR BD -61

4. Loosen the bolts and nuts, then remove the crash pad(C).


NOTE Make sure the crash pad fits onto the guide pins

correctly.

Before tightening the bolts, make sure the crashpad wire harnesses are not pinched.

Make sure the connectors are plugged in prop-erly, and the antenna lead is connected properly,

Enter the anti- theft code for the radio, then enterthe customers radio station presets.

C

B

A

: Bolt : Nut

B

Fastener Locations

SUNBD6765L

BD -62 BODY (INTERIOR AND EXTERIOR)ROOF TRIM

COMPONENTS EDF975D6

7

1

87

87

6

5

4

3 2

1. Headliner2. Overhead console lamp3. Sunvisor4. Retainer

5. Sunvisor6. Holder7. Assist handle8. Room lamp

SUNBD6911L

INTERIOR BD -63

REPLACEMENT ED434AF3SUNVISOR REPLACEMENT


with protective tape to prevent damage. Put on gloves to protect your hands.

1. Remove the sunvisor (A) and retainer (B) from eachside.

2. Disconnect the connector (C).

: Screw locations

BC

A

SUNBD6884L


ASSIST HANDLE REPLACEMENT



1. Remove the covers, and remove the screws, then re-move the assist handle (A).

A


SUNBD6879L


OVERHEAD CONSOLE LAMP REPLACEMENT



1. Remove the overhead console Remove the screw. Pull out the roof console (A). Disconnect the connector (B).


B

A

SUNBD6903L


BD -64 BODY (INTERIOR AND EXTERIOR)ROOM LAMP REPLACEMENT



1. Remove the room lamp. Remove the lens (A). Remove the screws. Pull out the room lamp (B). Disconnect the connector (C).

B

C

A

locations

SUNBD6075L


HEADLINER REPLACEMENT

NOTE- Put on gloves to protect your hands.- When prying with a flat-tip screwdriver, wrap it

with protective tape to prevent damage.- Take care not to bend or scratch the trim and

panels.

1. Remove the following items.- Front seat, rear seat assembly (Refer to page

BD-80, 89).- Door scuff trim (Refer to page BD-66).- Front pillar trim (Refer to page BD-66).- Center pillar trim (Refer to page BD-67).- Rear pillar trim (Refer to page BD-68).- Overhead console (Refer to page BD-63).- Room lamp (Refer to page BD-64).- Sunvisor (Refer to page BD-63).- Assist handle (Refer to page BD-63).

2. Remove the roof trim (A).

: Clip locations

A

SUNBD6526L


NOTEReplace any damage clips.

INTERIOR BD -65

INTERIOR TRIM

COMPONENTS E626B959

9

8

7

6

1

2

3

4 5

1. Front pillar trim2. Cowl side trim3. Center upper pillar trim4. Center lower pillar trim5. Rear pillar trim

6. Front door scuff trim7. Rear door scuff trim8. Front door step9. Rear door step10. Center pillar trim

SUNBD6993L

BD -66 BODY (INTERIOR AND EXTERIOR)REPLACEMENT E4689BCBDOOR SCUFF TRIM REPLACEMENT

NOTE Put on gloves to protect your hands. When prying with a flat-tip screwdriver, wrap it

with protective tape to prevent damage. Take care not to bend or scratch the trim and

panels.

1. Remove the front door scuff trim (A).

A

B

SUNBD6841D


NOTE Replace any damage clips.

FRONT PILLAR TRIM



panels.

1. Remove the front pillar trim (A).

A

: Screw locations

SUNBD6842L



INTERIOR BD -67

COWL SIDE TRIM REPLACEMENT



panels.

1. Remove the front door scuff trim (Refer to pageBD-66).

2. Remove the cowl side trim (A).

A

: Screw : ClipFastener Locations

SUNBD6506L



CENTER PILLAR TRIM REPLACEMENT



panels.

1. Remove the front seat belt lower anchor(Refer to pageBD-103).

2. Remove the door scuff trim (Refer to page BD-66).3. Remove the center lower pillar trim (A).4. Remove the center upper pillar trim (B).

B

A

: Bolt : ScrewFastener Locations

SUNBD6847L



BD -68 BODY (INTERIOR AND EXTERIOR)REAR PILLAR TRIM REPLACEMENT



panels.

1. Remove the luggage side trim.

2. Remove the rear pillar trim (A).

A

: Bolt locations

SUNBD6861L



INTERIOR BD -69

LUGGAGE SIDE TRIM REPLACEMENT

NOTE Put on gloves to protect your hands. When prying with a flat-tipped screwdriver, wrap

it with protective tape to prevent damaged. Take care not to bend or scratch the trim and

panels.

1. Remove the rear seat (Refer to page BD-89).2. Remove the rear seat belt lower anchor (Refer to page

BD-104).3. After loosening the mounting screws, then remove the

luggage side trim.


12

4

3

1. Luggage side trim2. Transverse trim

3. Luggage side trim4. Luggage side cover

SUNBD6994L

BD -70 BODY (INTERIOR AND EXTERIOR)WINDSHIELD GLASS

COMPONENTS EF82E0AB

1

2

1. Windshield molding2. Windshield glass

SUNBD6995L

INTERIOR BD -71

REPLACEMENT EF0EE08AREMOVAL

NOTE- Put on gloves to protect your hands.- Use seat covers to avoid damaging any surfaces.

1. Remove the following items:- Inside rear view mirror.- Sunvisors and holders, both sides, overhead

console, Grab handles, both sides.- Front pillar trim, both sides.- Windshield wiper arms and cowl cover. (See

page BE- "Windshield wiper")

2. Remove the molding (A) from the edge of the wind-shield (B). If necessary, cut the molding with a utilityknife.

A

A

B

SHDBD6604L

3. Pull down the front portion of the headliner. Takecare not to bend the headliner excessively, or you maycrease or break it.

4. Cut out the sealant using the sealant cutting tool[A(09861-31100)].

A

A

SHDBD6515D

5. Remove the winshield (B) carefully using the glassholder [A (09861-31100)].

B

A

ASIE070D

BD -72 BODY (INTERIOR AND EXTERIOR)INSTALLTION

1. With a knife, scrape the old adhesive smooth to athickness of about 2mm (0.08 in.) on the bondingsurface around the entire windshield opening flange:- Do not scrape down to the painted surface of the

body; damaged paint will interfere with properbonding.

- Remove the rubber dam and fasteners from thebody.

- Mask off surrounding surfaces before painting.

2. Clean the body bonding surface with a sponge damp-ened in alcohol. After cleaning, keep oil, grease andwater from getting on the clean surface.

3. Apply the glass primer (A) to the side of the windshieldglass edge and stick the both-sided adhesive tape (B)on the inside of molding (C).

4. When attaching the molding, make it in line (D) withthe windshield glass and attach the windshield glasspad (E)to the designated place.

A

C

B

B

E

D

E

E

E

ESQE300M

5. Install the spacer (A) install the windshield glass (B)temperarily with making sure to position them on thecenter, and then place the alignment mark (C).

6. Remove the windshield.

C

AAB

SHDBD6513D

7. Apply a light coat of glass primer to the outside of thefasteners.

NOTE- Never touch the primed surface with your hand.

If you do, the adhesive may not bond to the glassproperly, causing a leak after the windshieldglass is installed.

- Do not apply body primer to the glass.- Keep water, dust, and abrasive materials away

from the primer.

: Apply glass primer here.

ESQE433D

INTERIOR BD -73

8. With a sponge, apply a light coat of body primer tothe original adhesive remaining around the windshieldopening flange. Let the body primer dry for at least 10minutes:- Do not apply glass primer to the body, and be

careful not to mixup glass and body primersponges.

- Never touch the primed surfaces with your hands.- Mask off the dashboard before painting the

flange.

: primer

SHDBD6603L

9. Pack adhesive into the cartridge without air pocketsto ensure continuous delivery. Put the cartridge in acaulking gun, and run a bead of sealant (A) aroundthe edge of the windshield (B) between the fastenerand molding as shown. Apply the adhesive within30 minutes after applying the glass primer. Make aslightly thicker bead at each corner.

B

A

A B

12.5mm

8mm

ESQE300W

10. Use glass holder (A) to hold the windshield over theopening, align it with the alignment marks (B) madein step 15, and set it down on the adhesive. Lightlypush on the windshield until its edges are fully seatedon the adhesive all the way around. Do not open orclose the doors until the adhesive is dry.

C

A B

SHDBD6514D

BD -74 BODY (INTERIOR AND EXTERIOR)11. Scrape or wipe the excess adhesive off with a putty

knife or towel. To remove adhesive from a paintedsurface or the windshield, wipe with a soft shop toweldampened with alcohol.

12. Let the adhesive dry for at least one hour, then spraywater over the windshield and check for leaks. Makeleaking areas, and let the windshield dry, then sealwith sealant:- Let the vehicle stand for at least four hours after

windshield installation. If the vehicle has to beused within the first four, it must be driven slowly.

- Keep the windshield dry for the first hour afterinstallation.

13. Reinstall all remaining removed parts. Install therearview mirror after the adhesive has dried thor-oughly. Advise the customer not to do the followingthings for two the three days:- Slam the door with all the windows rolled up.- Twist the body excessively (such as when going

in and out of driveways at an angle or driving overrough, uneven roads).

INTERIOR BD -75

COWL TOP COVER

REPLACEMENT EB022845

1. Remove the wiper (A).

: Bolt locations, 2

A

SUNBD6992L

2. Detach the clips, then remove the cowl top cover (A).

A

Clip locations

SUNBD6027L


BD -76 BODY (INTERIOR AND EXTERIOR)BUMPER

FRONT BUMPER

REPLACEMENT EB7632B0

1. Remove the front bumper


with protective tape to prevent damage. Take care not bend or scratch the cover and other

parts.


12

3

4

5

67

8

1. Front cover2. Bumper lip3. Bumper cover4. Radiator grill

5. Bumper center grill6. Fog lamp7. Energy8. Bumper rail

SUNBD6997L

BUMPER BD -77

65

4

3

1

2

7

1. Bumper lip2. Bumper cover3. Radiator grill4. Bumper center mech

5. Energy absorber6. Bumper rail7. Fog lamp

SUNBD6520L

BD -78 BODY (INTERIOR AND EXTERIOR)REAR BUMPER

REPLACEMENT EB90FF02

NOTE After remove the rear combinati0n lamp. When prying with a flat-tip screwdriver, wrap it

with protective tape and apply protective tapearound the related parts your hands.

Put on gloves to protect your hands. Take care not bend or scratch the cover and other

parts.

1. Remove the rear combination lamp (A).2. Loosen the rear bumper cover screws and clips.

3. Remove the rear bumper .


NOTEReplace any damage clips.

1

2

3

45

1. Bumper cover2. Energy absorber3. Bumper rail

4. Ultrasonic sensor5. Wiring

A

SUNBD6998L

SEAT BD -79

SEATFRONT SEAT

COMPONENTS EDC5B0DB

1. Headrest2. Headrest guide3. Seat back cushion4. Seat back frame5. Back panel

6. Recliner cover7. Recliner lever8. Height lever9. Recliner cover10. Leg assembly

11. Front cover12. Seat cushion frame13. Seat cushion14. Recliner cover15. Recliner cover

1

2

34

5

6

7

89

10

11

12

13

1415

SUNBD6607L

BD -80 BODY (INTERIOR AND EXTERIOR)REPLACEMENT E8ADFD33SEAT ASSEMBLY REPLACEMENT

1. Remove the seat assembly mounting cover.

2. After loosening the seat assembly mounting bolts andnuts, remove the seat assembly (A).

locations

A

34.3 ~ 53.9 N.m(3.5 ~ 5.5 kgf.m,25.3 ~ 39.8 lbf.ft)

SUNBD6029L

3. Disconnect the connector (A), and remove the seatassembly.

A

SUNBD6532D


CAUTIONSEAT MOUNTING BOLT INSTALLATION PROCE-DURE (manual seat only)

Set the into the most rearward position.Check then each slide is locked, and thentighten the front mounting bolt temporarily.

Set the seat into most forward position.Check that each slide is locked, and thentighten the rear mounting bolt completely.

Set the seat into the most rearward position.Check the front mounting bolt completely.

Check that the seat operates to and frosmoothy and the locking portion locks prop-erly.

SEAT BD -81

RECLINER COVER REPLACEMENT

DRIVERS

1. Remove the clip (D).2. Remove the recliner lever (C).3. Using a screw driver, remove the recliner lever cab

(A).4. After loosening the height lever mounting screw, then-

remove the height lever (B).


C

D

AB

D

SUNBD6537L

5. Remove the front cover (A).6. After loosening the mounting screws, then remove the

recliner cover (B).

A

B


SUNBD6542L


BD -82 BODY (INTERIOR AND EXTERIOR)SEAT CUSHION COVER REPLACEMENT

1. Remove front seat assembly (Refer to page BD -80).2. Remove the recliner cover (Refer to page BD-81).3. Disconnect the heater connector (A) and airbag con-

nector (B).

B

A

SUNBD6563D

4. Disconnect the seat cushion assembly (A) and seatback assembly (B).

A

B

: Bolt locations

SUNBD6567L

5. After disconnect the protector (A), then remove theseat cushion (B).

A

A

SUNBD6560D

6. Disconnect the heater connector and remove the seatcushion (A).

A

SUNBD6593D

7. After removing the hogring clip (A) on the front ofseatcushion and remove the seat cushion cover (B).

A

B

SUNBD6578D


SEAT BD -83

SEAT BACK COVER REPLACEMENT

1. Remove front seat assembly (Refer to page BD-80).2. Remove the recliner cover (Refer to page BD-81).3. After disconnecting the scuff band (A), remove the-

seat back panel (B).

B

A

SUNBD6559D

4. Disconnect the heater connector (A) and airbag con-nector (B).

B

A

SUNBD6563D


A

B

: Bolt locations

SUNBD6567L

6. Disconnect the protector (A) from the back frame.

A

A

A

A

SUNBD6569D

BD -84 BODY (INTERIOR AND EXTERIOR)7. Pull out the headrest guides (A) while pinching the

end of the guides, and remove them.

A

SUNBD6571D

8. AfterAfter removing the hogring clip (A) on the frontofseat cushion and remove the seat cushion cover(B).

A

B

SUNBD6577D


SEAT FRAME REPLACEMENT

NOTE Remove the side air bag for replacing side air bag

installation seat. Be fore service, be fully aware of precautions and

service procedure relevant to air bag (Refer topage RT-Airbag)

1. Disconnect the heater connector (A) and airbag con-nector (B).

B

A

SUNBD6563D


A

B

: Bolt locations

SUNBD6567L

SEAT BD -85

3. Remove the seat cushion cover.

4. Remove the seat back cover.


SEAT CUSHION HEATER REPLACEMENT

1. Remove the seat cushion cover (Refer to pageBD-82).

2. Cut the heater (A) attached to the pad (B), as shownin the picture.

3. Take off the paper from the backside of the heat-erassembly.

4. Attach the heater to the main part of pad.

5. Install the seat cushion cover.

A

B

SUNBD6582D

SEAT BACK HEATER REPLACEMENT

1. Remove the seat back cover (Refer to page BD- 83).2. Cut the heater (A) attached to the pad (B), as shown

in the picture.

3. Take off the paper from the backside of the heat-erassembly.

4. Attach the heater to the main part of pad.

5. Install the seat back cover.

A

B

SUNBD6587D

BD -86 BODY (INTERIOR AND EXTERIOR)REAR SEAT

COMPONENTS EECBBA25SECONDARY SEAT

1

3

2

4

5 6

7

89

10

11

12

13

14

15

17

16

20

1918

1 Headrest2 Recliner lever cover3 Headrest guide4 Seat back panel5 Recliner cover6 Armrest7 Cover

8 Recliner lever9 Seat back frame10 Seat cushion cover11 Seat cushion lower panel12 Seat cushion lower panel13 Seat cushion frame panel14 Seat cushion frame

15 Leg assembly16 Armrest17 Seat back cover18 Recliner cover19 Recliner cover20 Cover

SUNBD6103L

SEAT BD -87

1

2

11

12

3

4

5

6

7

8

9

10

13

14

1. Headrest2. Headrest guide3. Seat back cushion4. Armrest5. Seat cushion

6. Seat cushion panel7. Seat cushion panel8. Seat frame cover9. Seat frame10. Leg assembly

11. Seat back panel12. Seat back frame13. Recliner cover14. Recliner cover

SUNBD6104L

BD -88 BODY (INTERIOR AND EXTERIOR)THIRD SEAT

1

2

3

4

5

6

7

8

1. Seat back panel2. Headrest3. Headrest guide4. Seat back frame

5. Seat back cushion6. Seat cushion7. Seat cushion frame8. Leg assembly

SUNBD6334L

SEAT BD -89

REPLACEMENT E5D84D18SECONDARY SEAT

SEAT ASSEMBLY REPLACEMENT

1. Loosen the mounting bolt, then remove the rear seatassembly (A).

: Bolt locations34.3 ~ 53.9 N.m(3.5 ~ 5.5 kgf.m,25.3 ~ 39.8 lbf.ft)

A

SUNBD6339L


(RH)SEAT CUSHION COVER REPLACEMENT

1. Remove the clip (B).2. Remove the recliner lever (A).

A

B

B

SUNBD6354D

3. After loosening the mounting screw, then remove thecover (A).

A

: Screw locations

SUNBD6347L

BD -90 BODY (INTERIOR AND EXTERIOR)4. After loosening the mounting screws, then remove the

recliner cover (A).

A

: Screw locations

SUNBD6510L

5. After loosening mounting screws, then remove theseat cushion assembly (A).

A


SUNBD6351L

6. Remove the cover (A).

A

SUNBD6392D

7. Disconnect the protector (A) and remove the panel(B).

B

A

SUNBD6394D

8. Disconnect the adhesives (A) on the front of seatcushion, remove the seat cushion cover (B).

A

B

SUNBD6398D


SEAT BD -91


1. Remove the recliner cover.

2. Remove the recliner cable (A).

A

SUNBD6356D

3. After loosening the mounting bolt, then remove thearmrest (A).

A

: Bolt locations

SUNBD6360L

4. Remove the bend (A).A

SUNBD6363D

5. Remove the back panel (A).

A

SUNBD6364D

6. Pull out the headrest guides (A) while pinching theend of the guides, and remove them.

A

SUNBD6368D

BD -92 BODY (INTERIOR AND EXTERIOR)7. After removing the hogring clip on the front ofseat

cushion and remove the seat cushion cover (B).

B

SUNBD6369D



1. Remove the following items. Recliner cover Headrest guide Seat back cover Seat cushion cover

2. Remove the frame cover (A).

A

SUNBD6377D

3. After loosening the mounting bolts, then disconnectthe seat back frame (B) and seat cushion frame (A).

: Bolt locations, 4

B

A

SUNBD6385L

SEAT BD -93

4. After loosening the mounting nuts, then remove theseat cushion frame (A).

: Nut locations, 10A

SUNBD6390L


(LH)SEAT BACK COVER REPLACEMENT

1. After loosening the mounting screws, then remove therecliner cover (A).

A


SUNBD6436L

2. Remove the clip (B) and recliner lever (A).

A

B

B

SUNBD6428D

BD -94 BODY (INTERIOR AND EXTERIOR)3. After loosening the mounting screw, then remove the

recliner cover (A).

A

: Screw locations

SUNBD6443L

4. Remove the screw and cover (A).

A


SUNBD6446L

5. After loosening the mounting bolt and nut, then re-move the armrest mounting bracket (A).

: Bolt : Nut

A

Fastener Locations

SUNBD6450L

6. Remove the bolt and armrest (A).

A

: Bolt locations, 1

SUNBD6453L

SEAT BD -95

7. Remove the armrest (A).

A

: Bolt locations, 1

SUNBD6454L

8. Disconnect the protector (A) and zipper (B).

B

A

SUNBD6465D

9. Remove the panel (A).

A

SUNBD6458D


A

SUNBD6466D

11. After removing the hogring clip(B) on the front of seatcushion and remove the seat cushion cover (A).

A

B

SUNBD6468D


BD -96 BODY (INTERIOR AND EXTERIOR)SEAT CUSHION COVER REPLACEMENT

1. After puling the ribbon (A) remove the seat cushion(B).

B

A

SUNBD6429D

2. After loosening mounting screws, then remove theseat cushion assembly (A).


A

SUNBD6432L

3. Remove the panel (A).

A

: Clip locations

SUNBD6481L

4. Disconnect the protector (B) and remove the panel(A).

A

B

SUNBD6397D

SEAT BD -97


A

B

SUNBD6490D


1. Remove the following items. Recliner cover Headrest guide Seat back cover Seat cushion cover

2. Remove the frame cover (A).

A

SUNBD6472D

3. Remove the cover (A).


A

SUNBD6475L

BD -98 BODY (INTERIOR AND EXTERIOR)4. Disconnect the recliner cable (C).5. After loosening the mounting bolts, then disconnect

the seat back frame (B) and seat cushion frame (A).

B

A

C

: Bolt locations

SUNBD6479L


THIRD SEAT

SEAT ASSEMBLY REPLACEMENT

1. After loosening the mounting screws, then remove thebox (A).

A


SUNBD6267L

2. After loosening the mounting bolts, then remove theseat assembly (A).

: Bolt locations

A

34.3 ~ 53.9 N.m(3.5 ~ 5.5 kgf.m, 25.3 ~ 39.8 lbf.ft)

SUNBD6081L


SEAT BD -99


1. Remove the third seat assembly (Refer to pageBD-98).

2. Remove the seat back panel (A).

A

SUNBD6296D

3. Remove the recliner lever mounting nut (A).

: Nut locations, 1

A

SUNBD6301L

4. Disconnect the protector (A).

A

AA

A

SUNBD6307D


A

SUNBD6309D

BD -100 BODY (INTERIOR AND EXTERIOR)6. After removing the hogring clip (A) on the front ofseat

cushion and remove the seat cushion cover (B).

A

B

SUNBD6319D


SEAT CUSHION COVER REPLACEMENT

1. Remove the third seat assembly (Refer to pageBD-98)

2. Disconnect the protector (A).

A

A

SUNBD6283D

3. Remove the seat cushion (A).

A

SUNBD6288D

SEAT BD -101


B

A

SUNBD6321D



1. Remove the seat back cover (Refer to page BD-99).2. Remove the seat cushion cover (Refer to page

BD-100).3. Remove the clip (A) and pin (C).4. After loosening the mounting bolts, then disconnect

the seat back frame (D) and seat cushion frame (B).

: Bolt locations, 1

B

D

A

C

SUNBD6314L


BD -102 BODY (INTERIOR AND EXTERIOR)SEAT BELT

COMPONENTS E38B0C09

3

1

2

4

7

5

6

1. Front seat belt2. Front seat belt retractor3. Height adjuster4. Secondary seat belt

5. Secondary seat belt retractor6. Third seat belt7. Third seat belt retractor

SUNBD6102L

SEAT BD -103

REPLACEMENT EA6959DDFRONT SEAT BELT REPLACEMENT

CAUTIONWhen installing the belt, make sure not to damagethepretensioner.

1. Remove the following items fist. Front seat assembly (Refer to page BD-80). Door scuff trim (Refer to page BD-66).

2. After raise the lower anchor cover (A), loosen thelower anchor mounting bolt (B).

B

A

Bolt locations, 39.2 ~ 53.9 N.m4.0 ~ 5.5 kgf.m, 28.9 ~ 39.8 lbf.ft)

SUNBD6844L

3. Remove the center pillar lower trim (Refer to pageBD-67).

4. Remove the center pillar upper trim (Refer to pageBD-67).

5. Remove the upper anchor (A).

6. After disconnecting the pretensioner connector lockpin, remove the connector (B), Loosen the mounting-bolt, then remove the pretensioner (C).

B

A

C


SUNBD6889L


BD -104 BODY (INTERIOR AND EXTERIOR)SECONDARY SEAT BELT RELACEMENT

CAUTIONWhen installing the belt, make sure not to dam-aged thepretensioner.

1. Remove the following items first. Rear seat assembly (Refer to page BD-89). Rear door scuff trim (Refer to page BD-66).

2. Remove the lower anchor (A).

A


SUNBD6845L

3. Remove the luggage side trim (Refer to page BD-69).4. Remove the gate pillar trim. (Refer to page BD-68).5. Remove the upper anchor (A).

6. After loosening the retractor (B) mounting bolt, then-remove the rear seat belt (C).

C

A


B

SUNBD6893L


SEAT BD -105

THIRD SEAT BELT RELACEMENT

CAUTIONWhen installing the belt, make sure not to dam-aged thepretensioner.

1. Remove the following items first. Third seat assembly (Refer to page BD-98). Rear door scuff trim (Refer to page BD-66).

2. Remove the lower anchor (A).

A


SUNBD6860L

3. Remove the luggage side trim (Refer to page BD-69).4. After loosening the retractor (B) mounting bolt,remove

the rear seat belt .


AB

SUNBD6899L


FRONT SEAT BELT BUCKLE REPLACEMENT

1. Remove the front seat assembly (Refer to pageBD-80).

2. Remove the wire harness of buckle from seat.

3. Remove the seat belt buckle (A).

A


SUNBD6617L


SECONDARY SEAT BELT BUCKLE REPLACEMENT

1. Remove the secondary seat assembly

2. Remove the secondary seat cushion.

A


SUNBD6511L

3. Remove the seat belt buckle (A).

BD -106 BODY (INTERIOR AND EXTERIOR)HEIGHT ADJUSTER REPLACEMENT

1. Remove the following items first. Front seat assembly (Refer to page BD- 80). Door scuff trim (Refer to page BD- 66). Front seat belt (Refer to page BD- 104). Center pillar trim (Refer to page BD-67).

2. After loosening the mounting bolt, then remove theheight adjuster (A).


A

SUNBD6963L


Documents

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