Workshop Manual PAJERO SPORT

42-1BODYCONTENTS42109000317BODY MOUNTING ........................ 3ON-VEHICLE SERVICE ................ Door Fit Adjustment ................. Door Window Glass Adjustment ...... 272727HOOD .................................... 4Adjustment and Replacement When There is a Malfunction of The Power Windows ........ 27Power Window Safety Mechanism Check .. 28Door Outside Handle Play Check ..... 28Power Window Operation CurrentCheck .............................. 29Circuit Breaker (lncorporated in the Power Window Motor) Check ............... 29Door lnside Handle Play Check andFENDER .................................. 5SEALANT ............................... 5FENDER ................................ 5FUEL FILLER DOOR ..................... 6WINDOW GLASS ......................... 7Adjustment .......................... 29ADHESIVES ............................. 7DOOR ASSEMBLY ..................... 30SPECIAL TOOL ......................... 7DOOR TRIM AND WATERPROOFFILM .................................. WINDOW REPAIR ....................... 732WINDSHIELD ............................ 9DOOR GLASS AND REGULATOR ...... 35QUARTER WINDOW GLASS ........... 12DOOR HANDLE AND LATCH .......... 39TAILGATE WINDOW GLASS ........... 14WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP ..... 42DOOR .................................. 16TAILGATE .............................. 43SERVICE SPECIFICATIONS ............ 16SEALANT ............................. 43SEALANT ............................. 16SPECIAL TOOL ....................... 43SPECIAL TOOLS ...................... 16TROUBLESHOOTING .................. 43TROUBLESHOOTING .................. 18CONTINUED ON NEXT PAGE

42-2ON-VEHICLE SERVICE ................ Tailgate Fit Adjustment ............... Tailgate Handle Play Inspection ....... 434344SUNROOF .............................. 49SEALANT AND ADHESIVE ............. 49ON-VEHICLE SERVICE ................ Water Test .......................... Sunroof Fit Adjustment ............... Operation Check .................... 49494950TAILGATE ASSEMBLY ................. 45TAILGATE TRIM AND WATERPROOF FILM....................................... 47TAILGATE HANDLE AND LATCH ....... 48SUNROOF ............................ 52

42-3BODY Body MountingBODY MOUNTING42100370066REMOVALAND INSTALLATIONDDBCABBCBA19Mounting boltPlain washerBody mounting rubberBody mounting rubber ASpacerBody mounting rubber BBody mount washerBody mount stopperSelf locking nutA1245672927 31 NmB1245682927 31 NmC1245672927 31 NmD4568227 31 Nm

42-4BODY HoodHOODREMOVAL42100160328AND INSTALLATION17 1671510212 Nm822 Nm691134129 Nm15139 Nm12 Nm14around hoodHood lock release handleHood bumperHood bumperHood damperHood side weatherstripHood weatherstripHood weatherstripHood silencerHood support rodHood and hood hinge removal stepsWasher hose connectionHood latch and hood lock release cable removal stepsRadiator grilleHood latchCable protectorJunction blockHood lock release cableHood garnish removal stepsHood garnishHood intercooler weatherstripHood intercooler weatherstrip plate10. HoodFront deck garnish (Refer to GROUP51 Windshield Wiper and Washer.) 11. Hood hinge113Adjustment of clearance and height12Adjustment of hood step and hood striker linkage121

42-5BODYFenderFENDERSEALANT42100050175FENDERREMOVAL42100190273ANDINSTALLATION43211Removal stepsMud guardSplash shieldSide turn-signal lampFender]A}REMOVAL SERVICEPOINT]A} SIDE TURN-SIGNAL LAMP REMOVALUse a flat-tipped () screwdriver or similar toolto removethe lock from the fender panel, and remove the side turn-signal lamp.Lock(Right side only)2Sealant: 3M ATD Part No.8625 or equivalentPre-removal and Post-installation OperationFront Bumper Removal and lnstallation Headlamp Removal and lnstallation (Refer to GROUP(Refer to GROUP 51 Front Bumper.) 54 Headlamp and Front Combination Lamp.)Front Deck Garnish Removal and lnstallation (Refer Wide Fender Removal and lnstallation (Refer to to GROUP 51 Windshield Wiper and Washer.) GROUP 51 Wide Fender.)ltemSpecified sealantRemarkSplash shield3M ATD Part No. 8625 or equivalentRibbon sealer

42-6BODYFuelFillerDoorFUEL FILLER DOOR42100250308REMOVALANDINSTALLATION4123453Removal stepsFuel filler door panelFuel filler door hookFuel filler door lock release cableLid lock release handleClip2Fuel filler door height and clearance adjustmentPre-removal and Post-installation OperationDriver's Side Front Seat Removal and lnstallation(Refer to GROUP 52A Front Seat.)Rear Seat Removal and lnstallation (Refer to GROUP 52A Rear Seat.)Quarter Trim Lower (L.H.) Removal and lnstallation(Refer to GROUP 52A Trims.)

42-7BODYWindowGlassWINDOW GLASSADHESIVES42200050154SPECIAL TOOL42200060089WINDOW REPAIR42200560107The following glass sections are installed by means of a liquid urethane adhesive method.WindshieldQuarter window glass Tailgate window glassITEMS NEEDEDNOTEThe TEROSON 127.37V auto window sealer kit can also be used. lf using the TEROSON 127.37V autowindow sealer kit, follow the instructions in the manual included with the kit.NameRemarksAdhesive3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalentPrimer3M ATD Part No. 8608 Super Fast Urethane Primer or equivalentSpacersAvailable as service partDamAvailable as service partAnti-rust solvent(or Tectyl 506T...Valvoline Oil Company)For rust preventionlsopropyl alcoholFor grease removal from bonded surfaceSteel piano wireDia. length...0.6mm 1m for cutting adhesiveAdhesive gunFor pressing-out adhesiveToolNumberNameUseMB990480Glass holderRemoval and installation of windshieldltemsSpecified adhesivesWindshieldQuarter window glassTailgate window glass3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealants or equivalentWindshield mouldingDouble-sided tape (6 mm wide and 0.125 mm thick)

42-8BODY Window GlassHANDLING OF AUTO WINDOW SEALERKeep the sealant in a cool place, not exposed to the direct rays of the sun. Do not place any heavy article on the sealant nor press it, otherwise it will become deformed. Avoid storing the sealant for more than 6 months, because it will lose its sealing effect.BODY PINCH-WELD FLANGE SERVICING.Before servicing the body pinch-weld flange, remove old adhesive completely. lf the flange requires painting, bake it after painting is completed.WORKINGPROCESSReusing the glassadhering to the adhe-opropyl alcohol, andohol, and let dry forlet dry for 3 minutes or more.and let dry for 3 minutes or more.Glue the window spacer and dual lock fastener to the glass, following the standard positionand dual lock fastenerlass.installed.imeradhesion surface of theWindow glass installation procedureBody sideWindow glass sideReplacing the glassCleaning of adhesion surfaceCut off the residual adhesive until the thickness is less than 2 mm. Clean theCleaning of adhesion surfaceCompetely cut off all of the residualCleaning of adhesion surfaceClean off any dirtadhesive. Clean the adhesion surfacesion surface with isadhesion surface with isopropyl alcohol,with isopropyl alc3 minutes or more.Attaching of spacer and dual lockGluing window spacer and dual lock fastenerfastenerAttach the spacerall the way around the inside edge of the gto set the positionsfor the glass to beApplication of primerApplication of prApply sufficient primer evenly to the adhesionsurface so that there is no patchiness. Afterapplication, let dry for 3 minutes or more.Apply to thebody and let dry for3 minutes or more.Application of adhesiveWithin 30 minutes after applying the primer, apply the adhesive evenly all the way aroundthe inside edge of the glass.Installing the glassAfter applying the adhesive, lightly press the glass evenly so that it adherescompletely.CleaningAfter removing any adhesive that is sticking out or adhering to the body orglass with a spatula, ect., clean off with isopropyl alcohol.Checking for water leaksCarry out a shower test to check that no water will leak through.

42-9BODY WindowGlassWINDSHIELD42200100316REMOVALANDINSTALLATIONPrimer6211015367266415Removal stepsWiper deicer connectorWindshieldWindshield mouldingWindshield protectorWindow spacerWindow spacerDual lock fastener]A} }A]}A]3100 mm200 mm100 mmAdhesive tape: Double-sided tape(6 mm wide and 0.125 mm thick)mmSection A A Section B BSection C C15A 15 2110 Primer 6 Primer11.5C C6 14BAdhesive: 3M ATD Part No.8609 Super Fast Urethane Auto Glass Sealant or equivalentPre-removal and Post-installation OperationFront Deck Garnish Removal and lnstallation(Refer to GROUP 51 Windshield Wiper and Washer.)Front Pillar Trim Removal and lnstallation(Refer to GROUP 52A Trims.)Headlining Removal and lnstallation

42-10BODY Window GlassREMOVAL SERVICE POINT]A} WINDSHIELD REMOVAL1.ln order to protect the body (paint surface), apply cloth tape to all body areas around the installed windshield. Cut the moulding with a cutter knife.2.3.Using a sharp-point drill, make hole in the windshield adhesive.Pass the piano wire from the inside of the vehicle through the hole.Pull the piano wire alternately from the inside and outsidealong the windshield to cut the adhesive.CautionDo not let the piano wire touch the edge of the windshield.Make mating marks on the windshield and body.4.5.6.7.Use the special tool to remove the windshield.8.Use a knife to cut away the remaining adhesive so that the thickness is within 2 mm around the entire circumference of the body flange.Finish the flange surfaces so that they are smoothCautionBe careful not to remove more adhesive than is necessary.Be careful also not to damage the paintwork on the body surface with the knife. If the paintwork is damaged, repair the damaged area with repair paint or anti-rust agent.9.When reusing the windshield, remove the adhesive still adhering to the windshield, and clean with isopropyl alcohol.Clean the body side in the same way.CautionLet the cleaned places stand for 3 minutes or more, and carry out the next procedures after they have dried. Also, do not touch any surface that has been cleaned.MB990480

42-11BODY Window GlassINSTALLATION SERVICE POINT}A] DUAL LOCK FASTENER/WINDSHIELD INSTALLATIONation positionside1.When replacing the windshield, temporarily set the windshield against the body, and place a mating mark on the windshield and body.Use isopropyl alcohol to degrease the inside and outside of the windshield and the body flanges.Soak a sponge in the primer, and apply evenly to the windshield and the body in the specified places.Apply the primer, and then let it dry for 3 to 30 minutes.CautionThe primer strengthens the adhesive, so be sure to apply it evenly around the entire circumference.However, a too thick application will weaken theadhesive.Do not touch the coated surface.lnstall the dual lock fasteners to the windshield in the position shown in the illustration.lnstall the dual lock fasteners to the body flange in the positions that are corresponding to those on the windshield.Fill a sealant gun with adhesive. Then apply the adhesive evenly around the windshield within 30 minutes after applying the primer.NOTECut the tip of the sealant gun nozzle into a V shapeto simplify adhesive application.Align the mating marks on the windshield and the body, and lightly press the windshield evenly so that it adheres completely.Use a spatula or the like to remove any excessive adhesive. Then clean the surface with isopropyl alcohol. Try not to move the vehicle until the adhesive sets.2.3.4.5.6.7.8.9.10. Wait 30 minutes or more, and then test for water leakage.CautionDo not move the vehicle unless absolutely necessary.When testing for water leakage, do not pinch the end of the hose to spray the water.10 mm15 mmDual locGlass14Body sk fastener installEdge of glassEdge of ceramicsectionmmEdge of ceramic sectionideEdge of roof outer panel

42-12BODYWindowGlassQUARTER WINDOW GLASS42200250165REMOVALAND INSTALLATION3632B31CCA2ABRemoval stepsQuarter window glass assemblyDual lock fastenerWindow dam]A} }A]}A]}A]Section A A Section B B mm28 16314.5PrimerPrimerSection C CPrimerPrimer12.514.53Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalentPre-removal and Post-installation OperationQuarter Trim Upper Removal and lnstallation (Referto GROUP 52A Trims.)

42-13BODY Window GlassREMOVAL SERVICE POINT]A} QUARTER WINDOW GLASS REMOVALRemove the quarter window glass by the same procedure as for the windshield. (Refer to P.42-10.)INSTALLATION SERVICE POINTS}A] WINDOW DAM/DUAL LOCKFASTENER/QUARTER WINDOW GLASS INSTALLATION1.Use isopropyl alcohol to degrease the window dam and dual lock fastener mounting surface on both the glass and the body.Attach the window dam.lnstall the dual lock fastener to the shown position.Apply primer and adhesive. (Refer to P.42-12.)lnstall the glass in the same way as for the windshield.(Refer to P.42-11.)2.3.4.5.TransparentBody flange Ceramic lineB TransparentB Section A A22.7Section B B18.5Dual lock fastenermm

42-14BODYWindowGlassTAILGATE WINDOW GLASS42200370199REMOVALANDINSTALLATION51623B64BCAA7C51Removal stepsHarness connectorTailgate window glassTailgate window glass upper damTailgate window glass side dam}A]Tailgate window glass lower damDual lock fastenerClip]A} }A]}A]}A]}A]}A]Section A A Section B B Section C C mm31619.54Primer25Primer PrimerAdhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalentPre-removal and Post-installation OperationTailgate Garnish Removal and lnstallation (Refer to Tailgate Trim Removal and lnstallation GROUP 51 Grill, Moulding and Garnish.) (Refer to P.42-47.)High-mounted Stop lamp Removal and lnstallation(Refer to GROUP 54 High-mounted Stop lamp.)

42-15BODY Window GlassREMOVAL SERVICE POINT]A} TAILGATE WINDOW GLASS REMOVALRemove the tailgate window glass by the same procedure as for the windshield. (Refer to P.42-10.)INSTALLATION SERVICE POINT}A] CLIP/DUAL LOCK FASTENER/TAILGATE WINDOW GLASS LOWER DAM/TAILGATE WINDOW GLASS SIDE DAM/TAILGATE WINDOW GLASS UPPER DAM/TAILGATE WINDOW GLASS1.Use isopropyl alcohol to degrease the inside and outside edges of the tailgate window glass and the surface of the body flange.2.Face the clip's claws downward, and attach to the inner side of the tailgate window glass as shown in the illustration.Align the dual lock fastener to the markings on the glass, and install. Then, install the tailgate outer panel so that it is aligned.3.4.Attach the tailgate glass dam from the dam attachment reference mark to the edge of the glass.Apply primer and adhesive (Refer to P.42-14.)lnstall the glass in the same way as for the windshield.(Refer to P.42-11.)5.6.ence markTailgate glass side damDam att refer(ceramiTailgateglass upperdamachmentc white out)MarkingDual lock fastenerClip Centre36 mmGlass edge 350 mmView A

42-16BODYDoorDOORSERVICE42300030151SPECIFICATIONSSEALANT42300050034SPECIAL TOOLS42300060136ToolNumberNameUseMB991502MUT-II sub assemblyETACS-ECU input signal checkingMB990784Ornament removerRemoval of door trimltemsSpecified sealantRemarkWaterproof film3M ATD Part No. 8625 or equivalentRibbon sealerltemsStandard valueDoor outside handle play mm2.8 or morePower window operation current A7 or more (at 20C)Door inside handle play mm7.3 or moreGlass pad and glass holder installation position mmDistance (A) between glass holder and rear edge of glass106.7 108.2Distance (B) between glass holders417.5 420.5Distance (C) between glass holder and rear edge of glass127 131

42-17BODY DoorB: Power circuit inspectionToolNumberNameUseABCDMB991223A:MB991219B:MB991220C: MB991221D: MB991222Harness setA:Test harness B:LED harness C: LEDharnessadapter D: probeMeasurement of terminal voltageA: Connector pin contact pressure inspectionC: Power circuit inspectionD: Commercial tester connection

42-18BODY DoorTROUBLESHOOTINGDIAGNOSIS FUNCTIONINPUT SIGNAL INSPECTION POINTSConnect the MUT-II to the diagnosis connector.lf buzzer of the MUT-II sounds once when door lockactuator switch is operated (LOCK/UNLOCK), the ETACS-ECU input signal for that switch circuit system is normal.42300070207INSPECTION CHART FOR TROUBLE SYMPTOMSTrouble symptomlnspection procedureReference pagePower windowsThe power windows cannot be operated by any of the power window switches.142-19Driver's side power window cannot be operated by the power window main switch.242-20Passenger's side and rear power windows cannot be operated by the power window main switch. (However, they can be operated by the power window sub-switches.)342-21Passenger's side and rear power windows cannot be operated by the power window sub-switches. (However, they can be operated by the power window main switch.)442-21Passenger's side and rear power windows cannot be operated by both the power window sub-switches and by the power window main switch.542-22When the glass is raised, it then lowers automatically.642-24The glass is not lowered when something is jammed in the window.742-24When the glass is fully raised, it then lowers automatically.842-25Door locking mechanismNone of the door lock functions operate.942-25None of the doors lock or unlock when the driver's side inside door locking knob is operated (including by means of the door key).1042-26Some doors do not lock or unlock.1142-26MUT-II

42-19BODY DoorINSPECTION PROCEDUREFORTROUBLESYMPTOMSInspectionProcedure1NGheck.con-RepairNGswitch (lG2) and power window relay,con-NGwindow relay and the earth, and repairswitch, between power window relayRepairPower window relay continuity c(Refer to P.42-37.)ReplaceNGOKNGMeasure at the power window relay nector D-16X.Disconnect the connectormeasure at the harness side.Voltage between 3 and body earVoltage between 4 and body earOK: System voltageCheck the following connectC-37, D-16X, D-28, D-29and ththors:OKCheck trouble symptoms.Check the harness wire between ignitionbetween fusible link No.4 and power window relay, and repair if necessary.NGOKRepairNGMeasure at the power window relay nector D-16X.Disconnect the connectormeasure at the harness side.Continuity between 2 and body earOK: ContinuityCheck the following connectD-16Xand thor:OKCheck trouble symptoms.Check the harness wire between powerif necessary.NGOKOKCheck the following connectors:C-14, C-35, D-16X, E-02, E-26, E-39,F-05, F-07, F-19, F-21Check trouble symptoms.Check the harness wire between power window relay and power window mainand power window sub-switch, and re-pair if necessary.NGThe power windows cannot be operated by any of the power window switches.Probable causeThe cause may be a malfunction of the power window relay and of the power window relay drive circuit.Malfunction of power window relayMalfunction of wiring harness or connector

42-20BODYDoorInspectionProcedure2NGside)mainRepairWN)een powerRepairs:Repaireen powerPower window motor (driver's check (Refer to P.42-37.)ReplaceNGOKNGMeasure at the power window switch connector F-05.Voltage between 1 and body ear(When main switch is at UP)Voltage between 5 and body ear(When main switch is at DOOK: System voltageCheck the following connectC-35, F-05th thors:OKCheck trouble symptoms.NGOKNGCheck the harness wire betw window main switch and earth.NGOKReplace the power window main switch.RepairNGCheck the following connector F-03 , F-05, F-18 OKNGCheck trouble symptoms.Check the harness wire betw window main switch and power motor (driver's side).windowOKReplace the power window main switch.Driver's side power window cannot be operated by the power window main switch.Probable causeThe cause may be a malfunction of the earth circuit in the power window main switch or of the power supply circuit for the power window motor.The cause may also be a malfunction of the control circuit inside the power windowmain switch.Malfunction of power window motorMalfunction of power window main switchMalfunction of wiring harness or connector

42-21BODYDoorInspection Procedure 3 and switchswitch05, F-07-05, F-21OKCheck trouble symptoms.Check the harness wire between powersub-switch, and repair if necessary.OKOK NGCheck the following connectors: F-05, F-07 F-05, F-21Check trouble symptoms.Replace the power window main switch.NGMeasure at the power window switch connector F-05 and pow dow sub-switch connector F-19.Disconnect the connector measure at the harness sContinuity between 2 (main side) and 8 (sub-switch sid OK: ContinuityContinuity between 2 (mainside) and the earthOK: No continuityCheck the following cC-14, C-35, F-05, F-19Repairmainand switchswitchOKCheck trouble symptoms.Check the harness wire between powersub-switch, and repair if necessary.OKOK NGCheck the following connectors:F-05, F-19Check trouble symptoms.Replace the power window main switch.NGPassenger's side and rear power windows cannot be operated by the power window main switch. (However, they can be operated by the power window sub-switches.)Probable causeThe cause may be a malfunction of the power window main switch, or an open circuit or short-circuit in the communication line.Malfunction of power window main switchMalfunction of wiring harness or connector

42-22BODYDoorInspection Procedure 5 C-14, F-14 , F-28drive vehicles> E-26, F-07, F-11 E-02, F-21, F-25drive F-14 , F-28 F-07, F-11 F-21, F-25e ve-driveOKCheck trouble symptoms.NGOKCheck the harness between the limit switch and the power wi main switch or between the limit switch and the power wi sub-switch.Driver's side: Replace the power window main switch.Passenger's side: Replace the power window sub-switch.ndowNGWhen the glass is fully raised, it then lowers automatically.Probable causeWhen the window is within 10 mm of being fully closed, the limit switch turns off to prevent the window from being lowered. However, the above problem can occur if there is a malfunction of the limit switch or a short-circuit in a harness.Malfunction of limit switchMalfunction of wiring harness or connectorMalfunction of power window main switch or sub-switchlncorrect limit switch operation position

42-26BODYDoorInspectionProcedure 10NGNGiver's side).ounds onceactuatoronnectors:F-27 InspectionProcedure 11NGoperate.actuator of the door that does not operate, and repair if necessary.RepairCheck the door lock actuator of the door that does not(Refer to P.42-40, 41, 48.)ReplaceOKOKCheck the following connectors: C-34, D-31, F-13 ,F-27 D-31, E-25, E-40, F-08 D-31, E-01, E-40, F-22 C-01, D-31, E-16, G-04Check trouble symptoms.s>,NGCheck the harness between the ETACS-ECU and the door lockNGSome doors do not lock or unlock.Probable causeThe cause may be a malfunction of the door lock actuator or of a wiring harness or connector.Malfunction of door lock actuatorMalfunction of wiring harness or connectorMUT-II Pulse checkFront door lock actuator switch (dr side) input signalOK: The MUT-ll buzzer s when the front door lock moves from the locked to t locked position, or from th locked to the locked positDoor lock actuator check (dr(Refer to P.42-40.)ReplaceRepairiver's-he un- e un- ion.OKNGCheck the following cC-34, D-31, F-13 ,OKOKNGCheck trouble symptoms.Check the harness wire between the front door lock actuator (driver's side) and ETACS-ECU, between front door lock actuator and the earth, and repair if necessary.Replace the ETACS-ECU.None of the doors lock or unlock when the driver's-side inside door locking knob is operated (including by means of the door key).Probable causeThe cause may be a malfunction of the door lock actuator switch, the ETACS-ECU or of a wiring harness or connector.Malfunction of front door lock actuator (driver's side)Malfunction of ETACS-ECUMalfunction of wiring harness or connector

42-27BODY DoorON-VEHICLE SERVICEDOOR FIT ADJUSTMENT423000901591.lf the clearance between the door and body is uneven, remove the splash shield, loosen the mounting bolt of the body side door hinges from inside the fender, and then move the door to adjust so that the clearance is even.lf there is a step between the door and body, loosen the mounting bolts and nuts of the door hinges, and adjust the door alignment.lf the striker and latch do not engage properly, move the striker up and down or to the left and right.2.3.DOOR WINDOW GLASS ADJUSTMENT 42300100272Check that the window glass moves smoothly and touches the glass runchannel firmly when it is fully raised and fully lowered. lf the window glass doesn't move properly, adjustby1.the following procedure.Remove the door trim and waterproof film. (Refer toP.42-32.)Raise the window glass, loosen the channel guide mounting bolts and adjust the vertical tilt of the glass.2.ADJUSTMENT AND REPLACEMENT WHEN THERE IS A MALFUNCTION OF THE POWERWINDOWS42900190093lf the window glass automatically starts moving downwards at the wrong time while it is being raised, carry out the following adjustment or replacement procedures.Remove the door trim and waterproof film. (Refer to P.42-32.)Remove the window regulator assembly from the door window glass, and then raise and lower the door windowglass by hand to check the operation force.NOTElnsert a cushion or similar object to prevent damage to the glass if it should happen to fall down.RunchannelDoorsashLower sashChannel guideDoor hinge

42-28BODY Door3.lf the door window glass does not move up and down smoothly, check or repair the following points.Check the installation condition of the runchannel.Repair the twisting in the door sash.Check the installation condition of the lower sash or the center sash.NOTEThe lower sash cannot normally be adjusted, but it may be possible to adjust the sash span slightly within the range allowed by manufacturing tolerances by pushing the lower sash outwards while re-installing it.lf repair or adjustment is not possible, replace the door assembly.4.POWER WINDOW SAFETY MECHANISM CHECK42900100096Place a wooden board with a thickness of approximately 15 mm as shown in the illustration, and then raise the window glass.Check that the window lowers by a distance of approximately 150 mm when the window clamps thewoodenboard.lf thisdoesn't happen,referto Troubleshooting (P.42-24).DOOR OUTSIDE HANDLE PLAY CHECK 42300160157Check that the door outside handle play is within the standard value range.Standard value (B): 2.8 mm or morelf the door outside handle play is not within the standard value range, check the door outside handle or the door latch assembly. Replace, if necessary.AASection A AB

42-29BODY DoorPOWER WINDOW OPERATION CURRENTCHECK429001100991.Remove the power window fuse and connect a circuit analyser as shown in the illustration.When the power window switch is pulled to the UP position, a large amount of current flows at the time the window starts to close and when it is fully closed, so measurethe operation current in the interval between these twopoints.Standard value: 7A or more (at 20C)lf the operation current is outside the standard value,refer to Troubleshooting (P.42-18).2.3.CIRCUIT BREAKER (INCORPORATED IN THEPOWER WINDOW MOTOR) CHECK42900170127Pull the power window switch to the UP position to fully close the window glass, and keep pulling the switch for a further 10 seconds.Release the power window switch from the UP position and immediately press it to the DOWN position. Thecondition of the circuit breaker is good if the power window glass starts to move downwards within 60 seconds.DOOR INSIDE HANDLE PLAY CHECK ANDADJUSTMENT423001502531.Check that the door inside handle play is within the standard value range.Standard value (A): 7.3 mm or morelf the door inside handle play is outside the standard value range, remove the door trim. (Refer to P.42-32.) Loosen the inside handle mounting screws, and then move the inside handle back and forth to adjust the play.2.3.A

42-30BODYDoorDOOR ASSEMBLYREMOVAL AND INSTALLATION423002202823Front door4626 Nm12 Nm172826 Nm5Reardoor34626 Nm212 Nm26 Nm7815Door assembly removal stepsHarness connectorSpring pinStriker removalStrikerDoor switch removal stepsDoor switch capDoor switch3. Door assembly}A] 4. Door upper hinge}A] 5. Door lower hinge4, 5Post-installation OperationDoor Fit Adjustment (Refer to P.42-27.)

42-31BODY DoorINSTALLATION SERVICE POINT}A] DOOR LOWER HINGE/DOOR UPPER HINGE INSTALLATIONThe door hinges differ according so check the identification marksto where they are used,beforeinstallation.markINSPECTIONDOOR SWITCH CONTINUITY CHECK Driver's door switch42300600031Passenger's door and rear door switchSwitch positionTerminal No.12Open (ON)Depressed(OFF)21ON OFF StrokeSwitch positionTerminal No.123Open (ON)Depressed(OFF)123OFF ON StrokeApplicable locationldentificationFront left side doorUpper hingeF1Lower hingeE1Front right side doorUpper hingeE1Lower hingeF1Rear left side doorUpper hingeA1Lower hingeB1Rear right side doorUpper hingeB1Lower hingeA1Front Rearldentification mark ldentification mark

42-32BODY DoorDOOR TRIM AND WATERPROOF FILMREMOVAL AND INSTALLATION42300430265Frontdoor131019911A15A4121656A1817A8NOTE: Resin clip positionRemoval steps]A} }A] 1. Clip}A] 2. Regulator handle}A] 3. EscutcheonPull handle boxCoverDoor lamp8. Harness connectorRemote controlled mirror switchlnner delta coverDoor trimDoor inside handlePull handle bracketSpeakerSpeaker coverWaterproof film]B}9. Power window switch assemblySection A AClip1219Sealant:3M ATD Part No. 8625 orequivalent

42-33BODYDoorReardoor19151321641218141317857AANOTE: Resin clip positionRemoval stepsClipRegulator handleEscutcheonPull handle boxCoverAshtrayHarness connector12. Door trim]A} }A]}A]}A]Power window switchPower window switch coverDoor inside handlePull handle bracketSpeakerSpeaker coverWaterproof film19Sealant:3M ATD Part No. 8625 orequivalentSection A AClip12

42-34BODY DoorREMOVAL SERVICE POINTS]A} CLIP REMOVALRemove the clip by using a rag, and then remove the regulator handle.]B} POWER WINDOW SWITCH ASSEMBLY1.Use the special tool to remove the engagement.Remove the back claw engagement.frontareaclip2.AClipINSTALLATION SERVICE POINT}A] ESCUTCHEON/REGULATOR HANDLE/CLIP INSTALLATIONlnstall the escutcheon and the clip to the regulator handle.Fully close the front door glass, and install the regulator handle so that it faces as shown in the illustration.Horizontal line30Front of vehicleBBASection A A Section B BClaw

42-35BODY DoorDOOR GLASS AND REGULATOR42900130316REMOVALANDINSTALLATIONFrontdoor46387287109Power window relay removal stepsDriver's side under cover (Refer to GROUP 52A lnstrument Panel.)1. Power window relayFront window regulator assembly removal stepsDoor beltline inner weatherstripDoor beltline moulding assemblyDoor window glass runchannel6. Door window glass}B] 7. Door glass holderDoor glass padWindow regulator assembly}A] 10. Rear lower sash1Relay boxPost-installation OperationDoor Trim and Waterproof Film lnstallation(Refer to P.42-32.)Door Mirror lnstallation (Refer to GROUP 51 Door Mirror.)Door Window Glass Adjustment (Refer to P.42-27.)Pre-removal OperationDoor Trim and Waterproof Film Removal(Refer to P.42-32.)Door Mirror Removal (Refer to GROUP 51 Door Mirror.)

42-36BODY DoorReardoor41112 136532879Removal stepsDoor beltline inner weatherstripDoor beltline moulding assemblyDoor window glass runchannelDoor center sashDoor window glassDoor window glassDoor glass padWindow regulator assemblyStationary window glass andweatherstrip assemblyStationary window glassStationary window weatherstrip]A}}B]REMOVAL]A} DOORSERVICE POINTCENTER SASH REMOVAL (REAR DOOR)Remove the door outer opening weatherstrip from the door center sash section only.Remove the mounting screw for the door center sash,and remove the door center sash from the door panel.DoorcentersashDoor outeropeningweatherstripPost-installation OperationDoor Trim and Waterproof Film lnstallation(Refer to P.42-33.)Door Window Glass Adjustment (Refer to P.42-27.)Pre-removal OperationDoor Trim and Waterproof Film Removal(Refer to P.42-33.)

42-37BODY DoorINSTALLATION SERVICE POINTS}A] REAR LOWER SASH INSTALLATIONSecurely insert the rear lower sash into the window rear sash.}B] DOOR GLASS HOLDER INSTALLATIONlnstall the glass pad and the glass holders to the window glass as shown in the illustration.Standard value:holder(A)(B)(C)106.7 108.2 mm417.5 420.5 mm127 131 mmINSPECTIONPOWER WINDOW42900180069RELAY CONTINUITYCHECKPOWER WINDOWMOTOR CHECK42900150053Connect a battery directly to the motor terminals and check that the motor runs smoothly.Check that the motor runs in the opposite direction when the battery is connected with the polarity reversed.System voltageTerminal No.1234Not appliedAppliedFront door Rear doorGlassholder GlassB A C

fety mecha m releasengle becomes ger42-38BODY DoorLIMIT SWITCH OPERATION POSITION ADJUSTMENT42900230023Loosen the plate mounting screw and move the plate to the left or right to adjust where the limit switch starts working (safety mechanism stops working).BecomesllerSa-Rear doorscrewLIMIT SWITCH CONTINUITY CHECK42900220020Switch positionTerminal No.12ONOFFONOFFFront doorPlatemountingscrewsma nisa larPlate mBecomes largerountingSafetymechanismreleaseangle be-comessmaller

42-39BODYDoorDOOR HANDLE AND LATCH42300460301REMOVALANDINSTALLATIONReardoor3Frontdoor34*26 Nm7761616 Nm885Front door handle and door latch assembly removal steps}C]Rear door lock actuator assemblyDoor outside handleDoor latch assemblyDoor check removal stepsSpring pinDoor checkETACS-ECU removalETACS-ECU1. Door inside handleWaterproof film (Refer to P.42-32.)Door outside handleDoor lock key cylinderRear lower sashDoor latch assemblyRear door handle and door latch assembly removal steps1. Door inside handle}B]}A]NOTE*:This is equipped on passenger's side door lock key cylinder of vehicles with central door locking system.Waterproof film (Refer to P.42-32.)9Junction blockPost-installation OperationDoor lnside Handle Play Check (Refer to P.42-29.)Door Outside Handle Play Check (Refer to P.42-28.)Door Trim lnstallation (Refer to P.42-32.)Door Fit Adjustment (Refer to P.42-27.)Pre-removal OperationDoor Trim Removal (Refer to P.42-32.)

42-40BODY DoorINSTALLATION SERVICE POINTS}A] DOOR CHECK INSTALLATIONlnstall the door check so that the identification mark faces upwards.}B] REAR LOWER SASH INSTALLATIONSecurely insert the rear lower sash into the window rear sash.}C] REAR DOOR LOCK ACTUATOR ASSEMBLY1.2.3.Lock the inside lock knob.Lock the actuator lever and install.Fit the clip into the inside lock rod.INSPECTIONFRONT DOOR LOCK ACTUATOR CHECK with central door locking system>42300610133