Body PDF

Body
GENERAL
EXTERIOR
FRONT DOOR
FOLDING DOOR
FOLDING DOOR ENGINE ASSEMBLY
SWING DOOR
SWING DOOR CONTROL ASSEMBLY
FRONT BUMPER
REAR BUMPER
REAR LUGGAGE FLAP
GARNISH
INTERIOR
HEADLINING
INSTRUMENT PANEL
FRONT WINDOW
DRIVERS WINDOW
FOLDING DOOR GLASS
SWING DOOR GLASS
SIDE GLASS RH NO.1
SIDE SAFETY GLASS
SIDE SLIDING WINDOW
SIDE FIXING WINDOW
REAR WINDOW
DRIVERS SEAT
PASSENGER SEAT
SEAT BELT
BD -2
BODY
GENERAL
SPECIFICATION
E946E71E
Item
Door
Glass Thickness mm(in.)
Specifications
Construction
Front hinged, Full door construction
Regulator system
Wire drum type
Locking system
Pin - fork type
Windshield glass
6.76(0.27)
Door glass
5.0(0.2)
Rear glass
5.0(0.2)
Seat belt
E.L.R type
E.L.R : Emergency Locking Retractor

TIGHTENING TORQUE
Item
Door
Seat belt
Seat
Tightening Torque
Nm
Kgf.m
Ib - ft
Door hinge to body
20~29
2.0~3.0
14.4~21.6
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 adjuster

mounting bolt
39~54
4.0~5.5
28.9~39.7
Retractor mounting bolt
39~54
4.0~5.5
28.9~39.7
Buckle mounting
39~54
4.0~5.5
28.9~39.7
Bolt
34~54
3.5~5.5
25.3~39.7
Nut
37.3~68.6
3.8~7.0
27.5~50.6
GENERAL
BD -3
GENERAL SAFETY INFORMATION
EBFA6531
4.
PRECAUTIONS FOR ELECTRIC WELDING

WARNING
When electric-welding the electronic parts which
are con nected directly to the battery, current in
the welding machine can flow through the grounding 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.
Disconnect all ECU and controller connector.

Engine control system : ECU or ECM
Brake control system : ABS ECU
The other system : ETACS
NOTE
Refer the Electrical Troubleshooting Manual in relation position of ground terminal.
5.
Do not earth grounding circuit in the welding machine

to the fuel tank.
6.
The welding spark should be contacted to the fuel

tank.
7.
When tightening ground terminal to the body, clean

the neighborhood of body and tighten it with specified
torque.
NOTE
Refer the Electrical Troubleshooting Manual in relation position of ground terminal.
Tightening torque.
Outer Diameter of
bolt(mm)
Nm
kgfm
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
Item
BD -4
BODY
EXTERIOR
FRONT DOOR
COMPONENTS
E852DA41
1.
2.
3.
4.
5.
6.
7.
Front door outside handle

Door latch
Front door inside handle
Front door lower trim flange
Full handle
Front door inside handle bezel
Front door trim
ECOBD5001A
EXTERIOR
REMOVAL
1.
BD -5
4.
EC5BE638
Remove the front door lower trim flange(A).
Remove the front door inside handle housing(A).
NOTE
When using with a flat tip screwdriver, wrap it with a
shop towel to prevent damage in the paint.
A
KCOBD5502A
2.
Revove the cap using a sharp screwdriver.
3.
Remove door pull handle.
KCOBD5504A
5.
Loosen the door trim panel screws and by using the

trim panel remover, remove the door trim panel(A).
A
KCOBD5503A
KCOBD5505A
BD -6
6.
BODY
Remove the door outside handle
8.
Remove the door inside handle.
1)
Remove the 2 links.
1)
Remove the tapping screw.
2)
Remove the 2 bolts.
2)
3)
Using a screwdriver wrapped with protective

tape, remove the outside handle.
After removing the 2 links and loosening the 2

screws, remove the door inside handle.
KCOBD5508A
KCOBD5506A
7.
Remove the door key cylinder (A) after removing the

handle mounting bolt.
9.
Remove the door latch assembly.

After removing the 3 screws, remove the door latch
assembly(A).
A
A
KCOBD5507A
KCOBD5509A
EXTERIOR
INSTALLATION
1.
2.
BD -7
4.
E0C7DDD0
Grease application
Apply grease to each protrusion part of the door latch
assembly.
Installation of front door latch assembly

1)
Install the front door latch assembly(A) with

screws.
2)
Install the 2 links.
Front door key cylinder assembly

Install the door key cylinder(A) to the front door outside handle.
KCOBD5509A
5.
KCOBD5507A
3.
Front door inside handle installation

1)
Install the 2 links.
Front door outside handle installation

1)
Push the front door outside from the door panel

outside until it fits in mesh.
2)
Engage the front door outside handle together

with the key cylinder.
3)
Install the front door outside handle with 2 bolts.
KCOBD5510A
KCOBD5506A
BD -8
2)
BODY
Install the front door inside handle(A) with
screws.
8.
Pull handle installation

1)
Install the pull handle with 2 screws.
2)
Install the cap.
KCOBD5508A
6.
Front door trim installation

KCOBD5503A
1)
Install the front door trim(A) by tapping 12 clip

portions until they fit in mesh.
2)
Install screws.
9.
Install the front front door inside handle vessel(A).
A
KCOBD5502A
KCOBD5505A
7.
Install the front front door trim lower flange(A).

A
KCOBD5504A
EXTERIOR
BD -9
FOLDING DOOR
COMPONENTS
E027B1FC
5
2
3
6
1.
2.
3.
4.
5.
Inside full handle

Folding door front molding upper
Door hinge
Folding door rear molding upper
Rubber bumper
6.
7.
8.
9.
Folding door insertion rubber

Folding door insertion rubber
Plate & lower sealing weather strip
Stopper bracket
ECOBD5002A
BD -10
REMOVAL
1.
BODY
5.
EADFCF93
Remove the stopper bracket(A) with removing the

screw.
Remove the snap pin(A) and link pin(B) from the

bracket connected to the auto folding engine assembly.
KCOBD5514A
6.
Remove the lower sealing weather strip and plate.
KCOBD5512A
2.
Remove the center door hand-rail assembly(A) with

removing a screw.
KCOBD5515A
7.
Remove the folding door hinge(A) with removing a

screw.
KCOBD5513A
3.
Remove the folding door front molding upper.
4.
Remove the folding door rear molding upper.
KCOBD5516A
EXTERIOR
8.
BD -11
5.
Remove the door insertion rubbers.
Install the folding door stopper bracket.

CAUTION
After applying bond to the surface of rubber
bumper and door stopper bracket, let them dry
for 4 minutes and attach the rubber bumper to
the door stopper bracket.(Take care not to contaminate the adhesive portion.)
KCOBD5517A
INSTALLATION
E6D3B9E3
1.
Apply body grease to each protrusion part.
2.
Folding door insertion rubber installation

1)
2)
Take care that any part of the door insertion rubber does not come out of the door flange.
KCOBD5514A
6.
Align both upper and lower ends of the door insertion rubber with the door flange ends.
Installation of folding door inside handrail assembly(A).

CAUTION
After connecting the handrail assembly, make
sure that the handrail is not moving by rotating
it with hand.
NOTE
Apply the specific grease to all rotating and contact
surfaces.
KCOBD5517A
3.
Install the folding door hinge.
4.
Install the folding door lower sealing weatherstrip.
KCOBD5513A
7.
Install the auto folding engine assembly to the door

body.
8.
After installation, check operation of folding door.
BD -12
BODY
FOLDING DOOR ENGINE

ASSEMBLY
COMPONENTS
E5DB72EB
8
7
6
5
10
12
11
13
23
19
18
14
17
20
16
21
22
15
1. Auto and manual lever

2. Cap nut
3. Cover
4. Time relay assembly
5. Motor assembly
6. Micro box
7. Micro switch
8. Close switch cam
9. Connector
(MG 640333 SWP-4M)
10. Open switch cam
11. Base-A
12. Operation lamp
13. Door bracket
14. Base plate
15. Base-B
16. Buzzer assembly

17. Circuit breaker
18. Close stopper switch
19. Open stopper switch
20. Arm-A
21. Arm-C
22. Stroke bolt
23. Arm-B
ECOBD5006A
EXTERIOR
BD -13
DISASSEMBLY COMPONENTS
12
15
13
14
8 8
10
18
11
19
20
20
21
7
6
18
22
23
24
19
17
16
25
26
27
28
29
32
33
34
36
35
30
40
39
37
41
1
38
31
45
3
51
46
42
44
43
4
47
48
49
50
52
1. Cover
2. Control lever
3. Base plate
4. Base-B
5. Base-A
6. Motor
7. Motor bracket
8. Coupling
9. C-ring
10. Bearing
11. Worm gear
12. Gear box-A
13. Special bolt
14. Plate spring

15. Control shaft
16. Bolt
17. Adjust plate
18. Power spring nut
19. Power spring-A
20. Guide taper
21.Rack gear
22. Bearing
23. Worm wheel
24. Gear cover
25. Internal gear
26. Small gear
27. Drive shaft

28. Bearing
29. Gear box-B
30. Time relay
31. Buzzer
32. Switch cam No. 1 (Close)
33. Switch cam No. 2 (Open)
34. Cam shaft
35. Micro switch
36. Bush
37. Shaft
38. Connection bar
39. Stopper switch-A (Close)
40. Stopper switch-B (Open)

41. Operation lamp
42. Circuit breaker
43. Arm link
44. Taper pin
45. Link pin
46. Connection pin
47. Arm-A
48. Space ring
49. Arm-B
50. Arm-C
51. Link pin
52. Stroke bolt
ECOBD5007A
BD -14
BODY
REPLACEMENT
1.
SPECIFICATION
ECE8681A
Remove the folding engine assembly arm(A) from the

bracket connected to folding door body.
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.
ECOBD5512A
2.
Remove the 4 bolts connected to floor.
Motor
Connect the motor terminals directly to the battery
and check that the motor operates smoothly. Next,
reverse the polarity and check that the motor operates
smoothly in the reverse direction. If the operation is
abnormal, replace the motor.
ECOBD5008A
KCOBD5518A
3.
The installation is the reverse of removal.
2.
Buzzer
Connect the buzzer terminals directly to the battery
and check the buzzer sounds.
(Red terminal : + terminal, Black terminal : - terminal)
Black
Red
ECOBD5009A
EXTERIOR
3.
BD -15
Stopper switch
Check for continuity between the terminals and
bracket.
"A" direction :
"B" direction : 0
Stopper Switch
DOOR CAM ADJUSTMENT

Set the control lever in manual position.
1.
Close cam adjustment.

1)
Close the door at the door positioned parallel of

the body.
2)
Loosen the cam mounting screws (A,C) and adjust the close cam micro switch (Upper) for the
switch lever depressing.
3)
Tighten the cam mounting screws (A,C) when the

operating lamp is on if the cam positioned properly.
B
A
A
B
Close micro switch

<Close>
<Open>
ECOBD5010A
4.
Micro switch
Open the door by halves and check for continuity between the terminals.
Open micro switch/Close micro switch
Switch depressed
Terminal COM and N.O : 0

Terminal COM and N.C :
Switch released
Terminal COM and N.O :

Terminal COM and N.O : 0
N.O : Normally open

N.C : Normally close
COM : Common
Close micro
switch
Open micro
switch
N.C
COM
N.O
ECOBD5011A
ECOBD5012A
BD -16
2.
BODY
Open cam adjustment.

1)
Open the door at the door positioned a right angle

of the body.
2)
Loosen the cam mounting screws (A,B) and adjust the open cam micro switch (Lower) for the
switch lever depressing.
3)
Tighten the cam mounting screws (A,B) when the

operating lamp is on if the cam positioned properly.
Install the removed parts after adjustment and set
the control lever in auto position.
Open micro switch
A
B
ECOBD5013A
NOTE
For 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 be
operated.
3. For the door normally operate, the door control
switch fully operate.
4. Be care not catch in the door when the door is
operating.
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 necessary and reset the circuit breaker.
8. Regularly check the door operation and operating
lamp. If improper operation of the door adjust the
door cam position.
9. Uncertainty of the trouble, does not disassemble
at your disposal and see service center.
EXTERIOR
TROUBLESHOOTING
BD -17
E43919CC
Symptom
Probable cause
Remedy
Door does not operate
Fuse blown
Door control switch faulty
Wiring or ground faulty
Replace fuse and repair as necessary

Replace door control switch
Repair as necessary
Buzzer sounds, but door

does not operate
Time relay faulty

Micro switch faulty
Improper stopper switch ground position
Replace time relay

Replace micro switch
Tighten stopper switch ground
Repair as necessary
Door operates but buzzer

does not sound
Buzzer faulty
Replace buzzer
Micro switch faulty

Improper switch cam position
Motor ground short
Improper door operation

Adjust switch cam and reset the
circuit breaker
Repair as necessary
Check and repair as necessary
Repair as necessary
Motor is on when the door

fully open or close
Defect motor wiring

Defect micro switch wiring
Repair
Repair
Adjust switch cam
Buzzer is normal, but door

operates only one direction
Time relay faulty

Micro switch faulty
Improper stopper switch ground position
Replace time relay

Tighten stopper switch
Repair as necessary
Frequently main fuse blown or

circuit breaker operates
BD -18
BODY
SWING DOOR
COMPONENTS
EEBC1A70
4
5
2
3
6
10
11
9
12
1. Swing door rear latch

2. Swing door center link
3. Safety knob
4. Swing door service hole cover
5. Door inside handle
6. Inside handle link
7. Swing door front latch

8. Swing door upper trim
9. Swing door lower trim
10. Retainer
11. Key cylinder
12. Swing door checker
ECOBD5014A
EXTERIOR
REPLACEMENT
1.
BD -19
4.
EB1BBBBF
Remove the swing door check assembly and pipe

mounting from the swing door body.
Remove the door inside handle(A) with removing a

screw
KCOBD5527A
KCOBD5002A
2.
5.
Remove the swing door upper trim by using a trim

panel remover.
Remove the upper and lower pipe(A) from the swing

door body.
Clip
KCOBD5528A
ECOBD5524A
3.
Remove the lower arm(A) from swing door.
6.

CAUTION
Apply the general LATCH grease to all rotationg
and contact surfaces.
KCOBD5526A
BD -20
DISASSEMBLY
1.
BODY
E6AFC19A
Remove the door inside handle(A).
3.
Remove the swing door lower trim by using a trim

panel remover.
4.
Remove the door checker with removing bolts and

pins.
KCOBD5040A
2.
Remove the swing door upper trim by using a trim

panel remover.
KCOBD5527A
5.
Detach the door key cylinder(A).
Clip
ECOBD5524A
KCOBD5529A
6.
Remove the door outside handle.

A
KCOBD5003A
EXTERIOR
7.
BD -21
Remove the door inside handle link.
9.
Detect the door center link.
KCOBD5530A
8.
Remove the door front latch.
KCOBD5532A
10. Remove the door rear latch.
KCOBD5531A
KCOBD5533A
BD -22
REASSEMBLY
1.
2.
BODY
5.
EF0C912E
Installation of swing door outside handle assembly
Apply body grease to each protrusion part of the

swing door center assembly and door latch assembly.
Install the rear latch assembly with bolts.
KCOBD5003A
KCOBD5533A
3.
Install the door center assembly.

6.
1)
Engage the key cylinder together with the outside

handle.
2)
Install the outside handle with 4 screws.
3)
Install the link.
Engage the swing door key cylinder(A) together with

the outside handle.
KCOBD5532A
4.
Install the front door latch assembly with screws.
A
KCOBD5529A
KCOBD5531A
EXTERIOR
7.
BD -23
Installation of swing door inside handle link assembly.
9.
Swing door upper trim installation

Install the door trim by tapping the clips until they fit in
mesh.
Clip
KCOBD5530A
8.
1)
Install the inside handle with bolts.
2)
Install the knob.
3)
Install the link.
ECOBD5524A
10. Swing door inside handle installation

Install the door trim by tapping the clips until they fit in
mesh.
Installation of swing door checker assembly
11. Install the swing door inside handle (A).
KCOBD5527A
1)
Install the door checker with bolts.
2)
Install the pin.
KCOBD5002A
BD -24
BODY
SWING DOOR CONTROL

ASSEMBLY
COMPONENTS
E7612AE3
1
2
3
30
29
6
7
27
25
26
24
28
23
10
22
21
11
12
20
13
14
15
19
14
16 17
1. Switch adjust cover

2. Cover
3. Mounting bracket
4. Body
5. PCB assembly
6. Buzzer assembly
8. Relay and bracket assembly
10. Open stopper switch cam
18
11. Close stopper switch cam

12. Servo motor assembly
13. Base mounting bracket assembly
14. Lever
15. Photo sensor
16. Photo sensor switch
17. Circuit breaker
18. Connect
19. Push lever assembly
20. Gear box-A
21. Gear box-B

22. Switch board assembly
23. Close micro switch
24. Hi speed micro switch
25. Hi speed and close switch cam
26. Open micro switch
27. Driver shaft
28. Open switch cam
29. Cable assembly
30. Driver shaft boot
ECOBD5015A
EXTERIOR
BD -25
DISASSEMBLY COMPONENTS
2-1
12
3
13
14
22
15
17
23
15-1
25
16
26-2
26
19
26-1
1
20
7
27
24
30-1
28
18
30-2 30
29
21
39
39-1
31
40
51
32
49
34, 35
36, 37, 38
50
33
41
10
42
48
11
43
44, 45
46
47
49
1. Body and cover

2. Driver shaft boot
2-1. Boot
3. Switch adjust cover
4. Mounting bracket
5. Bolt
6. Buzzer
7. Relay and bracket
8. P.C.B assembly
9. Grommet
10. Base mounting bracket
11. Bolt
12. Cable
13. Key
14. C-ring
15. Cam body

15-1. Spacer
16. Switch board
17. Switch stopper
18. Bearing
19. Drive shaft
20. Gear box-B
21. C-ring
22. Screw cap
23. Cable holder
24. Nut
25. Washer
26. Rack gear sub assembly
26-1. Rack gear
26-2. Nut
27. Spring guide

28. Spring housing
29. Rack gear stopper
30. Push lever
30-1. Cable roller cover
30-2. Wire pulley
31. Planetary reducer and gear
housing assembly
32. Gear box-A
33. Push lever stopper
34. Bush cap
35. Bush
36. Spring
37. Ball guide pin
38. Ball
39. Servo motor

39-1. Worm
40. Servo cover
41. Control lever
42. C-ring
43. Handle
44. Worm wheel
45. Worm wheel
46. Bearing
47. Gear cover
48. Bolt
49. Washer
50. Photo sensor switch
51. Circuit breaker
ECOBD5016A
BD -26
BODY
REPLACEMENT
1.
INSPECTION OF COMPONENTS
E142EA90
Remove the retainer ring(A) , washer and mounting

bolt(B) from the pipe connected to swing door.
E1CB959C
1. MOTOR
a.
b.
Connect No. 1 inspection

Connect the motor terminals directly to the battery
and check that the motor operates smoothly. Next,
reverse the polarity and check that the motor operates
smoothly in the reverse direction. If the operation is
abnormal, replace the motor.
Connector No. 2 inspection
Check the terminals for continuity when motor shaft
operate manually. If the continuity is repeatedly, it is
normal.
B
A
Connector No.1
KCOBD5525A
2.
Remove the connector connected to swing door control assembly.
3.
Remove the mounting bolt connected to floor.

Connector No. 2
ECOBD5017A
2. RELAY
Check for continuity between terminal by using an ohmmeter. Connect the each battery terminal to 85 and 86
terminal. And the check to continuity 30 and 87 terminal .
Continuity is normal. If the continuity is abnormal, replace
the relay.
KCOBD5501A
4.
After installation, check the operation of door.
SPECIFICATION
85
86
30
87
86
CAUTION
30
87
85
EA66DCAF
Items
Specifications
Rated voltage
DC 24V
Door open angle
149 ~159
Circuit brake capacity
15A
Operating voltage
DC22V-DC32V
ECOBD5018A
EXTERIOR
BD -27
3. BUZZER
Connect the buzzer terminals directly to the battery and
check the buzzer sounds.
(Red terminal : + terminal, Black terminal : - terminal)
Black
Red
ECOBD5009A
4. SWITCH BOARD
1
7
Strong ward
8
2
Strong ward
3
4
5
6
1. High speed micro switch

2. Close micro switch
3. Open switch cam
4. Open micro switch

7. Close switch cam
8. Close stopper switch cam
9. Open stopper switch cam
ECOBD5019A
BD -28
BODY
Check for the continuity between the terminals.

Open micro switch
Close micro switch
High speed micro switch
Switch depressed
Terminal 1 and 2:
Not continuity
Terminal 1 and 4:
Not continuity
Terminal 1 and 3:
Not continuity
Switch released
Terminal 1 and 2:Continuity
5. PHOTO CELL
Check for the continuity of the photo cell
Condition
Emitter cell
Receiver cell
1 Terminal : +, 2 Terminal : -
100 ~ 150
15 k ~ 25 k
1 Terminal : - , 2 Terminal : +
If the continuity is abnormal replace the photo cell.
Emitter cell
Receiver cell
ECOBD5020A
NOTE
For the safety, be care of below description.
1. Look all around of the vehicle when door operates.
2. Does not open the door when the vehicle is moving.
You should operate the door when the vehicle is
stopped.
3. Not for battery discharge, operated the door
when engine is running.
4. If battery voltage is below 22V, the driving force
of motor is weakened and the door may not be
operated.
5. For the door normally operate, the door control
switch fully operate.
6. Improve of the durability of motor, as possibly
does not operate the door in the inclination.
7. Be care, not catch in the door when the door is
operating.
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
TROUBLESHOOTING
Symptom
BD -29
E14A3ABD
Probable cause
Remedy
Door does not operate
Fuse blown
Door control switch faulty
Replace fuse and repair as necessary

Replace door control switch
Repair as necessary
Buzzer sounds, but door

does not operate
Circuit breaker operates

Micro switch faulty
Relay faulty
Repair as necessary and reset the circuit

breaker
Replace relay
Buzzer faulty
Replace buzzer

Micro switch faulty
Motor wiring is short
Relay faulty
Improper door operation
Improper door catch operation
Wiring faulty
Adjust switch cam and reset the circuit

breaker
Replace motor and reset the circuit breaker
Replace relay and reset the circuit breaker
Check and repair as necessary
Check and repair door catch
Repair as necessary
Motor is on when the door

fully open or close
Micro switch faulty


Adjust switch cam
Buzzer is normal, but door

operates only one direction
Relay faulty
Micro switch faulty
Wiring faulty
Replace relay
Repair as necessary
Buzzer sound continuously

and only door open
Improper photo cell position

Photo cell faulty
Adjust photo cell position

Replace photo cell
Power is cutted, when door

operating
Overload of the door and fuse cutted

Does not fully close the door
in the inclination
Stop the door in the fully
opened position
Repair as necessary and replace the fuse

Setting the close stopper switch to
the strong ward
Setting the open stopper switch to
the strong ward
Door does not locking
Door catch device faulty

Improper door position
Improper stopper switch cam position
Replace door catch device

Adjust door position
Adjust switch cam position
Does not operate catch

when door opening
Improper catch operation

Improper cable position
Cable faulty
Check or replace catch

Check or adjust cable
Replace cable
Door operating speed

is irregular
Motor shaft magnetic faulty

Short or cut of motor servo
cover wiring
Check or replace motor

Replace servo cover
Door operates but buzzer

does not sound
Frequently main fuse blown
or circuit breaker operates
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 damaged.
1.
Disassemble the connector (A) of the both fog lamp.
ECOBD5021A
2.
After taking off the bolt, remove the bumper (A).
A
ECOBD5311A
3.
The installation is performed in the reverse order of

the 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
work, wind a protection tape on it.
Wear gloves for protect your hands.
Be careful that the trim and panel are not damaged.
1.
Remove the bolt and bumper.
ECOBD5023A
2.
The installation is performed in the reverse order of

the removal.
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
3
1. Luggage door trim
2. Lifter assembly
3. Garnish assembly
4. Retainer
5. Trunk lead key cylinder
6. Luggage door latch assembly
6
4
ECOBD5408A
REMOVAL
1.
E67564AF
Remove the luggage flap trim.
KCOBD5534A
EXTERIOR
2.
BD -33
Remove the screw and the luggage flap latch.
5.
Remove the gas lifter.
KCOBD5535A
3.
Remove the key cylinder.
KCOBD5009A
INSTALLATION
1.
EA3EBE1E
Installation is the reverse of removal procedure.

The opening gap of luggage flap and rear body : 5.5
~ 6.1 mm
NOTE
Apply the specific grease to all rotating and contact
surface.
CAUTION
-
KCOBD5536A
4.
Remove the garnish and disconnect the connector.
ECOBD5508A
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
REAR GARNISH REPLACEMENT
REPLACEMENT
1.
Remove the fastener and front rear garnish (A).
E1A52E3A
FRONT UPPER GARNISH

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

A
KCOBD5611A
2.
KCOBD5538A
2.
If the fastener is damaged, replace the new one.
If the fastener is damaged, replace the new one.

NOTE
To prevent the leakage of water, apply the sealant in
the fastener hole and install the rear garnish. Securely fasten the garnish in the body.
NOTE
To prevent the leakage of water, apply the sealant in
the fastener hole and install the upper garnish. Securely fasten the garnish in the body.
Position of fastener
KCOBD5612A
ECOBD5022A
INTERIOR
BD -35
INTERIOR
HEADLINING
COMPONENTS
E63AB4F4
[Short body]
6
5
3
2
1
11
9
7
10
14
8
13
4
12
18
17
15
16
1. Sunvisor
2. Front-rear headlining
3. Air con grill
4. Speaker
5. Front-front headlining
6. Clock
7. Inside rear view mirror

8. Sunvisor
9. Room lamp
10. Air con rubber
11. Air con double rubber
12. Ceiling No. 1 panel

14. Rear headlining
15. Ceiling molding
16. Booster ventilator
17. Room lamp lens
18. Room lamp
ECOBD5415A
BD -36
BODY
[Long body]
6
5
11
9
10
7
1. Sunvisor
2. Front-front headlining
3. Air conditioner radiator grill
4. Speaker
5. Front-rear headlining
6. Clock
7. Inside rear view mirror

8. Sunvisor
9. Interior lamp
10. Air conditioner rubber
11. Air conditioner double rubber
ECOBD5024A
INTERIOR
BD -37
[Long body]
4
2
3
10
9
11
14
12
13
15

2. Speaker
3. Speaker grill
4. Ceiling molding
6. Room lamp
7. Room lamp lens
8. Booster ventilator
9. Ceiling molding
10. Roof headlining
11. Speaker
12. Room lamp
13. Room lamp lens
15. Shelf
ECOBD5416A
BD -38
REPLACEMENT
BODY
E136DFBB
FRONT HEADLINING REMOVAL

1.
4.
Remove the roof ceiling molding.
5.
Remove the front-rear headlining.
Remove the air conditioning grill(A).
KCOBD5571A
KCOBD5570A
2.
6.
Remove the rear view inside mirror(A).
Remove the curtain rail.
KCOBD5572A
KCOBD5574A
3.
7.
Remove bolts and sunvisor assembly(A).
Remove the air conditioning rubbers.
KCOBD5573A
ECOBD5038A
8.
Remove the front front-headlining.
INTERIOR
BD -39
ROOF CEILING REMOVAL

1.
4.
Remove the room lamp(A).
Remove the roof ceiling No.1.

NOTE
Do not bent the roof ceiling.
KCOBD5575A
2.
Remove the shelf(A) (If installed).
KCOBD5577A
5.
Remove the roof vent (A), room lamp (B), speaker(C)

and roof ceiling molding.
A
C
A
ECOBD5575A
3.
Remove the speaker(A).

KCOBD5579A
KCOBD5576A
BD -40
6.
BODY
Remove the rear headlining.
KCOBD5580A
7.
Installation is the reverse of removal.

CAUTION
Install the cap screw to the roof headlining.
INTERIOR
BD -41
INSTRUMENT PANEL
COMPONENTS
ED43972C
6
1
10
3
2
5
7
1. Air vent bezel
2. Air vent duct
3. Crash pad lower panel
4. Column cover
5. Ashtray
6. Instrument crash pad
7. Glove box
8. Crash pad lower panel
9. Air vent duct
10. Side panel cover
ECOBD5025A
REPLACEMENT
EE7EBE78
1.
Remove the steering wheel. (Refer to the "Steering

System Group")
2.
Taking off the assistants seat crash pad lower panel

screw (A), remove the lower panel (B).
CAUTION

work, apply a tape on it to protect the parts.
A
ECOBD5026A
BD -42
3.
BODY
Remove the tightening screw (A) for instrument facia

panel.
6.
Taking off the cluster tightening screw (A) and disassembling the connector, remove the cluster (B).
B
A
A
A
ECOBD5027A
4.
Disassemble the emergency lamp connector, the fog

lamp connector, the heater mirror connector, cigar
light connector and the heater & air-con control connector.
5.
Disassemble the temperature controlling switch cable

(B) from the instrument facia panel (A).
ECOBD5029B
7.
Taking off the screw (A) installing the audio, disassemble the antenna jack and the audio connector.
Remove the audio unit (B).
NOTE
When removing the temperature controlling switch cable, release the locking by pressing the cable fixing
bracket (C) and lay down the cable (B) to downward.
A
ECOBD5030A
8.
Taking off the tightening screw (A) for glove box linkage, remove the glove box out lead (B).
A
A
ECOBD5028A
ECOBD5031A
INTERIOR
9.
BD -43
Taking off the tightening screw (A) of the glove box,

remove the glove box (B).
12. Remove the ventilator switch (A) and the door operating switch (B).
A
B
A
ECOBD5032A
ECOBD5035A
10. Remove the Front crash pad lower panel (A).
A
B
KCOBD5613A
ECOBD5033A
11. Remove the fuse box cover (A).
13. Remove the drivers seat side cover panel screw.

Fastener Locations
: Bolt
: Screw
ECOBD5034A
ECOBD5036A
BD -44
BODY
14. Remove the assistants seat side cover panel screw

and the crash pad tightening bolt and screw.
Fastener Locations
: Bolt
: Screw
ECOBD5037A
15. Remove the instrument crash pad.

16. The installation is performed in the reverse order of
the removal.
INTERIOR
BD -45
FRONT WINDOW
WINDSHIELD GLASS
EAA0CCAA
COMPONENTS
2
7
3
1. Inside mirror
2. Windshield weather strip
3. Windshield glass
4. Wiper arm
5. Wiper arm head cover
6. Wiper arm
7. Sunvisor
ECOBD5409A
BD -46
BODY
REMOVAL
2.
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).
When replacing the weatherstrip

1)
Cut the weatherstip from the outward using a

knife or equivalent.
2)
After removing the glass with an equal force, disconnect the weatherstrip by pulling it.
WINDSHIELD GLASS REMOVAL

1.
When reusing the weatherstrip

1)

tape, push the weatherstrip lip portion from the
inside to the body flange outside.
2)
Push the glass outward with an equal force and

disconnect the glass together with the weatherstrip.
KCOBD5540A
WINDSHIELD GLASS INSTALLATION

1.
Cleaning of windshield glass installation portion

Clean the glass and body installation portion with
gasoline.
2.
Windshield weatherstrip installation

Align the mating marks on the glass and weatherstrip
and install the weatherstrip.
Mating Marks
KCOBD5539A
ECOBD5039A
CAUTION
Replace the weatherstrip.
If the weaterstrip is worn, do not reuse it.
INTERIOR
3.
BD -47
Windshield glass installation

1)
Set around a string in the weatherstrip groove.

Make certain that the string overlaps each other
at each end.
B
3
1
2
G7BD025E
String
5.
Inspection for leaks
6.
Apply adhesive.
ECOBD5040A
2)
4.
CAUTION
Apply soap solution to entire surface of the flange

and weatherstrip lip portion.
Apply adhesive to where are leaks inspected.
As shown in figure, pull one end of the strip hanging in the room side to the both side with maintaining
higher angle than the flange. At the same time, tap
the weather strip portion of the glass from the outside
in order to install to the glass.
CAUTION
Pull the strip from the both ends of the wind shield
to the center portion and press from the outside
of the glass.
1)
Attach protective tape to the glass and body surfaces.
2)
Apply a sealer between the weatherstrip and

glass, and weatherstrip and body from the outside
3)
Scrape the rough and uneven sealer smooth together with protective tape.
CAUTION
Let the adhesive and sealed portion dry for about

1 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
G7BD025D
BD -48
BODY
DRIVERS WINDOW
FRONT DOOR GLASS
ECF2BE8E
COMPONENTS
1
2
10
11
3
12
13
14
14 13
5
7
16
15
1. Front door glass

2. Adhesive
3. Front door window rear glass
4. Window lock knob
5. Front door window center sash cap
6. Front door window glass dam
7. Front door window No. 1 piece

8. Front door glass clip cap
9. Front door glass clip
10. Pin
11. Front door window center frame
12. Front door window front glass
13. Retainer
14. Packing
15. Front door window outer frame
16. Clip
ECOBD5410A
INTERIOR
REPLACEMENT
BD -49
DISASSEMBLY OF FRONT DOOR WINDOW
E56645FC
1.
FRONT DOOR WINDOW GLASS

1.
Loosen the center seal mounting screw and remove

the front door glass.
Remove the clip cap and front door trim flange.
KCOBD5544A
KCOBD5541A
2.
2.
Disassemble the front door window frame.
Remove the clip.
KCOBD5017A
KCOBD5542A
3.
Using a cutter, cut the butyl tape and remove the front
door window frame.
FRONT DOOR FIXED GLASS

1.
Remove the clip cap and front door upper trim flange
(A).
KCOBD5543A
KCOBD5020A
BD -50
2.
BODY
Make hole in the fixed glass adhesive and pass the

piano wire from the inside of the vehicle through the
hole. Pull the piano wire alternately from the inside
and outside along the fixed glass to cut the adhesive.
INSTALLATION
EE893BB8
FRONT DOOR WINDOW GLASS

1.
Using a cutter knife or special tool, remove the butyl

tape on the bonding surface. Clean the window frame
and door panel bonding surface with cleaner. Apply
the butyl tape in the door window frame.
2.
Install the window frame to door panel and clip and

door trim flange and clip cap.
KCOBD5547A
CAUTION
Do not let the piano wire touch the edge of the
fixed glass
3.
Remove the fixed glass by detaching the glass fastener.
KCOBD5542A
FRONT DOOR FIXED GLASS

1.
Using a cutter knife or special, remove the adhesive

on the bonding surface. Clean the door fixed glass
and door panel bonding surface with cleaner.
2.
Remove the adhesive on the fixed glass if fixed glass

reused.
Adhesive
KCOBD5021A
ECOBD5566B
INTERIOR
3.
BD -51
Install male fastener on the fixed glass and female

fastener on the door frame.
6.
Install the removed parts.
10mm
8mm
KCOBD5548A
KCOBD5022A
4.
Apply the adhesive in the fixed and glass cleaner in

the inside of adhesive.
13.5mm
KCOBD5023A
5.
Apply the sealant in the fixed glass higher than adhesive and install fixed glass.
12mm
KCOBD5024A
NOTE
Let the car stand for at least four hours after fixed
glass installation.
If the car has to be used with in the first 8 hours, it
must be driven slowly.
BD -52
BODY
FOLDING DOOR GLASS

COMPONENTS
E1F5FB07
1
3
1. Center door glass

2. Center door glass inner weatherstrip
3. Center door inside pull handle
ECOBD5549A
REMOVAL
E92DCB06
FOLDING DOOR GLASS REMOVAL

1.
Disconnect the folding door inside pull handle.
2.
Disconnect the folding door glass weatherstrip.
KCOBD5513A
INTERIOR
3.
BD -53
INSTALLATION
Remove the folding door glass.

EF855DE7
FOLDING DOOR GLASS INSTALLATION
1)

tape, push the weatherstrip lip portion toward
the body flange outside.
2)
(Up and both lateral sides)

Push the glass outward with an equal force and
disconnect the glass together with the weatherstrip.
The glass together with the weatherstrip
1.
Preparation prior to folding door glass installation

Clean the glass and body installation portion with
gasoline.
CAUTION
For a new glass, clean it.
2.
Install the weatherstrip to the glass.

CAUTION
If the weaterstrip is worn, never reuse it.
3.
KCOBD5550A
3)
Cut the weatherstip from the outward using a

4)
Remove the glass by pushing its surface with

an equal force from the inside and remove the
weatherstrip by pulling it.
Folding door glass installation

1)

at each end.
2)

3)
Place the weatherstrip lateral portion to the windshield flange.
KCOBD5552A
BD -54
4)
BODY
To install the glass, with the aid of an assistant
to tap the glass around the weatherstrip from the
outside and pull strings in the inside (one string
higher than the flange).
KCOBD5551A
5)
Lightly tap the glass by hand from the outside to

seat it completely.
4.
5.
Apply adhesive.
CAUTION
6.
1)
2)

glass and weatherstrip and body from the outside
3)
Folding door inside full handle installation
INTERIOR
BD -55
SWING DOOR GLASS

COMPONENTS
EA48DC2C
3
2
1
1. Swing door glass molding

2. Swing door glass
3. Pin
4. Swing door glass clip
ECOBD5411A
BD -56
BODY
REMOVAL
1.
3.
EABEB731
Remove the swing door glass clip cap, and flange

trim.
Remove the swing door glass by detaching the glass

fastener.
Pin
ECOBD5554A
KCOBD5553A
2.
Make hole in the swing door glass adhesive and pass

the piano wire from the inside of the vehicle through
the hole.
Pull the piano wire alternatively from the inside and
outside along the swing door glass to cut the adhesive.
CAUTION
swing door glass.
Adhesive
portion
Protect
tape
ECOBD5555A
INTERIOR
INSTALLATION
1.
BD -57
E1DE7ADE
Using a cutter knife or special tool , remove the adhesive on the bonding surface. Clean the door glass
and door panel bonding surface with cleaner.
5.
Apply the sealant in the door glass higher than adhesive and install door glass.
6.

NOTE
Let the car stand for at least four hours after swing
door glass installation.
Adhesive
ECOBD5566B
2.
Remove the adhesive on the door glass if door glass

reused.
3.
Install the male fastener on the door glass and female

fastener on the door frame.
4.
Apply the adhesive in the door glass and glass cleaner

in the inside of adhesive.
Pin
ECOBD5554A
BD -58
BODY
SIDE GLASS RH NO.1

COMPONENTS
E24467C9
[Right side window]
3
2
1. Lock knob
2. Side window glass
3. Side window glass dam
4. Clip
5. Side window frame
6. Protector
ECOBD5556A
INTERIOR
BD -59
INSTALLATION OF SIDE GLASS RIGHT

SIDE NO.1 E4F475DD
1.
3.
Fix the window chassis assembly to the body with

clips.
Attach butyl tape all around the window chassis assembly.

Note that butyl tape should be applied to the entire
around of chassis.
CAUTION
Securely engage clips not to get loose.
CAUTION
Dons miss any portion. It can cause leaks.
KCOBD5027A
4.
Insert the protector to all around of the window assembly and body rail flange.
CAUTION
KCOBD5026A
2.
Securely insert the protector (A) not to get loose.
Fix the window chassis assembly to body

1)
Keep an opening gap within 30.5mm between

the window chassis lower surface and waist rail
side panel.
2)
Keep an opening gap within 30.5mm between

the window chassis end line and end of body A
pillar and dream rail.
3)
Align the window chassis end with the door pillar

end as shown in the illustration.
KCOBD5557A
BD -60
BODY
SIDE SAFETY GLASS

COMPONENTS
EDAF2A16
[Safety galss]
ECOBD5041A
SIDE SAFETY GLASS REMOVAL
E5E64B85
Pin
CAUTION
Be careful of the pin installed to the glass as
shown in the illustration.
Adhesive
portion
ECOBD5558A
INTERIOR
1.
BD -61
Apply protective tape along the edge of the side safety

glass and body.
SIDE SAFETY GLASS

INSTALLATION E9EFB70B
1.
Clean the body bonding (SIKA SF250PC) surface

and glass edge (Ceramic coating portion) with
cleaner (SIKA CLEANER No.1).
Adhesive
portion
Protect
tape
Spacer
12mm
Piano wire
ECOBD5559A
2.
3.
Cleaner
application arear
Push the piano wire through the hole between the

glass and body from the inside and wrap each end
around a piece of wood.
ECOBD5558B
Pull the piano wire in the inside and cut the adhesive.
CAUTION
Apply cleaner enough.
After applying cleaner, let it dry for 5-10 minutes.
(After cleaning, keep foreign material, especially finger print getting on the surface)
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 through
the gap between the pin and adhesive, and
then wrap the piano wire again around the
wood.
4.
Hold the glass in the outside, disengage the pin, and

then remove the side safety glass.
2.
Using a sealant gun, apply adhesive (SIKA SF250PC)

to the glass.
BD -62
3.
BODY
Adhesive bead figure

Constantly apply adhesive to a height of 20-30mm to
the connecting portion to continue the application.
2)
Press all around of the glass surface to securely

seat 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 fastener

served to glass, set the position from the lower to
upper portion and insert the glass by pressing.
10mm
CAUTION
8mm
Check the adhesive between the body and

glass for secure adhesion.
The glass attached should not move until the
adhesive hardens completely.
5)
KCOBD5548A
5.
CAUTION
Adhesive is so quickly hardening that the glass
attaching procedure should be finished within 8
minutes since its application to the body.
4.
Safety glass attachment

1)
Keep a gap to 31.0mm between the side panel

and its all around .
KCOBD5029A
When attaching the safety glass, keep a gap

within 30.5mm between the body side panel
and opening through all around.
Safety notice
Adhesive is poisonous, always wear mask while working, especially protect your eyes, if it splashes into the
eyes, wash them with clean water, and then see a doctor if its condition becomes serious.
INTERIOR
BD -63
SIDE SLIDING WINDOW

COMPONENTS
ED8C1F10
[Side window]
C
D
3
4
5
1. Side trim
2. Side trim
3. Protector
4. Window sash
5. Clip
6. Lock knob
7. Packing
8. Side window glass
9. Retainer
6
7
8
9
ECOBD5412A
BD -64
REMOVAL
1.
BODY
INSTALLATION
E42BFB7D
Remove the side trims and protectors.
E5B93E97
1.
Using a cutter knife remove the butyl tape on the

window frame and body flange. Clean the bonding
surface with cleaner on the window frame and body
flange. Apply the butyl tape around the window frame.
2.
Install the window frame on the body and clips.
KCOBD5030A
2.
Remove the clips in the window frame.
KCOBD5560A
3.
KCOBD5560A
3.
Using a cutter knife, cut the butyl tape.
4.
Remove the side window frame.
ECOBD5561A
Install the protectors and side trims.
INTERIOR
BD -65
SIDE FIXING WINDOW

COMPONENTS
EDA56BF5
[Fixed glass]
1
2
5
1. Garnish upper
2. Side window garnish
3. Spacer
4. Window glass
5. Fastener
ECOBD5563A
BD -66
BODY
[Side rear window]
1
5
2
3
1. Side window garnish upper

2. Side window garnish
3. Spacer
4. Side window garnish lower
5. Quarter bench letter lopper
6. Side rear glass
ECOBD5413A
INTERIOR
REMOVAL
1.
BD -67
[REAR SIDE WINDOW]
E8B4B683
SIDE WINDOW REMOVAL
Remove the clips and garnish.
1.
Using a flat tip screwdriver wrapped with protective

tape, disengage the clips and remove the side window
garnish.
KCOBD5564A
2.
Apply the protect tape around the glass on the body

panel.Make a hole in the glass adhesive and pass the
piano wire from the inside of the vehicle through the
hole. Pull the piano wire alternatively from the inside
and outside along the glass to cut the adhesive.
KCOBD5564A
CAUTION
Remove the side window garnishes from the upper and lower portions.
2.
Side window glass disassembly

CAUTION
Be careful of the pin installed to the glass as
shown in the illustration.
KCOBD5565A
1)
Apply protective tape along the body surface of

the side window edge.
2)
Push the piano wire through the hole between the

glass and body from the outside and wrap each
end around a piece of wood.
CAUTION
glass.
3.
Remove the glass by detaching the glass fastener.
KCOBD5565A
BD -68
3)
BODY
Pull the piano wire in the inside and cut the adhesive
REAR SIDE WINDOW ASSEMBLY

1.
CAUTION
Carefully cut through the adhesive around the
glass edge to prevent damage.
For the fastener portion, unwrap the piano wire from the wood in the inside, pass
through the adhesive of fastener, and then
wrap the piano wire again around the wood.
4)
Adhesive
Hold the glass in the outside, disengage the fastener, and remove the side window glass.
INSTALLATION
E05CA67D
1.
Using a cutter knife, remove the adhesive on the

bonding surface. Clean the glass and body panel
bonding surface with cleaner.
2.
Remove the adhesive on the glass if door glass

reused.
3.
Preparation prior to body side assembly

If the cut body side adhesive is obviously protruded,
scrape the rough and uneven portion smooth using a
ECOBD5566A
CAUTION
Install the male fastener on the glass and female fastener on the body frame.
Dont forget to remain some amount of adhesive

as shown in the illustration.
2.
Preparation prior to side window glass assembly

(When reusing the glass)
1)
Remove the adhesive and spacer remaining from

the glass.
2)
Remove the damaged fastener.
3)
Clean the glass with SIKA CLEANER.
4)
Attach the fastener to the place shown in the illustration.
5)
Attach the spacer to the place shown in the illustration.
Spacer
Spacer
ECOBD5567A
4.
Apply the adhesive in the door glass and glass cleaner

in the inside of adhesive.
5.
Apply the sealant in the door glass higher than adhesive and install door glass.
6.
Spacer
NOTE
Let the car stand for at least four hours after swing
door glass installation.
Spacer
ECOBD5567A
INTERIOR
3.
BD -69
Side window glass assembly

1)
CAUTION
Clean the body applied with the adhesive (SIKA

SF250PC) with SIKA CLEANER No.1.
Adhesive is poisonous, always wear mask

while working, especially protect your eyes, if it
splashes into your eyes, wash them with clean
water, and then see a doctor if its condition
becomes serious.
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 minutes and attach the glass.
After cleaning, keep foreign material, especially finger print getting on the surface.
2)
10mm
Clean the glass edge (Ceramic coating portion)

with cleaner (SIKA CLEANER No.1).
8mm
CAUTION
Do not apply cleaner too thick.
After applying cleaner, let it dry for 5-10 minutes and apply adhesive.
After cleaning, keep foreign material, especially finger print getting on the surface.
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 securely

seat the adhesive between the body and glass.
Spacer
CAUTION
The glass attached should not move until the adhesive hardens completely.
5.
Spacer
Leak inspection and repair

1)
After hardening the adhesive, check for leaks.
2)
If there are leaks inspected, apply three cement

black.
ECOBD5567A
4.
Using a sealant gun, apply adhesive (SIKA SF250PC)

to the body. (Per each window sash)
1)
Adhesive bead figure

Overlap adhesive to a height of 20-30mm to the
connecting portion to continue the application.
2)
Adhesive hardens so quickly that the glass attaching procedure should be finished within 8
minutes since its application to the body.
6.
Side window garnish assembly
BD -70
BODY
REAR WINDOW
COMPONENTS
EB804BDD
2
1
3
6
1. Rear end seat
2. Outer under rear view mirror
3. Rear window glass weatherstrip
4. Rear window glass
5. Rear wiper arm
6. Rear wiper arm cover
ECOBD5414A
INTERIOR
BD -71
REAR WINDOW GLASS

DISASSEMBLY EBDA21EE
1.
When replacing the weatherstrip
Rear wiper arm (A) removal (For the vehicle with rear
wiper)
3)
Cut around the weatherstrip using a knife or

equivalent.
4)
Remove the glass by pushing its surface with

an equal force from the outside and remove the
weatherstrip by pulling it.
REAR WINDOW GLASS ASSEMBLY
E8B9F23B
1.
Cleaning of rear window glass assembly portion

Clean the glass and body assembly portion with gasoline.
2.
Rear window weatherstrip assembly

Assemble the weatherstrip to the glass.
CAUTION
KCOBD5037A
2.
Outer under rear view mirror (B) removal (For the vehicle with outer under rear view mirror)
3.
Rear window glass removal

1)
2)

If the weaterstrip is worn, never reuse it.
3.
Using a flat tip screwdriver wrapped with protective tape, remove the weatherstrip lip part from
the body flange by prying the body flange edges
off (Upper and both lateral sides).
Pull the glass by equally pushing its surface with
an equal force from the outside and disassemble
it together with weatherstrip.
KCOBD5568A
Rear window glass assembly

1)

at each end.
2)

3)
Place the weatherstrip lower portion to the window flange.
KCOBD5569A
BD -72
BODY
4)
To install the glass, with the aid of an assistant

to tap the glass around the weatherstrip from the
outside and pull strings in the inside (one string
higher than the flange).
5)
Lightly tap the glass by hand from the outside to

seat it completely.
4.
5.
Apply adhesive.
CAUTION
1)
2)

glass, and weatherstrip and body from the outside
3)
CAUTION
Let the adhesive and sealed portion dry for about

1 hour.
4)
Inspect leaks.
INTERIOR
BD -73
DRIVERS SEAT
COMPONENTS
E0336FE0
13
12
8
11
10
1. Seat buckle belt

2. Seat back cover
3. Seat back pad
4. Seat back frame
5. Seat cushion cover
6. Recycling adjuster
7. Seat cushion pad
8. Seat cushion frame

9. Seat track
10. Seat equalizing wire
11. Seat outside shield
12. Lumber support lever
13. Lumber support
ECOBD5417A
BD -74
REMOVAL
1.
BODY
5.
E27CB8D6
Remove the screw and outside shield.
Loosen the seat mounting bolts and disconnect the

seat belt connector.
ECOBD5583A
6.
Remove the seat back.
KCOBD5581A
2.
Remove the front seat belt rest assembly.
3.
Remove the front seat inner belt assembly.
KCOBD5585A
7.
Remove the reclining adjust assembly.
KCOBD5582A
4.
Remove the reclining adjust release handle and out

side shield.
KCOBD5586A
KCOBD5583A
INTERIOR
8.
BD -75
Remove the seat cushion.
11. Separation of front seat cushion cover assembly

1)
Separate the seat cushion frame in mesh of the

seat cushion cover as shown in the illustration.
2)
After detaching the hog ring, disconnect the front

seat cushion cover and seat cushion pad from the
seat cushion frame.
KCOBD5587A
9.
Remove the lumber support lever.
KCOBD5590A
KCOBD5588A
10. Separation of lumber support assembly (For the vehicle with lumber support)
Remove the 2 bolts and disconnect the lumber support assembly from the front seat back frame.
KCOBD5589A
BD -76
BODY
FRONT SEAT ASSEMBLY

1.
4.
ED2A1C0E
When assembling the seat back cover strip band to

the frame, lightly tighten the hog ring using a hog ring
primer, and lightly tighten the band not to loose or not
to be damaged.
CAUTION
After installation, put the sub seat outer belt C
assembly into the front seat back pocket.
KCOBD5591A
CAUTION
Do not dirt or damage the seat cover while assembling.
2.
Install the hog ring for seat cover using a hog ring
primer.
CAUTION
Take care not to make wrinkles while installing the
hog ring if possible.
3.
If there are wrinkles in the seat cover, smooth them

out using a dryer or equivalent.
After that, if the wrinkles are still existed, lightly spray
it with water and dry.
KCOBD5584A
KCOBD5592A
INTERIOR
BD -77
PASSENGER SEAT
COMPONENTS
EF1F2251
[First row, No.2 Passsenger seat]
Left support seat
ECOBD5593A
BD -78
BODY
[First row, Passsenger's seat]
1
2
3
4
6
7
8
9
10
11
14
13
15
1. Plug
2. Handle
3. Ashtray
4. Seat back board
5. Arm rest
6. Seat back frame

7. Seat back pad
8. Seat back cover
9. Seat ommer be;t
11. Seat cushion pad

12. Outer seat belt
13. Seat cushion frame
14. Seat leg
15. Reclining shock absorber
ECOBD5418A
INTERIOR
BD -79
[No.2 Passsenger's support seat]

With slide
1
3
2
3
4
5
4
7
6
9
10
11
8
7
7
7
12
16
13
14
15
1. Seat back frame

2. Seat back frame
3. Seat back cushion
4. Seat back cover
5. Seat back frame spacer
6. Seat back frame guide
7. Bush
8. Seat back lower frame
9. Assist seat cover
10. Seat cushion
11. Cushion frame
12. Nut
13. Assist seat cushion bracket

14. Clip
15. Pin
16. Cover
ECOBD5419A
BD -80
BODY
[No.3 Support seat]
Second row support seat
ECOBD5542A
INTERIOR
BD -81
[No.3 Support seat]

1
9
4
5
6
7
8
10
11
13
12
12
1. Handle
2. Bush
3. Ashtray
4. Seat back board
5. Seat back frame
6. Seat back pad

7. Seat back cover
8. Seat belt
9. Seat outer belt
11. Seat cushion pad

12. Seat leg
13. Assist seat
ECOBD5420A
BD -82
BODY
[No.3 Support seat]
1
2
2
3
10
7
8
1. Seat back frame

2. Seat back cushion
3. Seat back cover
4. Support seat cover
5. Seat cushion
6. Cushion frame
7. Support seat cushion bracket
8. Cover
9. Seat back frame guide
10. Seat back lower frame
ECOBD5421A
INTERIOR
REPLACEMENT
BD -83
EC271A7E
SEPARATION LEFT SUB ASSEMBLY NO.2

1.
Remove the 4 bolts and disconnect the left sub seat

No.2.
KCOBD5597A
2)
Disengage the 2 clips and 2 bushes.
3)
Disengage the straight pin and detach the sub

seat cushion bracket from the sub seat assembly.
KCOBD5595A
2.
Remove the 2 screws.
3.
Separate the protrusion in mesh and detach the cushion panel as shown in the illustration.
KCOBD5598A
5.
Separation of sub seat back assembly

After removing the 2 bolts, 2 bushes, and 2 wave
washers, separate the sub seat back assembly.
KCOBD5596A
4.
Sub seat cushion bracket separation

1)
Remove the nut spring and washer and pull the

pin.
KCOBD5599A
BD -84
6.
7.
BODY
Separation of sub seat back cover assembly

Disengage the hog ring, and detach the seat back
cover and seat back pad.
ASSEMBLY OF LEFT SUB SEAT ASSEMBLY NO.2

1.
Separate the sub seat back frame guides (RH and

LH). (For the vehicle with double slide type seat back)
1)
Assembly is the reverse of disassembly

CAUTION
Remove the 2 bolts.
KCOBD5600A
2)
Detach the 2 E rings and remove the 2 spacers

and 2 pins.
3)
Remove the seat back upper frame from the

lower frame by pulling it.
KCOBD5592A
2.
Install the hog ring for seat cover using a hog ring
primer.
CAUTION
Take care not to fold while installing the hog ring
if possible.
3.
If there are wrinkles in the seat cover, smooth them

out using a dryer or equivalent.
After that, if the wrinkles are still existed, lightly steam
and dry.
NO.3 SUPPORT SEAT ASSEMBLY REMOVAL

1.
Remove the jump seat
KCOBD5601A
4)
After removing the 2 screws, separate the 2 spacers of the sub seat back frame No.1
5)
Separate the sub seat back frame guides (RH

and LH).
KCOBD5594A
INTERIOR
2.
BD -85
Loosen the screw and remove the cushion panel.
4.
Remove the jump seat back.
5.
Assembly is the reverse of disassembly.
KCOBD5596A
3.
Remove the jump seat cushion bracket.
KCOBD5599A
6.
Separation of sub seat back cover assembly

Disengage the hog ring, and detach the seat back
cover and seat back pad.
7.
Separate the sub seat back frame guides (RH and

LH). (For the vehicle with double slide type seat back)
1)
Remove the 2 bolts.
KCOBD5597A
KCOBD5600A
KCOBD5598A
BD -86
BODY
2)
Detach the 2 E rings and remove the 2 spacers

and 2 pins.
3)
Remove the seat back upper frame from the

lower frame by pulling it.
ASSEMBLY OF RIGHT SUB SEAT ASSEMBLY NO.3

1.
Assembly is the reverse of disassembly

CAUTION
KCOBD5601A
4)
5)
After removing the 2 screws, separate the 2 spacers of the sub seat back frame No.1.
Separate the sub seat back frame guides (RH
and LH).
KCOBD5592A
2.
Install the hog ring using a hog ring primer.

CAUTION
Take care not to make wrinkles while installing the
hog ring if possible.
3.
If the wrinkles are existed, smooth them out using a

dryer.
INTERIOR
BD -87
SEAT BELT
COMPONENTS
EDBC1FF7
5
3
6
1. Seat belt
2. Passenger seat
3. Seat inner belt
4. Driver seat
5. Seat belt
6. Retractor cover
ECOBD5422A
BD -88
REMOVAL
1.
BODY
4.
EEF1DC69
Remove the seat belt upper anchorage.
Remove the center pillar lower garnish.
ECOBD5605A
ECOBD5602A
2.
LEFT SIDE 3 POINT TYPE

1.
Remove the seat belt retractor cover.
Separation of front seat belt retractor cover (LH)

Remove the 4 screws and detach the front seat belt
retractor cover (LH).
ECOBD5603A
3.
Remove the seat belt retractor.
ECOBD5604A
2.
Separation of front seat belt retractor

Remove the 2 bolts mounting on the retractor and
detach the retractor assembly.
ECOBD5604A
KCOBD5607A
INTERIOR
3.
BD -89
Separation of front seat outer belt floor anchor (LH)

Remove the floor anchor bolt.
RETRACTOR INSPECTION
E8DBDB48
CAUTION
Do not disassemble the retractor.
1.
ELR lock opening inclination angle inspection

When the retractor is rather inclined than the installed
angle, check that the belt is locked at 45?or more, not
within 15?to all around.
2.
Inspection for ELR lock

With the vehicle assembled, check that the belt is fixed
when the belt is rapidly pulled.
ECOBD5608A
4.
Separation of front seat outer belt (LH)

Using a thin screwdriver with protective tape, open the
anchor cover, remove the bolt, and detach the front
seat outer belt (LH).
ECOBD5610A
FRONT SEAT OUTER BELT INSTALLATION

RIGHT SIDE
1.
ECOBD5609A
Front seat outer belt (RH) installation

1)
Insert the retractor into the panel and install the

floor anchor bolt.
2)
Install the retractor upper bolt.
3)
Install the shoulder belt anchor bolt.

CAUTION
After tightening the anchor bolt, check the anchor for smooth operation.
With the belt installed, check the belt for
smooth operation.

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Body

Glass Thickness mm(in.)

Front hinged, Full door construction

Wire drum type

Pin - fork type

E.L.R : Emergency Locking Retractor

Door hinge to body

Door hinge to door

Upper anchor mounting bolt

Seat belt height adjuster

Retractor mounting bolt

GENERAL SAFETY INFORMATION

PRECAUTIONS FOR ELECTRIC WELDING

Turn off all of the electric switches in vehicle.

Remove the (-) Battery.

Disconnect all of grounding circuits earthed in vehicle,

Disconnect all ECU and controller connector.

Do not earth grounding circuit in the welding machine

The welding spark should be contacted to the fuel

When tightening ground terminal to the body, clean

Battery (+) cable tightening

Battery (+) terminal

Battery (-) cable tightening

Battery (-) terminal

Alternator "B" terminal

Engine grounding strap

Main Fuse box

Front door outside handle

Remove the front door lower trim flange(A).

Remove the front door inside handle housing(A).

Revove the cap using a sharp screwdriver.

Remove door pull handle.

Loosen the door trim panel screws and by using the

Remove the door outside handle

Remove the door inside handle.

Remove the 2 links.

Remove the tapping screw.

Remove the 2 bolts.

Using a screwdriver wrapped with protective

After removing the 2 links and loosening the 2

Remove the door key cylinder (A) after removing the

Remove the door latch assembly.

Installation of front door latch assembly

Install the front door latch assembly(A) with

Install the 2 links.

Front door key cylinder assembly

Front door inside handle installation

Install the 2 links.

Front door outside handle installation

Push the front door outside from the door panel

Engage the front door outside handle together

Install the front door outside handle with 2 bolts.

Pull handle installation

Install the pull handle with 2 screws.

Install the cap.

Front door trim installation

Install the front door trim(A) by tapping 12 clip

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

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

Inside full handle

Folding door insertion rubber

Remove the stopper bracket(A) with removing the