SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (If body maintenance is required)

Transcription

1 SUPPLMNTL RSTRINT SYSTM (SRS) (If body maintenance is required) The Ridgeline SRS includes a driver s airbag in the steering wheel hub, a passenger s airbag in the dashboard above the glove box, seat belt tensioners in the front seat belt retractors, side curtain airbags in the sides of the roof, and side airbags in the front seat-backs. Information necessary to safely service the SRS is included in this Service Manual. Items marked with an asterisk ( ) on the contents page include or are located near SRS components. Servicing, disassembling, or replacing these items requires special precautions and tools, and should be done by an authorized Honda dealer. To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event of a severe frontal or side collision, all SRS service work should be done by an authorized Honda dealer. Improper service procedures, including incorrect removal and installation of the SRS, could lead to personal injury caused by unintentional deployment of the airbags and/or side airbags. o not bump or impact the SRS unit, front impact sensors, or side impact sensors when the ignition switch is ON (II), or for at least 3 minutes after the ignition switch is turned OFF; otherwise, the system may fail in a collision, or the airbags may deploy. SRS electrical connectors are identified by yellow color coding. Related components are located in the steering column, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, in the front seats, in the roof side, and around the floor. o not use electrical test equipment on these circuits.

2 ody Special Tools oors omponent Location Index-Front oor omponent Location Index-Rear oor Front oor Panel Removal/Installation Front oor Outer Handle Replacement Front oor Latch Replacement Front oor Glass and Regulator Replacement Front oor Glass Outer Molding Replacement Front oor Weatherstrip Replacement Front oor Side Sill Seal Replacement Rear oor Panel Removal/Installation Rear oor Outer Handle Replacement Rear oor Latch Replacement Rear oor Glass and Regulator Replacement Rear oor Glass Outer Molding Replacement Rear oor Weatherstrip Replacement Rear oor Side Sill Seal Replacement Front and Rear oor Glass djustment Front and Rear oor Position djustment Front and Rear oor Striker djustment Mirrors omponent Location Index Power Mirror Replacement Mirror Holder Replacement Rearview Mirror Replacement Glass omponent Location Index Windshield Replacement Rear Window Replacement Rear Window Middle Glass Regulator Replacement Rear Window Middle Glass Replacement Rear Window Glass Run hannel Replacement Moonroof omponent Location Index Symptom Troubleshooting Index Glass Position djustment Glass Replacement Wind eflector Replacement rain hannel Replacement Sunshade Replacement Motor Replacement Frame and rain Tube Replacement rain hannel Slider and able ssembly Replacement Limit Switch djustment losing Force and Opening rag heck Interior Trim omponent Location Index Trim Removal/Installation-oor reas Trim Removal/Installation-Pillar reas Rear Panel Insulator Replacement Headliner Removal/Installation arpet Replacement onsoles enter onsole Removal/Installation enter onsole isassembly/reassembly onsole rmrest Removal/Installation onsole rmrest isassembly/reassembly enter onsole Trim isassembly/reassembly ashboard Instrument Panel Removal/Installation river s ashboard Lower over Removal/Installation ashboard enter Lower over Removal/Installation ashboard enter Lower over isassembly/reassembly Glove ox Removal/Installation Glove ox amper Replacement Glove ox Lock Replacement Glove ox Striker racket Replacement Passenger s Tray Replacement ashboard Vent Removal/Installation ashboard/steering Hanger eam Removal/Installation ashboard/steering Hanger eam isassembly/reassembly

3 Seats omponent Location Index Front Seat Removal/Installation Front Seat isassembly/reassembly Front Seat Linkage isassembly/reassembly-manual Front Seat Linkage isassembly/reassembly -Manual Height djustable Front Seat Linkage isassembly/reassembly -10-Way Power Front Seat Lumbar Support Replacement Front Seat-back over Replacement Front Seat ushion over Replacement Rear Seat Removal/Installation Rear Seat Leg Guide Replacement Rear Seat rmrest Replacement Rear Seat rmrest everage Holder Replacement Rear Seat ushion isassembly/reassembly Rear Seat ushion Handle Replacement Rear Seat ushion Pivot able Replacement Rear Seat-back over Replacement Rear Seat ushion over Replacement Rear Seat rmrest over Replacement umpers Front umper Removal/Installation Rear umper Removal/Installation Rear umper Step Replacement Hood Hood djustment Hood Seal Replacement Tailgate omponent Location Index Tailgate Lock-out Override Tailgate Trim Panel Removal/Installation Tailgate Upper Handle Replacement Tailgate Lower Handle Replacement Tailgate Latch Synchronizer Replacement Left Tailgate Upper Latch Replacement Left Tailgate Lower Hinge Replacement Right Tailgate Upper Latch Replacement Right Tailgate Lower Hinge-latch Replacement Tailgate Support able Replacement Tailgate Removal Tailgate Installation/djustment Fuel Fill oor Fuel Fill oor djustment Pickup ed ed Rail Trim Replacement pillar Outer Trim Replacement Front ed Panel Removal/Installation Side ed Panel Removal/Installation ed Floor Removal/Installation Rear ir Outlet Replacement In-ed Trunk Lid Removal/Installation In-ed Trunk Lid Hinge Replacement In-ed Trunk Lid lignment In-ed Trunk Lid Weatherstrip Replacement xterior Trim Front ulkhead over Replacement Front Grille Replacement owl over Replacement Roof Molding Replacement Rear Roof Trim Replacement mblem/sticker Replacement Fenderwell Front Inner Fender Replacement Front Splash Shield Replacement Front Fender Fairing Replacement Left Front Splash Guard Reinforcement Replacement Rear Fender over Replacement Openers omponent Location Index Hood Opener able Replacement Fuel Fill oor Opener able Replacement Hood Latch Replacement Fuel Fill oor Opener Replacement In-ed Trunk Lid Latch Replacement In-ed Trunk Lid Opener Replacement In-ed Trunk Lid Lock ylinder Replacement Frame Trailer Hitch Replacement Subframe Replacement Frame Repair hart

4 ody Special Tools Ref. No. Tool Number escription Qty 07G-SJ100 Tailgate Height Step Gauge 1 07G-SJ200 Tailgate Left Hinge lignment Fixture

5 oors omponent Location Index - Front oor OOR WTHRSTRIP Replacement, page OOR Position djustment, page OOR GLSS OUTR MOLING Replacement, page HING OOR HKR SPKR HING PULL POKT LI POWR WINOW SWITH PNL POWR MIRROR SWITH PLSTI OVR OOR GLSS INNR WTHRSTRIP OOR SI SILL SL Replacement, page OURTSY LIGHT SUHRNSS GRIP S POWR RR WINOW SWITH POWR WINOW SWITH Passenger s POWR WINOW SWITH PNL GRIP OVR OURTSY LIGHT LNS GRIP RKT OOR PNL Replacement, page 20-7 POWR WINOW SWITH (cont d) 20-3

6 oors omponent Location Index - Front oor (cont d) IMMOILIZR LL or IMMOILIZR and SURITY LL NTR LOWR HNNL GLSS RUN HNNL GLSS Replacement, page djustment, page OUTR HNL PROTTOR RGULTOR Replacement, page FRONT LOWR HNNL OUTR HNL Replacement, page 20-8 INNR HNL KY YLINR SWITH LOK KNO OVR INNR HNL L LOK L STRIKR djustment, page LTH Replacement, page LTH PROTTOR POWR OOR LOK TUTOR 20-4

7 omponent Location Index - Rear oor QURTR INNR TRIM OOR WTHRSTRIP Replacement, page OOR Position djustment, page OOR GLSS OUTR MOLING Replacement, page PLSTI OVR HING OOR HKR RMRST OURTSY LIGHT LNS SPKR OOR GLSS INNR WTHRSTRIP HING OOR SI SILL SL Replacement, page PULL POKT LI OOR PNL RKT POWR WINOW SWITH PNL OOR PNL Replacement, page POWR WINOW SWITH (cont d) 20-5

8 oors omponent Location Index - Rear oor (cont d) RR LOWR HNNL GLSS RUN HNNL GLSS Replacement, page djustment, page ULV STIKR Replacement, page NTR LOWR HNNL OUTR HNL PROTTOR RGULTOR Replacement, page RO PROTTOR OVR INNR HNL OUTR HNL Replacement, page LOK KNO INNR HNL L STRIKR djustment, page LOK L LTH Replacement, page POWR OOR LOK TUTOR LTH PROTTOR 20-6

9 Front oor Panel Removal/Installation Special Tools Required KT trim tool set SOJTP2014 Trim pad remover, Snap-on 177 or equivalent, commercially available vailable through the merican Honda Tool and quipment Program; call Remove the screw from under the pull pocket lid (). Fastener Location :Screw,1 NOT: Use the appropriate tool from the KT trim tool set to avoid damage when prying components. Take care not to scratch the door and related parts. 1. Lower the glass fully. 2. Remove the mirror mount cover (see step 2 on page 20-27). 3. Pull back the inner handle knob (). Using a trim tool, push on the lower hook () and pivot the cover () on the upper hooks (), then remove the cover. 6. Remove the door panel () with as little bending as possible to avoid creasing or breaking it. 1 Remove the screws (). 2 Use a commercially available trim pad remover to detach the clips (). 3 Starting at the rear, pull the door panel upward, then release the lock knob (). NOT: To avoid damaging components inside the door, do not use excessive force when lifting up on the panel. 4. Remove the screws, then remove the inner handle (), and disconnect the inner handle cable (). :Screw,3 : lip,8 :Screw,2 (cont d) 20-7

10 oors Front oor Panel Removal/ Installation (cont d) Front oor Outer Handle Replacement 7. isconnect the courtesy light subharness connector (), power mirror switch connector () (driver s), power window switch connector (), and power rear window switch connector () (driver s). NOT: Put on gloves to protect your hands. 1. Raise the glass fully. 2. Remove these items: oor panel (see page 20-7) Plastic cover, as necessary (see step 2 on page 20-11) enter lower channel (see step 3 on page 20-10) (driver s side only) 3. Remove the maintenance seal () from the rear of the door, then disconnect the outer handle rod () and cylinder rod () (driver s). 8. Install the door panel in the reverse order of removal, and note these items: heck if the clips are damaged or stresswhitened, and if necessary, replace them with new ones. Make sure the connectors are plugged in properly, and the rod is connected securely. Push the clips into place securely. When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its outside perimeter to seal out water. 4. river s: Release the retainer clip () with a hookshaped tool, then remove the lock cylinder (). 20-8

11 5. With cylinder switch: isconnect the cylinder switch connector (), and detach the harness clips (), then remove the cylinder switch (). 7. Release the hook (), then pull the outer handle () out of the door panel. Take care not to scratch the door. 6. Remove the bolts, and slide the outer handle protector () to release the hook (), then remove the outer handle protector. :olt,2 6x1.0mm 9.8 N m (1.0 kgf m, 7.2 lbf ft) 8. Install the handle in the reverse order of removal, and note these items: Make sure the cylinder switch harness is routed properly. Make sure the cylinder switch connector is plugged in properly, and each rod is connected securely. Install the lock cylinder retaining clip on the handle, then install the lock cylinder. e sure the clip is fully seated in the slot on the lock cylinder. Make sure the door key cylinder/door locks operate properly. Make sure the door handle works properly. When installing the lock cylinder, leave the outer door handle bolts loose so the inner protector does not interfere with the lock cylinder, then tighten the handle bolts. When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its outside perimeter to seal out water. 20-9

12 oors Front oor Latch Replacement NOT: Put on gloves to protect your hands. 1. Raise the glass fully. 6. isconnect the actuator connectors (), and detach the inner handle cable clip (). Remove the screws securing the latch (). 2. Remove these items: oor panel (see page 20-7) Plastic cover, as necessary (see step 2 on page 20-11) 3. Pull the glass run channel () away as needed, and remove the bolt, then remove the center lower channel () by pulling it downward. :Screw,3 6x1.0mm 6N m (0.6 kgf m, 4lbf ft) Fastener Location :olt,1 7. Remove the latch () through the hole in the door. Take care not to bend the outer handle rod (), cylinder rod (), lock cable (), and inner handle cable (). 6x1.0mm 8N m (0.8 kgf m, 6lbf ft) 4. Remove the maintenance seal from the rear of the door, then disconnect the outer handle rod and cylinder rod (see step 3 on page 20-8). 5. Remove the screw securing the lock knob (). Fastener Location :Screw,

13 8. Remove the screw and release the hooks (), then remove the latch protector (). Fastener Location :Screw,1 Front oor Glass and Regulator Replacement NOT: Put on gloves to protect your hands. 1. Remove the door panel (see page 20-7). 2. Remove the plastic cover (). 1 etach the harness clip () and remove the caps (). 2 Slide the inner handle cable (), the lock knob () and the harness (F) in through the hole in the plastic cover. 9. isconnect the inner handle cable () and lock cable (). F 10. Install the latch in the reverse order of removal, and note these items: 3. arefully raise the glass () until you can see the bolts, then remove them. arefully pull the glass out through the window slot. Take care not to drop the glass inside the door. :olt,2 Make sure the actuator connectors are plugged in properly and that the cables and each rod is connected securely. Make sure the door locks and opens properly. When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its outside perimeter to seal out water. 6x1.0mm 9.8 N m (1.0 kgf m, 7.2 lbf ft) (cont d) 20-11

14 oors Front oor Glass and Regulator Replacement (cont d) Front oor Glass Outer Molding Replacement 4. isconnect the connector () from the regulator (). :olt,2 :olt,5 6x1.0mm 9.8 N m (1.0 kgf m, 7.2 lbf ft) 5. Remove the bolts (), and loosen the bolts (), then remove the regulator through the hole in the door. Special Tools Required KT trim tool set SOJTP2014 vailable through the merican Honda Tool and quipment Program; call NOT: Put on gloves to protect your hands. Take care not to scratch the door. Use the appropriate tool from the KT trim tool set to avoid damage when prying components. 1. Remove the power mirror (see page 20-27). 2. Starting at the front, pull the door glass outer molding () to release the clips (). 6. pply multipurpose grease to the sliding surfaces of the regulator () where shown. 7. Install the glass and regulator in the reverse order of removal, and note these items: Roll the glass up and down to see if it moves freely without binding. Make sure that there is no clearance between the glass and glass run channel when the glass is closed. djust the position of the glass as necessary (see page 20-23). o the power window control unit reset procedure (see page ). heck for water leaks (see step 7 on page 20-23). Test-drive, and check for wind noise and rattles. When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its outside perimeter to seal out water. Make sure the power door locks, windows, and power mirror operate properly

15 3. Release from the rear portion of the glass outer molding () from the glass run channel (). Front oor Weatherstrip Replacement NOT: Take care not to scratch the door. Use a clip remover to remove the clips. 1. Remove the door checker mounting bolt (). :olt,1 :lip,25 : lip, 2 4. Install the glass outer molding in the reverse order of removal, and note these items: heck if the clips are damaged or stresswhitened, and if necessary, replace them with new ones. Make sure the rear portion of the glass outer weatherstrip connected to the glass run channel properly. 8x1.25mm 29 N m (3.0 kgf m, 22 lbf ft) 2. etach the clips (, ), then remove the door weatherstrip (). 3. Install the weatherstrip in the reverse order of removal, and note these items: heck if the clips are damaged or stresswhitened, and if necessary, replace them with new ones. Make sure the weatherstrip is installed in the holder () securely. pply medium strength type liquid thread lock to the door checker mounting bolt before installation. heck for water leaks (see step 7 on page 20-23)

16 oors Front oor Side Sill Seal Replacement Rear oor Panel Removal/ Installation NOT: Take care not to scratch the door. Use a clip remover to remove the clips. 1. etach the clips, then remove the door side sill seal (). :lip,12 Special Tools Required KT trim tool set SOJTP2014 Trim pad remover, Snap-on 177 or equivalent, commercially available vailable through the merican Honda Tool and quipment Program; call NOT: Use the appropriate tool from the KT trim tool set to avoid damage when prying components. Take care not to scratch the door and related parts. 1. Lower the glass fully. 2. Pull back the upper portion of the door quarter inner trim () to detach the clip. Fastener Location : lip, 1 2. Install the side sill seal in the reverse order of removal, and note these items: heck if the clips are damaged or stresswhitened, and if necessary, replace them with new ones. Push the clips into place securely. 3. Release the hooks (), then remove the door quarter inner trim () to detach the clip

17 4. Pull back the inner handle knob (). Using a trim tool, push on the lower hook () and pivot the cover () on the upper hooks (), then remove the cover. 6. Remove the screw from under the pull pocket lid (). Fastener Location :Screw,1 5. Remove the screws and inner handle () to release the hooks (, ), then disconnect the inner handle cable (). :Screw,2 7. Remove the door panel () with as little bending as possible to avoid creasing or breaking it. 1 Use a commercially available trim pad remover to detach the clips. 2 Starting at the rear, pull the door panel upward, then release the lock knob (). NOT: To avoid damaging components inside the door, do not use excessive force when lifting up on the panel. :lip,7 (cont d) 20-15

18 oors Rear oor Panel Removal/ Installation (cont d) Rear oor Outer Handle Replacement 8. isconnect the courtesy light bulb socket () and the power window switch connector (). NOT: Put on gloves to protect your hands. 1. Remove these items: oor panel (see page 20-14) Rear door glass (see page 20-19) Rear lower channel (see step 2 on page 20-17) 2. Remove the maintenance seal () from the rear of the door, then disconnect the outer handle rod (). 9. Install the door panel in the reverse order of removal, and note these items: heck if the clips are damaged or stresswhitened, and if necessary, replace them with new ones. Make sure the connectors are plugged in properly, and that the cable and the courtesy light bulb socket are connected properly. Make sure the window and power door lock operate properly. 3. Loosen the nut (), and remove the bolt (), then remove the rod protector (). :Nut,1 : olt, 1 6x1.0mm 9.8 N m (1.0 kgf m, 7.2 lbf ft) 6x1.0mm 8N m (0.8 kgf m, 6lbf ft) 20-16

19 Rear oor Latch Replacement 4. Remove the bolt, and slide the outer handle protector () to release the hook (), then remove the outer handle protector. Fastener Location :olt,1 NOT: Put on gloves to protect your hands. 1. Remove these items: oor panel (see page 20-14) Rear door glass (see page 20-19) 2. Pull the glass run channel () away as needed, and remove the bolt, then remove the rear lower channel () by pulling it downward. Fastener Location :olt,1 6x1.0mm 9.8 N m (1.0 kgf m, 7.2 lbf ft) 5. Release the hook (), then pull the outer handle () out of the door panel. Take care not to scratch the door. 6x1.0mm 8N m (0.8 kgf m, 6lbf ft) 3. Remove the maintenance seal from the rear of the door, then disconnect the outer handle rod (see step 2 on page 20-16). 4. Remove the nut and bolt then remove the rod protector (see step 3 on page 20-16). 5. Remove the screw securing the lock knob (). Fastener Location :Screw,1 6. Install the handle in the reverse order of removal, and note these items: Make sure the rod is connected securely. Make sure the door handle works properly before closing the door. When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its outside perimeter to seal out water. (cont d) 20-17

20 oors Rear oor Latch Replacement (cont d) 6. isconnect the actuator connectors (), and detach the inner handle cable clip (). Remove the screws (, ) securing the latch (). :Screw,2 :Screw, 1 8. Remove the screw and release the hooks (), then remove the latch protector (). Fastener Location :Screw,1 Inside 6x1.0mm 6N m (0.6 kgf m, 4lbf ft) 7. Remove the latch () with the protector through the hole in the door. Take care not to bend the outer handle rod (), lock cable (), and inner handle cable (). 9. isconnect the inner handle cable () and lock cable (). 10. Install the latch in the reverse order of removal, and note these items: Make sure the actuator connectors are plugged in properly and that the cables and each rod are connected securely. Make sure the door locks and opens properly. When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its outside perimeter to seal out water

21 Rear oor Glass and Regulator Replacement NOT: Put on gloves to protect your hands. 1. Remove these items: oor panel (see page 20-14) Rear glass outer molding (see page 20-20) 4. arefully move the glass () until you can see the bolts, then remove them. arefully lower the glass. Take care not to drop the glass inside the door. :olt,2 2. Remove the plastic cover (). 1 Remove the caps (). 2 Remove the screws, then remove the panel bracket (). 3 Slide the inner handle cable (), lock knob (), courtesy light bulb socket (F) and the harness (G) in through the hole in the plastic cover. 4 Remove the plastic cover. :Screw,2 6x1.0mm 9.8 N m (1.0 kgf m, 7.2 lbf ft) G 5. Rotate the glass as shown, and carefully remove the glass () out through the window opening. Take care not to drop the glass inside the door. F 3. Pull the glass run channel () away as needed, and remove the bolt, then remove the center lower channel () by pulling it downward. Fastener Location :olt,1 6x1.0mm 8N m (0.8 kgf m, 6lbf ft) (cont d) 20-19

22 oors Rear oor Glass and Regulator Replacement (cont d) Rear oor Glass Outer Molding Replacement 6. isconnect the connector () from the regulator (). :olt,2 : olt, 5 6x1.0mm 9.8 N m (1.0 kgf m, 7.2 lbf ft) 7. Remove the bolts (), and loosen the bolts (), then remove the regulator through the hole in the door. 8. pply multipurpose grease to the sliding surfaces of the regulator () where shown. Special Tools Required KT trim tool set SOJTP2014 vailable through the merican Honda Tool and quipment Program; call NOT: Put on gloves to protect your hands. Take care not to scratch the door. Use the appropriate tool from the KT trim tool set to avoid damage when prying components. 1. Lower the glass fully. 2. Starting at the front, pull the door glass outer molding () to release the clips (). 9. Install the glass and regulator in the reverse order of removal, and note these items: Roll the glass up and down to see if it moves freely without binding. Make sure that there is no clearance between the glass and glass run channel when the glass is closed. djust the position of the glass as necessary (see page 20-23). heck for water leaks (see step 7 on page 20-23). Test-drive, and check for wind noise and rattles. When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its outside perimeter to seal out water. Make sure the power door locks and windows operate properly

23 3. Release from the front portion of the glass outer molding () from the glass run channel (). Rear oor Weatherstrip Replacement NOT: Take care not to scratch the door. Use a clip remover to remove the clips. 1. Remove the door checker mounting bolt (). :olt,1 :lip,17 :lip,1 4. Install the glass outer molding in the reverse order of removal, and note these items: heck if the clips are damaged or stresswhitened, and if necessary, replace them with new ones. Make sure the rear portion of the glass outer weatherstrip catch the glass run channel properly. 8x1.25mm 29 N m (3.0 kgf m, 22 lbf ft) 2. etach the clips (, ), then remove the door weatherstrip (). 3. Install the weatherstrip in the reverse order of removal, and note these items: heck if the clips are damaged or stresswhitened, and if necessary, replace them with new ones. Make sure the weatherstrip is installed in the holder () securely. pply medium strength type liquid thread lock to the door checker mounting bolt before installation. heck for water leaks (see step 7 on page 20-23)

24 oors Rear oor Side Sill Seal Replacement NOT: Take care not to scratch the door. Use a clip remover to remove the clips. 1. etach the clips, then remove the door side sill seal (). : lip, Install the side sill seal in the reverse order of removal, and note these items: heck if the clips are damaged or stresswhitened, and if necessary, replace them with new ones. Push the clips into place securely

25 Front and Rear oor Glass djustment NOT: heck the weatherstrips and glass run channel for damage or deterioration, and replace them if necessary. Wipe the run channel clean with a shop towel. Lubricate the run channel with Shin-tsu silicone grease P/N heck that the glass moves smoothly. 6. Raise the glass fully, and check for gaps. heck that the glass () contacts the glass run channel () evenly. 1. Place the vehicle on a firm, level surface. 2. Remove these items: oor panel: Front door (see page 20-7) Rear door (see page 20-14) Plastic cover: Front door (see step 2 on page 20-11) Rear door (see step 2 on page 20-19) 3. arefully move the glass () until you can see the glass mounting bolts (), then loosen them. Front door 7. heck for water leaks. Run water over the roof and on the sealing area as shown, and note these items: Usea12mm(1/2in.)diameterhose(). djust the rate of water flow as shown (). o not use a nozzle. Hold the hose about 300 mm (12 in.) away from the door. 12 mm (1/2 in.) 0.5m(18in.) Rear door 6x1.0mm 9.8 N m (1.0 kgf m, 7.2 lbf ft) 300 mm (12 in.) 6x1.0mm 9.8 N m (1.0 kgf m, 7.2 lbf ft) 4. Push the glass against the channel (), then tighten the glass mounting bolts. 8. ttach the plastic cover making sure it is sealed around its outside perimeter to seal out water, then install the door panel. 9. Test-drive, and check for wind noise and rattles

26 oors Front and Rear oor Position djustment NOT: heck for a flush fit with the body, then check for equal gaps between the front, rear, and bottom door edges and the body. heck that the door and body edges are parallel. efore adjusting, replace the mounting bolts. 1. Place the vehicle on a firm, level surface when adjusting the doors. 2. djust at the hinges (): Pad a floor jack () with shop towels (), then use the jack to support the door to prevent damage to the door while adjusting it. On the front door: Remove the front inner fender (see page ) and front fender fairing (see page ). Loosen the hinge mounting bolts () slightly, and move the door backward or forward, up or down as necessary to equalize the gaps. On the rear door: Loosen the hinge mounting bolts () slightly, and move the door backward or forward, up or down as necessary to equalize the gaps. Front door F 8x1.25mm 29 N m (3.0 kgf m, 22 lbf ft) Rear door 8x1.25mm 29 N m (3.0 kgf m, 22 lbf ft) F 8x1.25mm 29 N m (3.0 kgf m, 22 lbf ft) 8x1.25mm 29 N m (3.0 kgf m, 22 lbf ft) F 8x1.25mm 29 N m (3.0 kgf m, 22 lbf ft) 3. If necessary, replace the door mounting bolts with the adjusting bolts (P/N SF-305) made specifically for door adjustment, then adjust at the door: Loosen the door mounting bolts (F) slightly, and move the door up or down as necessary to equalize the gaps, and in or out until it s flush with the body. 8x1.25mm 29 N m (3.0 kgf m, 22 lbf ft) 8x1.25mm 29 N m (3.0 kgf m, 22 lbf ft) F 8x1.25mm 29 N m (3.0 kgf m, 22 lbf ft) 20-24

27 4. heck that the door and body edges are parallel. If necessary, adjust the door cushions () to make the rear of the doors flush with the body. Front and Rear oor Striker djustment Make sure the door latches securely without slamming it. If necessary, adjust the striker (): The striker can be adjusted slightly up or down, and in or out. 1. Loosen the screws (). 5. pply touch-up paint to the hinge mounting bolts, and around the hinges. 6. heck for water leaks (see step 7 on page 20-23). 8x1.25mm 18 N m (1.8 kgf m, 13 lbf ft) 2. Wrap the striker with a shop towel, then adjust the striker by tapping it with a plastic hammer (). o not tap the striker too hard. 3. Lightly tighten the screws. 4. Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door latches properly, tighten the screws and recheck

28 Mirrors omponent Location Index POWRMIRRORTUTOR Replacement, page POWR MIRROR Replacement, page MIRROR MOUNT OVR MIRROR HOLR Replacement, page Without ompass With ompass MOUNT MOUNT MIRROR HRNSS UPPR OVR MIRROR HRNSS LOWR OVR RRVIW MIRROR RRVIW MIRROR Replacement, page Replacement, page

29 Power Mirror Replacement 1. Lower the door glass fully. 2. With your hand, carefully release the clip, lift the cover upward to release the hooks (), and remove the cover () in the sequence shown. 6. While holding the mirror, push in on the connector clips (), then push out to remove the mirror (). Take care not to scratch the door. Fastener Location :lip,1 3. Remove the front door panel (see page 20-7). 7. Install the mirror in the reverse order of removal, and note these items: 4. isconnect the connector (). :Nut,3 5x0.8mm 5N m (0.5 kgf m, 4lbf ft) Make sure the connector is plugged in properly. When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its outside perimeter to seal out water. 5. While holding the mirror, remove the nuts securing the mirror

30 Mirrors Mirror Holder Replacement NOT: Put on gloves to protect your hands. 1. arefully push on the top edge of the mirror holder () by hand. 3. Twist the screwdriver to release the clips () from the actuator (). arefully pull out the bottom edge of the mirror holder (), then separate the mirror holder from the actuator by releasing the hooks (). isconnect the mirror defogger connectors () from the heater pad terminals. 4. Reconnect the mirror defogger connectors. 2. Put a shop towel in the opening between the lower edge of the mirror holder and the mirror housing () to prevent scratches. Insert a flat-tip screwdriver wrapped with protective tape through the slot () at the bottom of the mirror holder. 5. Reattach the hooks of the mirror holder to the actuator, then position the mirror holder on the actuator. arefully push on the clip portions of the mirror holder until the mirror holder locks into place. 6. heck the operation of the actuator

31 Rearview Mirror Replacement 1. With compass: Slide the mirror harness upper cover () forward, then remove the mirror harness lower cover (). 3. Turn the rearview mirror base () With compass: isconnect the connector (). 4. Slide the rearview mirror () down toward the bottom of the windshield to detach it from the spring () in the mount (). 5. If necessary, remove the spring from the mount. 6. Install the rearview mirror in the reverse order of removal

32 Glass omponent Location Index WINSHIL MOLING MOLING UPPR SL, 2 UPPR RUR M (Required for replacement or reinstallation) UPPR FSTNR, 2 (Self-adhesive-type, glass side) (Required for replacement or reinstallation) UPPR FSTNR, 2 (lip-type, body side) (Required for replacement or reinstallation) MOLING RUR, 2 NON WOVN FRI, 2 MOLING SI SL, 2 SI RUR M, 2 (Required for replacement or reinstallation) UPPR RUR M SHOR SL WINSHIL Replacement, page LOWR RUR M 20-30

33 RR WINOW Replacement, page UPPR SPR FSTNR, 4 (Self-adhesive-type, glass side) FSTNR, 4 (Self-adhesive-type, body side) MOTOR RKT RR WINOW GLSS RUN HNNL Replacement, page RR WINOW SLIR SWITH RR WINOW MIL GLSS Replacement, page RR WINOW MIL GLSS RGULTOR Replacement, page

34 Glass Windshield Replacement NOT: Put on gloves to protect your hands. Wear eye protection when removing the glass with piano wire. Use seat covers to avoid damaging the seat. When replacing a broken windshield, a commercially available windshield cutter can be efficiently used for cutting the adhesive. For details, follow the instructions of the manufacturer of the tool. o not damage the windshield defogger grid lines and defogger terminals. 1. Remove these items: Rearview mirror (see page 20-29) -pillar trim, both sides (see page 20-63) Windshield wiper arms (see page ) owl cover (see page ) Right tweeter grille (see step 7 on page 20-90) 2. Lower the glove box (see page 20-85). 3. isconnect the windshield defogger connector () through the glove box opening, and pull out the windshield defogger harness () from the tweeter grille opening in the dashboard (). 5. If the old windshield will be reinstalled, make alignment marks across the glass and body with a grease pencil. 6. Pull down the front portion of the headliner (see page 20-70). Take care not to bend the headliner excessively, or you may crease or break it. 7. pply protective tape along the edge of the dashboard and body. Using an awl, make a hole through the rubber dam, adhesive, and dashboard seal from inside the vehicle at the corner portion of the glass. Push a piece of piano wire through the hole, and wrap each end around a piece of wood. 8. pply the protective plastic plates () between the dashboard () and piano wire () and between the windshield () and piano wire. With a helper on the outside, pull the piano wire back and forth in a sawing motion. Hold the piano wire as close to the windshield as possible to prevent damage to the body and dashboard. arefully cut through the rubber dam and adhesive () around the entire windshield. Take care not to damage the windshield defogger harness (F). F 4. Remove the molding () from the edge of the windshield (). If necessary, cut the molding with a utility knife

35 utting positions 13. ttach the upper rubber dam (), side rubber dams (), and lower rubber dam () with adhesive tape. pply primer where the fasteners () are to be applied, then attach the fasteners with adhesive tape and dashboard seal () to the inside face of the windshield (F) as shown: e sure the rubber dams, fasteners, and dashboard seal line up with the alignment marks (G). e careful not to touch the windshield where adhesive will be applied. 9. arefully remove the windshield. 10. With a putty knife, scrape the old adhesive until smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire windshield opening flange: o not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding. Remove the rubber dam and fasteners from the body. Rubber dams adhesive tape: Thickness 0.16 mm (0.006 in.) Width 4 mm (0.16 in.) Fasteners and dashboard seals adhesive tape: Thickness 0.2 mm (0.008 in.) Width 7.5 mm (0.30 in.) : pply primer here. G G 12 mm (0.47 in.) Inside 12 mm (0.47 in.) Inside F 11. lean the body bonding surface with a sponge dampened in isopropyl alcohol. fter cleaning, keep oil, grease and water from getting on the clean surface. F 12. If the old windshield will be reinstalled, use a putty knife to scrape off all of the old adhesive, the rubber dam and the dashboard seal from the windshield. lean the inside face and the edge of the windshield with isopropyl alcohol where new adhesive is to be applied. Make sure the bonding surface is kept free of water, oil, and grease. F 12 mm (0.47 in.) 132 mm (5.2 in.) F G (cont d) 20-33

36 Glass Windshield Replacement (cont d) 14. pply primer to the edge of the windshield between the alignment marks (). e careful not to touch the windshield where adhesive will be applied. : pply primer here. 16. ttach the molding upper seals (), molding lower seals (), and non woven fabric () to the inside surface of the molding (), and attach the molding rubbers () with the adhesive tape to the inside surface of the molding lip (F) as shown: e sure the molding upper seal and molding side seal line up with the alignment dots (G). e sure the molding rubber lines up with the alignment mark (H) of the molding. e careful not to touch the windshield where adhesive will be applied. Molding rubber adhesive tape: Thickness 0.16 mm (0.006 in.) Width 3 mm (0.12 in.) lignment dot location G H G 15. ttach the molding () with adhesive tape () to the edge of the windshield (): e sure the alignment mark () of the molding lines up with the alignment mark () of the windshield. e careful not to touch the windshield where adhesive will be applied. F H dhesive tape: Thickness 0.8 mm (0.03 in.) Width 4 mm (0.16 in.) G 20-34

37 17. Install the fasteners to the body. : Fastener, With a sponge, apply a light coat of glass primer around the edge of the windshield () between the upper rubber dam (), side rubber dams (), lower rubber dam (), and molding () as shown, then lightly wipe it off with gauze or cheesecloth: pply glass primer to the molding. o not apply body primer to the windshield, and do not get the body and glass primer sponges mixed up. Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the windshield properly, causing a leak after the windshield is installed. Keep water, dust, and abrasive materials away from the primed surfaces. 18. Set the windshield in the opening, and center it. Make alignment marks () across the windshield and body with a grease pencil at the four points shown. e careful not to touch the windshield where adhesive will be applied. : pply glass primer here. 12 mm (0.47 in.) Inside 12 mm (0.47 in.) Inside Inside (cont d) 20-35

38 Glass Windshield Replacement (cont d) 20. With a sponge, carefully apply a light coat of body primer to any exposed paint around the flange where new adhesive will be applied. Let the primer dry for at least 10 minutes: o not apply body primer to any remaining original adhesive on the flange. e careful not to mix up the body and glass primer sponges. Never touch the primed surface with your hands. 20 mm (0.79 in.) : pply body primer to any exposed paint as shown. 20 mm (0.79 in.) 22. Put the cartridge in a caulking gun, and run a bead of adhesive () around the edge of the windshield () between the upper rubber dam (), side rubber dams (), lower rubber dam (), and molding (F) as shown. pply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner. 2mm (0.08 in.) 13 mm (0.51 in.) 8mm (0.31 in.) F 1.5 mm (0.059 in.) Inside F 1.5 mm (0.059 in.) Inside 20 mm (0.79 in.) F 21. ut a V in the end of the nozzle () on the adhesive cartridge as shown. 2.5 mm (0.098 in.) Inside 13 mm (0.51 in.) 8 mm (0.31 in.) 20-36

39 Rear Window Replacement 23. Use suction cups to hold the windshield over the opening, align it with the alignment marks made in step 18, and set it down on the adhesive. Lightly push on the windshield until its edges are fully seated on the adhesive all the way around. NOT: o not open or close the doors for about an hour until the adhesive is dry. 24. Scrape or wipe any excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the windshield, wipe with a soft shop towel dampened with isopropyl alcohol. 25. fter the adhesive has dried, spray water over the windshield and check for leaks. Mark leaking areas, and let the windshield dry, then seal with sealant: Let the vehicle stand for at least 4 hours after windshield installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly. Keep the windshield dry for the first hour after installation. 26. Reinstall all removed parts. Install the rearview mirror after the adhesive has dried thoroughly. dvise the customer not to do the following things for 2 to 3 days: Slam the doors with all the windows rolled up. Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads). NOT: Put on gloves to protect your hands. Use seat covers to avoid damaging any surface. 1. Remove these items: Rear seat assembly (see page ) -pillar trim, both sides (see page 20-68) Rear seat belt lower anchor, both sides (see step 2 on page 24-7) Rear seat side trim, both sides (see step 9 on page 20-62) Subwoofer, for some models (see page 23-60) Rear panel insulator (see page 20-69) Rear window middle glass regulator (see page 20-41) 2. Pull down the rear portion of the headliner as needed (see page 20-70). 3. From inside the vehicle, use a utility knife () to cut through the adhesive () all the way around: If the rear window () will be reinstalled, take care not to damage the molding (). pply protective tape along the edge of the entire rear window opening flange. 4. arefully remove the rear window. heck the molding for damage, and replace the rear window if necessary. (cont d) 20-37

40 Glass Rear Window Replacement (cont d) 5. With a putty knife, scrape the old adhesive smooth to a thickness of about 2 mm (0.08 in.) on the bonding surface around the entire rear window opening flange: o not scrape down to the painted surface of the body; damaged paint will interfere with proper bonding. Remove the fasteners from the body. 6. lean the body bonding surface with a sponge dampened in isopropyl alcohol. fter cleaning, keep oil, grease and water from getting on the surface. 7. If the old rear window will be reinstalled, use a putty knife to scrape off all of the old adhesive and the fasteners from the rear window molding. lean the inside face and the edge of the rear window molding with isopropyl alcohol where new adhesive will be applied. Make sure the bonding surface is kept free of water, oil and grease. 8. ttach the fasteners () with adhesive tape to the rear window molding () as shown: e sure the fasteners line up with the alignment marks () and molding shapes (). e careful not to touch the rear window molding where adhesive will be applied. dhesive tape: Thickness 0.6 mm (0.03 in.) Width 7.5 mm (0.3 in.) 20-38

41 9. ttach the fasteners with adhesive tape to the rear window opening flange of the body on both sides. dhesive tape: : Fastener, 4 Thickness 0.6 mm (0.03 in.) Width 9.5 mm (0.37 in.) 12. With a sponge, apply a light coat of glass primer along the edge of the rear window molding () as shown, then lightly wipe it off with gauze or cheesecloth: o not apply body primer to the rear window, and do not get body and glass primer sponges mixed up. Never touch the primed surfaces with your hands. If you do, the adhesive may not bond to the rear window properly, causing a leak after the rear window is installed. Keep water, dust, and abrasive materials away from the primed surfaces. : pply glass primer here. 12 mm (0.47 in.) 10. Set the rear window in the opening, and center it. Make alignment marks () across the rear window and body with a grease pencil at the four points shown. Make sure insert nuts () are aligned in the body holes (inside). e careful not to touch the rear window molding where adhesive will be applied. Inside 12 mm (0.47 in.) Inside 12 mm (0.47 in.) Inside 11. Remove the rear window. (cont d) 20-39

42 Glass Rear Window Replacement (cont d) 13. With a sponge, carefully apply a light coat of body primer to any exposed paint around the flange where new adhesive will be applied. Let the primer dry for at least 10 minutes: o not apply body primer to any remaining original adhesive on the flange. e careful not to mix up the body and glass primer sponges. Never touch the primed surfaces with your hands. 20 mm (0.79 in.) : pply body primer to any exposed paint as shown. 20 mm (0.79 in.) 15. Put the cartridge in a caulking gun, and run a bead of adhesive () around the edge of the rear window molding () as shown. pply the adhesive within 30 minutes after applying the glass primer. Make a slightly thicker bead at each corner. 2mm (0.08 in.) 13 mm 2mm (0.51 in.) (0.08 in.) 8mm (0.31 in.) Inside 3mm (0.11 in.) 20 mm (0.79 in.) 2mm (0.08 in.) Inside 2mm (0.08 in.) Inside 14. ut a V in the end of the nozzle () on the adhesive cartridge as shown. 13 mm (0.51 in.) 8 mm (0.31 in.) 20-40

43 16. Use suction cups to hold the rear window over the opening, align it with the alignment marks you made in step 10, and set it down on the adhesive. Lightly push on the rear window until its edges are fully seated on the adhesive all the way around. NOT: o not open or close any of the doors for about an hour until the adhesive is dry. 17. Scrape or wipe any excess adhesive off with a putty knife or towel. To remove adhesive from a painted surface or the rear window, use a soft shop towel dampened with isopropyl alcohol. 18. fter the adhesive has dried, then spray water over the rear window and check for leaks. Mark any leaking areas, let the rear window dry, then seal with sealant. Let the vehicle stand for at least 4 hours after rear window installation. If the vehicle has to be used within the first 4 hours, it must be driven slowly. 19. Reinstall all remaining removed parts. Rear Window Middle Glass Regulator Replacement NOT: Put on gloves to protect your hands. Take care not to bend or scratch the trim and panels. 1. Remove these items: Rear seat assembly (see page ) -pillar trim, both sides (see page 20-68) Rear seat belt lower anchor (see step 2 on page 24-7) Rear seat side trim, both sides (see step 9 on page 20-62) Subwoofer, for some models (see page 23-60) Rear panel insulator (see page 20-69) 2. Remove the rear window middle glass mounting bolts. :olt,2 NOT: dvise the customer not to do the following things for 2 to 3 days: Slam the doors with all the windows rolled up. Twist the body excessively (such as when going in and out of driveways at an angle or driving over rough, uneven roads). 6x1.0mm 9.8 N m (1.0 kgf m, 7.2 lbf ft) (cont d) 20-41

44 Glass Rear Window Middle Glass Regulator Replacement (cont d) 3. isconnect the connector () from the regulator motor (). 6. Install the regulator in the reverse order of removal, and note these items: :olt,2 : olt, 3 F 6x1.0mm 9.8 N m (1.0 kgf m, 7.2 lbf ft) Slide the glass right and left to see if it moves freely without binding. Make sure the connector is plugged in properly. 4. Remove the bolts (, ), and detach the cable clips (), then remove the regulator (F) and motor. 5. pply multipurpose grease to the sliding surfaces of the regulator () where shown

45 Rear Window Middle Glass Replacement NOT: Put on gloves to protect your hands. Take care not to bend or scratch the trim and panels. 1. Remove these items: 4. Move the glass () until you can remove it as shown. Pull up the glass to release the bottom of the glass, and pull out the top of the glass from the glass run channel (), and then remove the glass. Rear seat-back (see page ) Rear trim panel (see step 2 on page 20-68) 2. Remove the rear window middle glass mounting bolts. :olt,2 5. Install the glass in the reverse order of removal, and note these items: 6x1.0mm 9.8 N m (1.0 kgf m, 7.2 lbf ft) 3. Open the middle glass () fully by hand. Insert a pick tool () to the glass run channel () as shown, and pull out the edge of the upper spacer (), and then pull out the spacer by hand from between the glass run channel and glass. Make sure the spacer is installed properly. Slide the glass to see if it moves freely without binding. Make sure that there is no clearance between the glass and glass run channel when the glass is closed. heck for water leaks (see step 7 on page 20-23). Test-drive, and check for wind noise and rattles

46 Glass Rear Window Glass Run hannel Replacement NOT: Put on gloves to protect your hands. Take care not to bend or scratch the trim and panels. 4. With a knife, scrape the remaining glass run channels () from the grooves () on the middle glass areas of the rear window molding (). 1. Remove these items: Rear seat-back (see page ) Rear trim panel (see step 2 on page 20-68) Rear window middle glass (see page 20-43) 2. arefully cut the glass run channel () on the middle glass areas () with a utility knife (), and then pull out the glass run channel from the top and bottom groove areas of the rear window molding (). Take care not to damage the molding. 5. lean the molding bonding surface with a sponge dampened in isopropyl alcohol. fter cleaning, keep oil, grease and water from getting on the clean surface. 6. pply a light coat of primer to the groove areas () of the rear window molding (). Install the glass run channel () to the top and bottom groove areas of the molding, and then attach the glass run channel to the middle glass areas of the molding with adhesive (3M P8005). 3. heck the molding for damage, and replace the rear window if necessary. 7. Scrape or wipe the excess adhesive off with a soft shop towel dampened with alcohol. 8. Reinstall the removed parts