INSTRUCCIONES TECNICAS

Transcription

1 INSTRUCCIONES TECNICAS INSTALACIÓN DEL REFUERZO EN EL PANEL DE ACCESO DEL FJ CRUISER (Traducción al Español Parcialmente) 1. FUNCIONAMIENTO ORGANIGRAMA 3 2. IDENTIFICACIÓN DE VEHÍCULOS AFECTADOS 4 3. PREPARACIÓN 5 4. DESCRIPCIÓN GENERAL 7 5. MEDIDAS DE SEGURIDAD PARA LA REMACHADORA 8 6. PRECAUCIONES PARA COMPLETAR EL TRABAJO COMPONENTES PROCEDIMIENTO DE TRABAJO REMOVER LAS PARTES INTERIORES INSPECCIONAR EL PANEL PUERTA TRASERA (VER NECESIDAD DE INSTALACIÓN DEL REFUERZO EN EL PANEL DE ACCESO) INSPECCION DEL PANEL DE LA PUERTA TRASERA POR ROTURA (INSPECCIONAR LA NECESIDAD DEL REEMPLAZO DEL PANEL DEL LA PUERTA) INSPECCIÓN DEL PANEL LA PUERTA TRASERA POR GRIETAS (NECESIDAD DE INSPECCIONAR EL CINTURON POR REEMPLAZO) INSTALAR EL REFUERZO EN EL PANEL DE ACCESO RE-INSTALAR LAS PARTES INTERIORES 39 1

2 <<SAFETY PRECAUTIONS>> A. Be sure to observe the following precautions to prevent accidents and injuries. Park the vehicle and chock the wheels. If it is necessary to start the engine, perform the operation in a well ventilated area. Before removing and reinstalling heavy parts such as the engine, transmission and differential using lifting equipment, check that there are no problems with the equipment. When working in a group of 2 or more, each person must work to ensure the safety of all team members. To prevent burns and other injuries, use extra caution when handling parts that are subject to high temperatures, as well as rotating, sliding, or vibrating parts. When lifting the vehicle using a jack, support it in the specified location using a rigid rack. When lifting the vehicle using a lift, lock the lift for safety. B. Also perform the following operation with care. Use of auto lift Make absolutely certain that there are no other workers and no tools, parts, or other objects within the movable range of the lift. Also, be sure to announce all lift operations out loud (such as Raising the lift! and Lowering the lift! ) to alert other workers. When raising or lowering the lift to adjust the vehicle position, etc., pay attention to the positions of your arms, legs, and other body parts, and be extremely careful to prevent them from being caught in the lift. Use of brake cleaner Use brake cleaner for appropriate purposes in accordance with instructions in the manual. Do not use brake cleaner to remove dirt or stains from work clothes, etc. It can catch on fire and cause serious burns. <Precautions> Do not use brake cleaner near flame or fire. Do not use large amounts of brake cleaner in a room where a fire is burning. Do not keep brake cleaner in a place subject to high temperatures exceeding 40 C, such as a place subject to direct sunlight or near fire. Do not put brake cleaner in fire. Edges When handling the edges of parts and panels, wear protective gloves or apply protective tape to the edges to prevent injuries to your hands and fingers. 2

3 1. DIAGRAMA DE LA OPERACIÓN Realice los siguientes procedimientos para las puertas derecha e izquierda del FJ. REMUEVA LAS PARTES INTERIORES VER EL PANEL DE PUERTA TRASERA Compruebe visualmente si el panel de la puerta tiene una mejora o no. No Mejorado INSPECCIÓN PANEL PUERTA TRASERA - POR FRACTURA Sin Fractura Fracturado Mejorado INSPECCIÓN PANEL PUERTA TRASERA - POR GRIETAS Sin Grietas Agrietado INSTALL THE ACCESS PANEL REINFORCEMENT INSTALL THE ACCESS PANEL REINFORCEMENT AND REPLACE THE SEAT OUTER BELT ASSEMBLY REPLACE THE DOOR PANEL AND REPLACE THE SEAT OUTER BELT ASSEMBLY REPLACE THE SEAT OUTER BELT ASSEMBLY REINSTALE LAS PARTES INTERIORES FIN 3

4 2. IDENTIFICACION DE LOS VEHICULOS AFECTADOS AFFECTED VEHICLE IDENTIFICATION NUMBER Model WMI VDS VIN Range Range FJ CRUISER JTE BU# ZU# K K # indicates that various characters may occupy that position. As for the total number of affected vehicles shipped to your country, please refer to the attached VIN-list. 1. CHECK THE VEHICLE IDENTIFICATION NUMBER (a) Confirm that the VIN is within the range shown in the table above. HINT: The Vehicle Identification Number (VIN) is stamped on location A and B shown in the illustration. 4

5 3. PREPARACION PARTS Part Number Part Description Quantity Others Body Fitting Reinforcement Kit Access Panel Reinforcement RH Access Panel Reinforcement LH Rivet 20 *16 Rivets used for a vehicle. (Kit includes 20 Rivets.) Bolt w/ Washer Bolt Nut Plate 2 - TOOLS&EQUIPMENT Part Number Name Quantity Others - Global TechStream (GTS) or Intelligent Tester II Standard Hand Tools Torque Wrench Drill Drill Bits (5mm, 8mm, 10mm) TORX Socket Wrench T Clip Remover Moulding Remover Punch Protective eyewear gloves Vacuum Cleaner Riveter Socket wrench (15mm) Burr Remover 1-5

6 ATERIALS Part Number Name Quantity Others - Brake Cleaner Protective Tape Strings Shop Cloth Touch-up Paint Seal Packing - - 6

7 4. DESCRIPCION GENERAL 1. Inspect the right and left rear doors for cracking, and determine whether it is necessary to replace the front seat outer belt assembly and rear door panel sub-assembly. 2. Install the access panel reinforcement (black; paint application not required) to the installation area of the front seat outer belt assembly with seal packing, rivets and bolts. 7

8 5. MEDIDAS DE SEGURIDAD PARA LA REMACHADORA 1. DO NOT POINT A RIVETER AT ANOTHER PERSON OR LOOK DIRECTLY INTO A RIVETER (a) When using a riveter, ensure it is pressed firmly against the panel intended to be riveted. If not pressed firmly against a panel, the rivet may be forcibly shot out of the riveter. Never point a riveter at another person or look into the riveter regardless of whether a rivet is loaded. 2. ATTACH THE MANDREL CUP TO REAR OF AIR RIVETER (a) A rivet mandrel (center pin) is shot out of the rear of an air riveter with great force when a rivet is installed. Always be sure to attach the air riveter mandrel cup. 8

9 3. HOW TO USE THE RIVETER (a) Use the riveter properly according to the manufacturer's instruction manual. 9

10 6. PRECAUCIONES PARA COMPLETAR EL TRABAJO 1. PAY ATTENTION TO LIFTING UP OR JACKING UP A VEHICLE (a) Perform safe and secure work according to instructions in general description of a repair manual. (b) When operate a lifting or jacking device, make sure that all workers around the device including your self are safe and call to each other in order to prevent a trample accident. 2. WEAR PROTECTIVE EYEWEAR (a) Always wear protective eyewear in situations where gas or contaminations may fly such as fuel leakage prevention, carbon removal from a piston head, work on underbody parts etc. 3. DO NOT CLEAN CLOTHES WITH BRAKE CLEANER (a) Never spray brake cleaner on your clothes since it is easy to evaporate and flammable. A cigarette or a stove may cause a serious burn accident. 4. TAKE CARE NOT TO BURN YOURSELF (a) When the engine is hot, wear gloves etc. to protect yourself against burn injury. 10

11 5. PROTECT THE VEHICLE (a) In order not to contaminate or damage the vehicle, be sure to install the fender cover, the grill cover and the seat cover, and attach the masking tape etc. HINT: Some illustrations in the relevant instructions manual may not show the above-mentioned protective parts to make the target part easy and simple to recognize. 6. PAY ATTENTION TO HANDLING REPLACEMENT PARTS (a) The removed parts shall be marked or broken and stored in a replacement parts box etc. to avoid reassembling in error. (b) Check the replacement parts in final inspection. HINT: Illustrations are for work description only and not related to actual replacement parts. 7. DO NOT BREAK PARTS DURING WORK INSIDE ENGINE ROOM (a) Do not be absorbed in work and place your hand carelessly in the engine room resulting in breakage of parts. 8. CHECK THE ENGINE ROOM BEFORE STARTING THE ENGINE (a) Check if you have forgotten to attach any parts. (b) Check if you have forgotten to remove any tools, shop cloths, etc. 11

12 7. COMPONENTES 12

13 8. PROCEDIMIENTO DEL TRABAJO 8.1 REMOVER LAS PARTES INTERIORES THE WORK PROCEDURES ARE PERFORMED ON BOTH THE RIGHT AND LEFT SIDES. THESE INSTRUCTIONS USE THE RIGHT SIDE IN EXPLAINING THE PROCEDURES. ALWAYS BE SURE TO PERFORM THE SAME PROCEDURES ON BOTH THE LEFT AND RIGHT SIDES. 1. RECORD AUDIO SETTINGS (a) When the battery cable is disconnected, some audio settings may be reset. Therefore, before disconnecting the cable from the negative (-) battery terminal, make a note of the settings. 2. CHECK FOR DTCs (a) When error codes are output, confirm and record the codes and the freeze frame data, and repair as necessary. 3. DISCONNECT NEGATIVE BATTERY CABLE Always be sure to disconnect the negative (-) battery terminal before starting work in order to prevent improper operation of the pretensioner system. 4. REMOVE THE REAR ACCESS PANEL WEATHERSTRIP 13

14 5. REMOVE THE No.1 CUP HOLDER (a) Remove the screw. (b) Affix protective tape to the locations shown in the figure. (c) Using moulding remover, disengage the 4 claws and remove the cup holder. (d) Remove the protective tape. 6. REMOVE THE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY (a) Press the snap ring with a flat-head screwdriver wrapped with protective tape to remove the snap ring. Cover the snap ring with a shop cloth when working to prevent the snap ring from flying off. (b) Remove the rear door inside handle sub-assembly. (c) Set the snap ring in the inside handle. Be sure to always perform this procedure in order not to lose the snap ring. 14

15 7. REMOVE THE LAP BELT OUTER ANCHOR COVER 8. DISCONNECT FRONT SEAT OUTER BELT ASSEMBLY 9. PROTECT PARTS AGAINST DAMAGE (a) Affix protective tape to the seatbelt anchor. Always be sure to affix protective tape as the anchor can possibly contact and damage the trim board, body or other parts. 10. REMOVE THE REAR DOOR TRIM BOARD SUB-ASSEMBLY (a) Remove the 9 clips. (b) Pull in the direction indicated by the arrow to disengage the claw, and remove the trim board. 15

16 11. REMOVE THE UPPER CENTER PILLAR GARNISH (a) Remove the clip and 2 screws. (b) Disengage the 2 claws by using a clip remover wrapped with protective tape. (c) Disengage the 2 clips and garnish. 12. PROTECT AGAINST INJURY (a) Wear gloves in order to protect your hands from injury due to burrs and other sharp parts of panels and reinforcements. 16

17 13. REMOVE THE FRONT SEAT OUTER BELT ASSEMBLY Completely remove the seatbelt due to the possibility that it will interfere with work or get dirty. (a) Record the height of the shoulder part. (b) Remove the nut and disconnect the shoulder part. (c) for 1 CONNECTOR TYPE: (1) Disconnect the pretensioner connector by using a screwdriver wrapped with protective tape. Do not start this procedure until 90 seconds or more have elapsed after disconnecting the negative (-) terminal of the battery due to the backup power source equipped to the pretensioner system. (d) for 2 CONNECTORS TYPE: (1) Disconnect the pretensioner connector by using a screwdriver wrapped with protective tape. Do not start this procedure until 90 seconds or more have elapsed after disconnecting the negative (-) terminal of the battery due to the backup power source equipped to the pretensioner system. (2) Disconnect the connector. (LH Only) (e) Remove the 2 bolts and front seat outer belt assembly. (f) Store the 2 removed bolts because they are used in procedures described below. 17

18 14. DISCONNECT THE DOOR WIRE (a) Remove the ground bolt. (b) Disengage each clamp and remove the door wire. (c) Secure the door wire by using string. 15. REMOVE THE LOWER ACCSESS PANEL LOCK ASSEMBLY (a) Disconnect the connector and clamp. (b) Disconnect the control cable. (c) Using T30 Torx socket. Remove the 3 screws. (d) Hold the access panel lock and disengage the clip. As the clip is firmly engaged, be careful not to injure yourself when disengaging it. This clip is used as a positioner during the manufacturing process. If it is damaged, remove it and reuse the lock assembly. There is no need to replace this clip. (e) Remove the access panel lock. 18

19 Mejorado/ Improved panel No Mejorado/ Not improved panel 8.2 INSPECCIONAR EL PANEL DE PUERTA TRASERA (CHECK NECESSITY OF ACCESS PANEL REINFORCEMENT INSTALLATION) Visually inspect that the rear door panel is an improved one in order to determine the necessity of access panel reinforcement installation. (Inspect right and left doors.) It is not necessary to install an access panel reinforcement if the vehicle has had the door panel replaced with an improved part. This could have occurred during sheet metal repair due to an accident or similar occurrence before the vehicle was brought to the dealer for this repair. IMPORTANT: If the door panel has been replaced due to a previous repair, replace the seat outer belt assembly with a new part because the condition before the door panel was replaced is not known. 1. INSPECT THE REAR DOOR PANEL (a) Visually inspect the inside of the door panel (from the underside) to determine whether there is a large retainer present. HINT: You can also make a determination based on the amount of spot welding locations. Resultados Procedimientos Ir a: INSPECCION DEL PANEL DE LA PUERTA POR FRACTURA (1) NO ES NECESARIO INSTALAR UN REFUERZO EN EL PANEL DE ACCESO (2) REEMPLAZAR EL CONJUNTO DEL CINTURON DE SEGURIDAD Ir a: INSTALAR LAS PARTES INTERIORES 19

20 8.3 INSPECCION DEL PANEL DE LA PUERTA POR FRACTURA (INSPECT NECESSITY OF DOOR PANEL REPLACEMENT) Visually inspect for any door panel (part where the seat outer belt assembly is installed) breakage, and determine whether it is necessary to replace the door panel (inspect doors on both sides). If breakage is found, replace the seat outer belt assembly due to the possibility of load being applied to the seat outer belt assembly. 1. VISUALLY INSPECT FOR ANY BREAKAGE No Fracturado (con grietas) No Breakage (Cracks Found) Fractura/ Breakage Resultados Procedimientos NO HAY QUE CAMBIAR EL PANEL PUERTA TRASERA Ir a la INSPECCIÓN por AGRIETAMIENTO del PANEL DE LA PUERTA TRASERA NO HAY QUE CAMBIAR EL PANEL PUERTA TRASERA Ir a la INSPECCIÓN por AGRIETAMIENTO del PANEL DE LA PUERTA TRASERA Si la ruptura se produce durante el trabajo, lleve a cabo los mismos procedimientos que para la "fractura". SUSTITUIR EL PANEL DE LA PUERTA TRASERA Y EL CONJUNTO DEL CINTURON Remplace el panel y el cinturón, y vuelva a INSTALAR PARTES circundantes. No es necesario instalar un refuerzo en el panel de la puerta mejorada debido a que ya está equipado con un retén grande. Este retenedor proporciona el mismo propósito que el panel de refuerzo acceso. 2. APPLY ANTI-RUST TREATMENT TO THE REAR DOOR PANEL (IF CRACKING IS PRESENT) (a) Apply touch-up paint to the crack in order to prevent rust formation. 20

21 8.4 INSPECCION DEL PANEL DE LA PUERTA POR GRIETAS (INSPECT NECESSITY OF SEAT OUTER BELT ASSEMBLY REPLACEMENT) Visually inspect for cracking of the 2 spot welding locations on the door panel, and determine whether it is necessary to replace the seat outer belt assembly (inspect doors on both sides). If cracking is found, replace the seat outer belt assembly because of the possibility of load being applied to the seat outer belt assembly. 1. VISUALLY INSPECT FOR ANY CRACKING Do not confuse cracking with normal wear and paint being peeled off due to the use of seat outer belt assembly. Do not confuse cracking with welding spatter. Sin Grietas No Cracking Agrietado Cracking Resultados Procedimientos NO HAY QUE REEMPLAZAR EL CONJUNTO DEL CINTURON DE SEGURIDAD Ir a: INSTALAR EL REFUERZO EN EL PANEL DE ACCESO REEMPLAZAR EL CINTURON DE SEGURIDAD LUEGO DE LA INSTALACIÓN DEL REFUERZO EN EL PANEL DE ACCESO Aplicar el tratamiento anti-óxido y luego ir a INSTALAR EL REFUERZO EN EL PANEL DE ACCESO 2. APPLY ANTI-RUST TREATMENT TO THE REAR DOOR PANEL (IF CRACKING IS PRESENT) (a) Apply touch-up paint to the crack in order to prevent rust formation. 21

22 8.5 INSTALACION DEL REFUERZO EN EL PANEL DE ACCESO 1. WRAP DRILL BITS WITH TAPE (a) Wrap the 3 drill bits (5mm, 8mm, and 10mm) with tape at approximately 10mm from the tip. This is done in order to prevent damage to the outer panel. Failure to apply a secure, thick wrapping of tape can result in the drill piercing the inner door panel, resulting in damage to the outer panel. 2. PREPARE FOR INSTALLATION OF THE ACCESS PANEL REINFORCEMENT (a) Prepare the correct access panel reinforcement for the corresponding door. (b) Prepare the 2 bolts that were previously removed from the vehicle. These will be used to align the access panel reinforcement prior to final installation. Do not use a new upper bolt (black) with locking agent applied at this stage. Do not confuse the removed lower bolt with the new lower bolt, as it is a different size. 22

23 3. DRILL THE INSTALLATION HOLES FOR THE ACCESS PANEL REINFORCEMENT (a) Press the access panel reinforcement upwards and hold it while installing the 2 bolts. Torque Spec: 8.5 N*m (87 kgf*cm, 75 in.*lbf) (Bolt A) 42 N*m (428 kgf*cm, 31 ft.*lbf) (Bolt B) Be sure to press upwards while tightening the bolts to ensure close contact of the door panel and access panel reinforcement. (b) Affix tape to the holes shown in the figure to prevent shavings from getting into the holes. The number of holes differs depending on the specifications. (c) Lay a shop cloth inside of the door panel to catch shavings when drilling. (d) Always be sure to wear protective eye wear for safety when drilling holes, removing burrs, and installing/removing rivets. 23

24 (e) Drill holes using the 8mm and 10mm drill bits that match the holes in the access panel reinforcement. Do not wear gloves when using the drill to prevent them from being caught in the drill. (f) Continue to use the drill in the drilled 10mm hole to widen it until is the same diameter as the hole of the access panel reinforcement. Only widen the 10mm diameter hole. 24

25 (g) Remove any burrs created on the back side of the 2 drilled holes using the burr remover. Failure to remove burrs can result in the access panel becoming loose, and not firmly seating against the door. (1) Insert the tool into the hole. (2) Firmly press the blade against the edge of the hole. (3) Pull the blade towards you while moving it around the edge of the hole to remove the burrs. (4) Wear gloves and check that all burrs have been removed. 25

26 (h) Hold the nut plate using a 15mm socket and install the added nut plate with the NEW bolt. Torque Spec: 64 N*m (653 kgf*cm, 47 ft.*lbf) Failure to hold the nut plate when installing the bolt can result in deformation of the positioner. Be sure to always install the nut plate in order to prevent misalignment when drilling the rivet holes. (i) Using the 5mm drill bit, drill the eight holes in the door panel according to the existing holes in the access panel reinforcement. Do not wear gloves when using the drill to prevent them from being caught in the drill. (j) Hold the nut plate by using the 15mm socket, and remove the added nut plate and bolt. Failure to hold the nut plate and allowing it to be loose can result in deformation of the positioner. 26

27 (k) Remove the 2 bolts and the access panel reinforcement. (l) Remove any burrs that have formed in the 5mm rivet holes (eight for each door panel) by using the burr remover. Failure to remove burrs can result in the access panel becoming loose, and not firmly seating against the door. (1) Insert the tool into the hole. (2) Firmly press the blade against the edge of the hole. (3) Pull the blade towards you while moving it around the edge of the hole to remove the burrs. 27

28 (4) Wear gloves and check that the burrs have been removed from the eight holes. (m) Remove the burrs from the front side of all 10 holes (5mm, 8mm, and 10mm) using the burr remover. Remove burrs from the 8mm and 10mm holes. (1) Insert the tool into the hole. (2) Firmly press the blade against the edge of the hole. (3) Push the blade towards door panel while moving it around the edge of the hole to remove the burrs. (4) Wear gloves and check that the burrs have been removed from the 10 holes. 28

29 4. CLEAN UP THE SHAVINGS (a) Remove the shop cloth and tape from the door panel. (b) Use a vacuum cleaner to remove the shavings. 5. CLEAN/DEGREASE THE MATING SURFACES OF THE DOOR PANEL AND ACCESS PANEL REINFORCEMENT (a) Clean the mating surface of the door panel by using brake cleaner and allow it to dry completely. (b) Clean the mating surface of the access panel reinforcement (side where punch marks have been made) by using brake cleaner and allow it to dry completely. 29

30 6. APPLY ANTI-RUST TREATMENT TO THE NUT PLATE INSTALLATION HOLES (a) Apply touch-up paint to the nut plate installation holes (8mm and 10mm) to prevent rust formation. Rivet installation holes (5mm) do not require touch-up paint because seal packing will be applied later. If the paint on the access panel reinforcement mounting hole is peeling, apply touch-up paint to prevent rust formation. 30

31 7. APPLY SEAL PACKING TO ACCESS PANEL REINFORCEMENT (a) Apply seal packing with a diameter of approximately 3mm, ensuring that the punch marks are connected. For the one location where there is no mating punch mark, apply seal packing as shown in the figure (for each side). After applying the seal packing, be sure to replace the lid and properly store the seal packing so that it does not harden. 31

32 8. REINSTALL THE ACCESS PANEL REINFORCEMENT (a) Set the upper right and left rivets of the access panel reinforcement so that they serve as guides. (b) Affix access panel reinforcement to the door panel. 9. PREPARE FOR RIVET INSTALLATION (a) Set rivets by hand in the remaining rivet installation holes. Set all bolts and rivets as indicated in order to prevent misalignment. HINT: There are 20 rivets supplied in the kit. Four of these are spares. (b) Temporarily install the two bolts previously removed from the vehicle. Do not use a new upper bolt (black) with locking agent applied at this stage. Do not confuse the removed lower bolt with the new lower bolt, as it is a different size. 32

33 (c) Hold the nut plate by using the 15mm socket and install the added nut plate with the added bolt. Torque Spec: 64 N*m (653 kgf*cm, 47 ft.*lbf) Failure to hold the nut plate and allowing it to be loose can result in deformation of the positioner. 33

34 10. INSTALL THE RIVET DO NOT POINT A RIVETER AT ANOTHER PERSON OR LOOK DIRECTLY INTO A RIVETER When using a riveter, ensure it is pressed firmly against the panel intended to be riveted. If not pressed firmly against a panel, the rivet may be forcibly shot out of the riveter. Never point a riveter at another person or look into the riveter regardless of whether a rivet is loaded. ATTACH THE MANDREL CUP TO REAR OF AIR RIVETER A rivet mandrel (center pin) is shot out of the rear of an air riveter with great force when a rivet is installed. Always be sure to attach the air riveter mandrel cup. 34

35 HOW TO USE THE RIVETER Use the riveter properly according to the manufacturer's instruction manual. 35

36 11. INSTALL THE RIVET Perform steps (a), (b), and (c) one rivet at a time. Always be sure to install the rivets in the order shown in the figure in order to prevent the access panel reinforcement from moving up. Failure to press the riveter perpendicularly can result in gaps between the panel and reinforcement. If a rivet is installed incorrectly, remove the rivet according to the procedures below and install a NEW rivet. (a) Starting with number 1 remove the rivet and apply seal packing as shown in the figure. (b) Place the rivet in the door panel. (c) Press the riveter perpendicularly against the door panel and install the rivets following the order shown in the figure. 36

37 (d) If seal packing is found on the riveter, clean it before it hardens. (e) Wipe away any seal packing that is protruding from the rivets to prevent the seat belts from getting dirty. Do not use brake cleaner as it can cause the rivet seal packing to peel off. (f) Check that there are no gaps by pressing a flat-head screwdriver against all rivets. Do not pry under the rivet head. Only press the screwdriver against the rivet. Perform steps (f) and (g) one rivet at a time to ensure that the work is performed properly. If there are any gaps between the rivet head and reinforcement panel, remove the rivet and reinstall according to the procedures on the following page. (g) After confirming the rivet is secure, apply touch-up paint to the hole in the center of the rivet to indicate it has been checked, and to prevent rust. (h) Confirm paint has been applied to all eight rivets. 37

38 12. REMOVING A RIVET HINT: If a rivet has not been properly installed, remove the rivet according to the following procedures. (a) Affix tape to the holes previously shown in the figure found in step (b) to prevent shavings from getting into the holes. (b) Lay a shop cloth inside of the door panel to catch shavings when drilling. (c) Drill out the center of the rivet using a 5mm drill bit and remove the rivet. (d) If the rivet turns with the drill and cannot be removed when performing step (c), cut the rivet using side cutters. Use caution as the rivet head may fly off unexpectedly. (e) Repeat steps (c) and (d) to remove rivet heads, Once the head is removed, use a punch or similar tool to remove the rivet. (f) Remove the shop cloth and tape from within the door panel. (g) Use a vacuum cleaner to remove the shavings. 38

39 8.6 RE-INSTALAR LAS PARTES INTERIORES 1. RECONNECT THE DOOR WIRE TO THE LOWER ACCESS PANEL LOCK ASSEMBLY (a) Insert the hook through the body hole and engage the clip. This clip is used as a positioner during the manufacturing process. If it is damaged, remove it and reuse the lock assembly. (b) Using a T30 Torx socket, Install the access panel lock with the 3 screws. Torque Spec: 5.0 N*m (51 kgf*cm, 44 in.*lbf) (c) Connect the control cable. (d) Connect the clamp and connector. Pass the control cable under the door harness (cabin side). 39

40 2. RECONNECT THE DOOR WIRE (a) Remove the string. (b) Connect each clamp with the door wire. (c) Install the ground bolt. Torque Spec: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 3. REINSTALL THE FRONT SEAT OUTER BELT ASSEMBLY If the door panel was cracked as indicated in step 8.4. install a NEW seat outer belt assembly. (a) Remove the 2 bolts. (b) Put a mark on the removed upper bolt and dispose of it according to the recalled parts disposal procedure. (c) Insert the 2 hooks through the retractor bracket, and temporarily install it with a NEW bolt A (black, and with locking agent applied) and bolt B (reused part, silver). Only replace upper bolt A with a new part. (d) Install the NEW bolt (A). Torque Spec: 8.5 N*m (87 kgf*cm, 75 in.*lbf) (e) Install the bolt (B). Torque Spec: 42 N*m (428 kgf*cm, 31 ft.*lbf) 40

41 (f) for 1 CONNECTOR TYPE: (1) Connect the pretensioner connector. (g) for 2 CONNECTORS TYPE: (1) Connect the pretensioner connector. (2) Connect the connector. (LH Only) (h) Install the shoulder nut. Torque Spec: 42 N*m (428 kgf*cm, 31 ft.*lbf) The locking function is activated if the seat belt is pulled out with the door completely open. Move the door in the closing direction to release the lock. 41

42 4. REINSTALL THE UPPER CENTER PILLAR GARNISH (a) Engage the 2 claws 2 clips. The clips cannot be engaged unless the pillar garnish is correctly set on the shoulder adjuster. (b) Install the garnish with the clip and 2 screws. (c) Return the seat belt shoulder part to the recorded position. 5. REINSTALL THE REAR DOOR TRIM BOARD SUB-ASSEMBLY (a) Engage the 9 clips and claws to install the trim board. 6. RECONNECT FRONT SEAT OUTER BELT ASSEMBLY (a) Remove the protective tape. 42

43 (b) Install the outer belt with the bolt. Torque Spec: 42 N*m (428 kgf*cm, 31 ft.*lbf) (c) Install the lap outer anchor cover. 7. REINSTALL THE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY (a) Check that the snap ring is attached, and install the inside handle. 8. REINSTALL THE No.1 CUP HOLDER (a) Engage the 4 claws and install the cup holder. (b) Install the screw. 43

44 9. REINSTALL THE REAR ACCESS PANEL WEATHERSTRIP 10. RECONNECT NEGATIVE BATTERY CABLE 11. INSPECT SRS WARNING LIGHT (a) Turn the ignition switch on (IG), and check that the SRS warning light comes on for approximately 6 seconds (primary check). (b) Check that the SRS warning light goes off approximately 6 seconds after the ignition switch is turned on (IG) (constant check). HINT: If the warning light remains lit, the pretensioner connector may not have been properly connected. 12. CHECK FOR DTCs 13. CHECK OPERATION OF ALL PARTS 14. INSPECT THE SEAT BELT ELR LOCK (a) Check that the seat belt locks when it is pulled out quickly. 15. PERFORM SETTING AFTER CONNECTION OF BATTERY TERMINAL (a) After connecting the terminal, perform setting of systems. (1) Restore data recorded before disconnection of the terminal. 44