2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

Transcription

1 2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX ODY SECTION HVAC SYSTEM (HEATER, VENTILATOR AND A/C) HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) AIRAG SYSTEM AC AC A This service manual has been prepared to provide SUARU service personnel with the necessary information and data for the correct maintenance and repair of SUARU vehicles. This manual includes the procedures for maintenance, disassembling, reassembling, inspection and adjustment of components and diagnostics for guidance of experienced mechanics. Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition. When replacement of parts during repair work is needed, be sure to use SUARU genuine parts. AIRAG SYSTEM (DIAGNOSTICS) SEAT ELT SYSTEM LIGHTING SYSTEM WIPER AND WASHER SYSTEMS ENTERTAINMENT COMMUNICATION SYSTEM A S LI WW ET COM GW ODY STRUCTURE S INSTRUMENTATION/DRIVER INFO IDI SEATS SE SECURITY AND LOCKS SL IMMOILIZER (DIAGNOSTICS) IM All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval. SUNROOF/T-TOP/CONVERTILE TOP (SUNROOF) EXTERIOR/INTERIOR TRIM SR EI FUJI HEAVY INDUSTRIES LTD. G1830GE6

2 2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX ODY SECTION EXTERIOR ODY PANELS E CRUISE CONTROL SYSTEM CC CRUISE CONTROL SYSTEM (DIAGNOSTICS) CC G1830GE6

3 GW Page 1. General Description Power Window System Rear Window Defogger System Remote Control Mirror System Front Door Glass Front Regulator and Motor Assembly Rear Door Glass Rear Regulator and Motor Assembly Windshield Glass Rear Gate Glass Rear Quarter Glass Rear Window Glass Roof Window Glass Inner Rearview Mirror Power Window Control Switch Rear Window Defogger Outer Mirror Assembly Outer Mirror Remote Control Mirror Switch...49

4 GENERAL DESCRIPTION 1. General Description A: COMPONENT 1. FIXED GLASS (SEDAN) O0234 (1) Windshield glass (4) Rearview mirror mount (7) Spring (2) Dam rubber (5) Locate pin (3) Molding (6) Rear window glass GW-2

5 GENERAL DESCRIPTION 2. FIXED GLASS (WAGON) O0235 (1) Windshield glass (4) Rearview mirror mount (7) Rear quarter glass (2) Dam rubber (5) Locate pin (8) Locate pin (3) Molding (6) Fastener (9) Glass GW-3

6 GENERAL DESCRIPTION 3. FRONT DOOR GLASS O0236 (1) Glass (5) Motor ASSY Tightening torque: N m (kgf-m, ft-lb) (2) Door sash (Front) T1: 7.35 (0.75, 5.4) (3) Door sash (Rear) T2: 14 (1.4, 10.1) (4) Regulator ASSY GW-4

7 GENERAL DESCRIPTION 4. REAR DOOR GLASS O0237 (1) Glass (5) Motor ASSY Tightening torque: N m (kgf-m, ft-lb) (2) Door sash (Front) T1: 7.35 (0.75, 5.4) (3) Door sash (Rear) T2: 14 (1.4, 10.1) (4) Regulator ASSY GW-5

8 GENERAL DESCRIPTION 5. MIRRORS O0238 (1) Outer mirror (3) Mount (5) Mirror (2) Inner rearview mirror (4) Spring GW-6

9 : CAUTION When electrical connectors are disconnected, always conduct an operational check after connecting them again. Avoid impact and damage to the glass. GENERAL DESCRIPTION GW-7

10 GENERAL DESCRIPTION C: PREPARATION TOOL TOOL NAME Circuit Tester Piano Wire Windshield Knife REMARKS Used for checking voltage and continuity. Used for window glass removal. Used for window glass removal. GW-8

11 2. Power Window System A: SCHEMATIC POWER WINDOW SYSTEM GW-9

12 POWER WINDOW SYSTEM 1. POWER WINDOW LHD MODEL P/W(L)-01 TO POWER SUPPLY ROUTING M-12 SF-6 () W IG IGNITION RELAY (IG) GW P/W(L)-01 F44 POWER WINDOW CIRCUIT REAKER W W WG 41 POWER WINDOW RELAY 17 WG 18 G 14 GW A C P/W(L)-02 P/W(L)-03 P/W(L)-04 POWER WINDOW MAIN SWITCH LOCK FRONT LH OFF UP DOWN AUTO-UP AUTO-DOWN G 4 G G 13 LR 2 FL U L 1 FL D 1 5 E D7 30 D1 LR 2 L 1 D3 REF. TO GND-01 FRONT POWER WINDOW MOTOR LH 41 F44 D7 D1 42 D3 1 2 (GREEN) RELAY LOCK (LACK) GL70-20A GW-10

13 POWER WINDOW SYSTEM P/W(L)-02 P/W(L)-02 P/W(L)-01 A FRONT POWER WINDOW SU-SWITCH RH OFF UP DOWN POWER WINDOW MAIN SWITCH FRONT RH 3 G OFF UP DOWN 8 G G 4 G G 4 G 13 4 L L 8 L L 8 L 6 FR U FR D 7 5 L LR D E D17 30 D1 D7 2 LR 1 L D13 FRONT POWER WINDOW MOTOR RH REF. TO GND-01 D13 (GREEN) D17 D7 D D GL70-20 GW-11

14 POWER WINDOW SYSTEM P/W(L)-03 P/W(L)-03 P/W(L)-01 REAR POWER WINDOW SU-SWITCH LH OFF UP DOWN POWER WINDOW MAIN SWITCH REAR LH 3 G OFF UP DOWN 8 G G 1 G G 4 G 13 4 GW GW 2 LY LY 2 LY 10 U 6 LW LW 3 GY GY 5 GOr 9 D 7 5 RW D E D25 30 D1 D7 2 1 RW D24 REAR POWER WINDOW MOTOR LH REF. TO GND-01 D24 (GREEN) D22 D25 D7 D GL70-20C GW-12

15 POWER WINDOW SYSTEM P/W(L)-04 P/W(L)-04 P/W(L)-01 C REAR POWER WINDOW SU-SWITCH RH OFF UP DOWN POWER WINDOW MAIN SWITCH REAR RH 3 G OFF UP DOWN 8 G G 1 G G 4 G 13 4 GW GW 2 GW GW 6 GW 16 RR U 6 LW LW 3 LW LW 7 LW 15 RR D 7 5 RW D E D31 30 D1 D7 2 1 RW D30 REAR POWER WINDOW MOTOR RH REF. TO GND-01 D30 (GREEN) D28 D31 D7 D GL70-20D GW-13

16 POWER WINDOW SYSTEM 2. POWER WINDOW RHD MODEL P/W(R)-01 TO POWER SUPPLY ROUTING M-12 SF-6 () W F-17 F/ FUSE NO.18 (IG) G P/W(R)-01 POWER WINDOW CIRCUIT REAKER 2 1 W WG 41 POWER WINDOW RELAY 29 WG 30 G 31 G A C P/W(R)-02 P/W(R)-03 P/W(R)-04 POWER WINDOW MAIN SWITCH LOCK FRONT RH OFF UP DOWN AUTO-UP AUTO-DOWN G 4 G G 12 LR 6 FR U L 7 FR D 1 1 E D7 30 D1 LR 2 L 1 D3 REF. TO GND-01 FRONT POWER WINDOW MOTOR RH 41 D7 D1 42 D3 1 2 (GREEN) RELAY LOCK (LACK) GR70-20A GW-14

17 POWER WINDOW SYSTEM P/W(R)-02 P/W(R)-02 P/W(R)-01 A FRONT POWER WINDOW SU-SWITCH LH OFF UP DOWN POWER WINDOW MAIN SWITCH FRONT LH 3 G OFF UP DOWN 8 G G 4 G G 4 G 12 4 L L 8 L L 8 L 3 FL U FL D 7 5 L LR D E D17 30 D1 D7 2 LR 1 L D13 FRONT POWER WINDOW MOTOR LH REF. TO GND-01 D13 (GREEN) D17 D7 D D GR70-20 GW-15

18 POWER WINDOW SYSTEM P/W(R)-03 P/W(R)-03 P/W(R)-01 REAR POWER WINDOW SU-SWITCH LH OFF UP DOWN POWER WINDOW MAIN SWITCH REAR LH 3 G OFF UP DOWN 8 G G 1 G G 4 G 12 4 GW GW 2 LY LY 2 LY 10 U 6 LW LW 3 GY GY 5 GOr 9 D 7 5 RW D E D25 30 D1 D7 2 1 RW D24 REAR POWER WINDOW MOTOR LH REF. TO GND-01 D24 (GREEN) D22 D25 D7 D GR70-20C GW-16

19 POWER WINDOW SYSTEM P/W(R)-04 P/W(R)-04 P/W(R)-01 C REAR POWER WINDOW SU-SWITCH RH OFF UP DOWN POWER WINDOW MAIN SWITCH REAR RH 3 G OFF UP DOWN 8 G G 1 G G 4 G 12 4 GW GW 2 GW GW 6 GW 14 RR U 6 LW LW 3 LW LW 7 LW 13 RR D 7 5 RW D E D31 30 D1 D7 2 1 RW D30 REAR POWER WINDOW MOTOR RH REF. TO GND-01 D30 (GREEN) D28 D31 D7 D GR70-20D GW-17

20 POWER WINDOW SYSTEM : INSPECTION Symptom All power windows does not operate. One window does not operate. Window Lock does not operate. Repair order (1) Fuse (SF-6) (F/ No. 18: RHD model) (2) Power window circuit breaker (3) Power window relay (4) Wire harness (1) Power window main switch (2) Power window sub switch (3) Power window motor (4) Wire harness (1) Power window main switch GW-18

21 3. Rear Window Defogger System A: SCHEMATIC REAR WINDOW DEFOGGER SYSTEM GW-19

22 REAR WINDOW DEFOGGER SYSTEM 1. REAR WINDOW DEFOGGER LHD MODEL R/DEF(L)-01 NA : NON-TURO ENGINE MODEL T : TURO ENGINE MODEL F-15 REAR DEFOGGER RELAY TO POWER SUPPLY ROUTING F-16 REAR DEFOGGER RELAY L F-20 F/ FUSE NO. 17 (IG) GOr GOr 4 L 3 R REAR DEFOGGER TIMER R/DEF(L)-01 SD : SEDAN WG WC OC : WAGON : WITH CHOKE COIL MODEL : WITHOUT CHOKE COIL MODEL NA T L L A3 21 A: 134 ENGINE CONTROL MODULE (TURO MODEL) : 135 ENGINE CONTROL MODULE (NA MODEL) REF. TO GND-02 R A13 A: 282 A14 AUTO A/C CONTROL MODULE REAR DEFOGGER (SEDAN) 8 97 R1 REAR DEFOGGER (WAGON-WITHOUT CHOKE COIL) SD WG 2 OC R17 WC D40 3 OC R65 R39 D35 WC D48 REAR DEFOGGER (WAGON-WITH CHOKE COIL) 2 1 CHOKE COIL GD REF. TO GND-05 D74 D74 D A: 282 (GRAY) A: 134 : GL52-20 GW-20

23 2. REAR WINDOW DEFOGGER RHD MODEL REAR WINDOW DEFOGGER SYSTEM R/DEF(R)-01 NA T : NON-TURO ENGINE MODEL : TURO ENGINE MODEL F-15 REAR DEFOGGER RELAY TO POWER SUPPLY ROUTING F-16 REAR DEFOGGER RELAY L F-17 F/ FUSE NO. 18 (IG) G G 4 L 3 R REAR DEFOGGER TIMER R/DEF(R)-01 SD : SEDAN WG : WAGON NA T L A3 A: 134 ENGINE CONTROL MODULE (TURO MODEL) L 21 : 135 ENGINE CONTROL MODULE (NON-TURO MODEL) REF. TO GND-02 R A13 A: 282 A14 AUTO A/C CONTROL MODULE REAR DEFOGGER (SEDAN) 1 97 R1 REAR DEFOGGER (WAGON) SD WG 2 R17 D40 3 R65 R39 D35 D48 GD REF. TO GND-05 D A: 282 (GRAY) A: 134 : GR52-20 GW-21

24 REAR WINDOW DEFOGGER SYSTEM : INSPECTION Symptom Rear window defogger does not operate. Repair order (1) Fuse (M/ No. 1) (F/ No. 17) (2) Rear defogger relay (3) Rear defogger timer (4) Defogger switch (5) Rear defogger condenser (6) Deffogger wire (7) Wire harness GW-22

25 4. Remote Control Mirror System A: SCHEMATIC REMOTE CONTROL MIRROR SYSTEM GW-23

26 REMOTE CONTROL MIRROR SYSTEM 1. REMOTE CONTROL MIRROR LHD MODEL R/M(L)-01 MILLOR HEATER RELAY F-30 F/ FUSE NO. 19 () RW TO POWER SUPPLY ROUTING F-15 REAR DEFOGGR RELAY F-28 F/ FUSE NO. 4 (ACC) YR R/M(L) RW Y REARVIEW MIRROR RH MIRROR HEATER 171 WH OH 1 L 23 Y REMOTE CONTROLLED REARVIEW MIRROR SWITCH REMOTE CONTROL SWITCH CHANGE OVER SWITCH 4 1 L R DOWN UP R N L UP DOWN YR R 21 R Lg 8 LH RH 7 5 LR 20 LR 6 R R 22 R D15 D LR 9 REARVIEW MIRROR LH MIRROR HEATER WH OH 1 4 L 23 1 REF. TO GND-03 Y R UP DOWN LH RH 7 5 Lg 20 D5 Lg 8 6 R 22 R D1 30 WH : WITH MIRROR HEATER MODEL OH : WITHOUT MIRROR HEATER MODEL REF. TO GND-02 D5 : OH D5 : WH 284 D1 D D15 : OH D15 : WH RELAY LOCK (LACK) GL79-20 GW-24

27 2. REMOTE CONTROL MIRROR RHD MODEL REMOTE CONTROL MIRROR SYSTEM R/M(R)-01 MILLOR HEATER RELAY F-30 F/ FUSE NO. 19 () RW TO POWER SUPPLY ROUTING F-15 REAR DEFOGGR RELAY F-28 F/ FUSE NO. 4 (ACC) YR R/M(R) RW Y REARVIEW MIRROR RH MIRROR HEATER 171 WH OH 1 L 23 Y REMOTE CONTROLLED REARVIEW MIRROR SWITCH REMOTE CONTROL SWITCH CHANGE OVER SWITCH 4 1 L R DOWN UP R N L UP DOWN YR R 21 R Lg 8 LH RH 7 5 LR 20 LR 6 R R 22 R D15 D LR 9 REARVIEW MIRROR LH MIRROR HEATER WH OH 1 4 L 23 1 REF. TO GND-03 Y R UP DOWN 6 4 R 21 LH RH 7 5 Lg 20 D5 Lg 8 6 R 22 R D1 30 WH : WITH MIRROR HEATER MODEL OH : WITHOUT MIRROR HEATER MODEL REF. TO GND-02 D5 : OH D5 : WH 284 D1 D D15 : OH D15 : WH RELAY LOCK (LACK) GR79-20 GW-25

28 REMOTE CONTROL MIRROR SYSTEM : INSPECTION Symptom All function does not operate. One side of the mirror motor does not operate. Mirror heater does not operate. Repair order (1) Fuse (F/ No. 1) (F/ No. 4) (F/ No. 19) (2) Mirror switch (3) Wire harness (1) Mirror switch (2) Mirror motor (3) Wire harness (1) Mirror switch (2) Mirror heater (3) Wire harness GW-26

29 5. Front Door Glass A: REMOVAL 1) Remove front door trim. <Ref. to EI-20, REMOV- AL, Front Door Trim.> 2) Remove sealing cover. <Ref. to E-13, REMOV- AL, Front Sealing Cover.> 3) Remove outer mirror assembly. <Ref. to GW-46, REMOVAL, Outer Mirror Assembly.> 4) Operate the power window switch to move glass to position shown in the figure, and then remove the two nuts from service holes. FRONT DOOR GLASS 7) Remove gusset. 5) Remove stabilizers. O0085 8) Take out door glass. O0088 6) Remove weather strip outer. O0086 5M1047 CAUTION: Do not turn regulator in the closing direction after removal of the glass. Otherwise gear may be disengaged. Avoid impact and damage to the glass. O0087 GW-27

30 FRONT DOOR GLASS : INSTALLATION 1) Install in the reverse order of removal. CAUTION: Make sure that glass stay is placed securely in sash. 2) Adjust front door glass. <Ref. to GW-29, AD- JUSTMENT, Front Door Glass.> GW-28

31 C: ADJUSTMENT NOTE: efore adjustment, ensure that all adjusting bolts of stabilizer, upper stopper, and sash are loose and door glass is raised so that it is in contact with weatherstrip. 1) Temporarily tighten one adjusting bolt on one side of rear sash at the midpoint of slotted hole in the inner panel. 2) Temporarily tighten regulator -channel in a position slightly lower than midpoint of slotted hole. 3) Lower door glass 10 to 15 mm (0.39 to 0.59 in) from fully closed position. While applying outward pressure of 49.0±4.9 N (5.0±0.5 kg, 11.0±1.1 lb) (F) to upper edge of glass above midpoint of two outer stabilizers, press inner stabilizer until it just touches the glass, then secure it. FRONT DOOR GLASS 5) For adjustment of upper and lower ends of center pillar, loosen adjusting nut (A) of -channel (). 5M0729A 6) Adjust so that upper and lower ends of center pillar are the same size. G5M0421 4) For adjustment of clearance between front and rear glasses, loosen nuts (A), and move glass sash back and forward until clearance becomes the value shown. 5M0728A 7) For glass stroke adjustment, close door, raise glass until positional relationship between glass and weatherstrip becomes as shown. And secure the glass so that upper stopper lightly touches the glass holder. O ( ) 12 (0.472) 12 (0.472) A A A 3 (0.118) 3 (0.118) A Unit: mm (in) A-A Unit: mm (in) 6 (0.236) O0267 O0266 GW-29

32 FRONT DOOR GLASS 8) After stabilizer adjustment, carry out glass crimp adjustment. First, visually ensure positional relationship between retainer & molding and glass of the roof side, and then begin with rear sash adjustment. Adjust two adjusting bolts alternately step by step to obtain dimensions shown below (cross-section A). NOTE: If two nuts are loosened at the same time, sash moves back and forth. Therefore, when one nut is adjusted, secure the other. 9) Make the same adjustment of two adjusting bolts of rear sash. 13) During adjustments, loosen other three clamping bolts. 2-3 ( ) A A Unit: mm (in) 6 (0.236) O0267 CAUTION: Do not tilt sash bracket to inner panel during adjustment. Otherwise smooth regulator operation cannot be achieved. O ) After adjustment, tighten bolts and nuts. S5M0201A 10) Make adjustment of front sash in the same manner as that of rear sash. CAUTION: Although front and rear sashes must, as a rule, be adjusted in the same manner, in some door installation, the adjustment in a different manner may be required. However, adjustment of one sash to the maximum amount and the other to the minimum amount is not permitted. Such adjustment may result in application of excessive load to regulator. 11) After adjustments, tighten nuts. 12) After adjustment of glass, if there is a gap between outer lip of gusset and glass surface, adjust the gap with adjusting bolt (A) in lower fitting part of gusset to prevent generation of wind noise. GW-30

33 FRONT REGULATOR AND MOTOR ASSEMLY 6. Front Regulator and Motor Assembly A: REMOVAL 1) Remove door glass. <Ref. to GW-27, REMOV- AL, Front Door Glass.> 2) Loosen nuts to remove rear sash. : INSTALLATION 1) Install in the reverse order of removal. 2) Adjust front door glass. <Ref. to GW-29, AD- JUSTMENT, Front Door Glass.> C: INSPECTION 1) Make sure that power window motor rotates properly when battery voltage is applied to terminals of motor connector. 2) Change polarity of battery connections to terminals to ensure that motor rotates in reverse direction. O0089 3) Disconnect motor connector. 4) Loosen four bolts and two nuts to remove regulator assembly. O0090 5) Loosen screw to remove motor assembly. O0091 GW-31

34 7. Rear Door Glass A: REMOVAL 1) Remove rear door trim. <Ref. to EI-21, REMOV- AL, Rear Door Trim.> 2) Remove sealing cover. <Ref. to E-16, REMOV- AL, Rear Sealing Cover.> 3) Remove stabilizer. REAR DOOR GLASS 5) Loosen two screw to remove weather strip outer. 4) Remove door weather strip. 5M1044 O0093 6) Operate power window switch to remove glass as shown in the figure, and remove two nuts. O0094 7) Remove two nuts, and then separate front sash and glass stay. O0092 8) Pull out glass. CAUTION: Avoid impact and damage to the glass. O0095 GW-32

35 REAR DOOR GLASS : INSTALLATION 1) Install in the reverse order of removal. CAUTION: Make sure that glass stay is placed securely in sash. 2) Adjust rear door glass. <Ref. to GW-33, AD- JUSTMENT, Rear Door Glass.> C: ADJUSTMENT NOTE: Rear door glass, as a rule, should be adjusted in the same manner as front glass, although they are different in dimension. Special notes for rear glass are given below. 1) Adjust glass position using the following dimensions as a guide line. 12 (0.472) 12 (0.472) A A 3 (0.118) 3 (0.118) Unit: mm (in) A-A CAUTION: If dimensions are smaller than the given dimensions, glass may get caught in weatherstrip during lifting/lowering operation. In the worst case, it may cause glass not to be opened fully. After adjustment, move glass up and down to check whether it is caught. 2) Adjust crimp of glass using the following dimensions as a guide line. A 2-3 ( ) O0268 A Unit: mm (in) 6 (0.236) O0269 CAUTION: If crimp of rear glass is higher than necessary, glass may get caught in weatherstrip of center pillar corner, resulting in early wear of weatherstrip. e careful when adjusting. After adjustment, move glass up and down to check whether it is caught. GW-33

36 REAR REGULATOR AND MOTOR ASSEMLY 8. Rear Regulator and Motor Assembly A: REMOVAL 1) Remove door glass. <Ref. to GW-32, REMOV- AL, Rear Door Glass.> 2) Disconnect motor connector. 3) Loosen four bolts and two nuts to remove regulator assembly. O0097 4) Loosen screws to remove motor assembly. O0098 : INSTALLATION 1) Install in the reverse order of removal. 2) Adjust rear door glass. <Ref. to GW-33, AD- JUSTMENT, Rear Door Glass.> C: INSPECTION 1) Make sure that power window motor rotates properly when battery voltage is applied to terminals of motor connector. 2) Change polarity of battery connections to terminals to ensure that motor rotates in reverse direction. GW-34

37 9. Windshield Glass A: REMOVAL 1. USING WINDSHIELD KNIFE 1) Remove cowl panel. <Ref. to EI-17, REMOVAL, Cowl Panel.> 2) Remove glass molding. 3) Tape body side of the circumference of windshield glass for protection. 4) Apply sufficient amount of soapy water to adhesive layer. 5) Insert windshield knife into the adhesive layer. 6) While holding the knife edge and windshield glass edge at a right angle, move windshield knife in parallel to windshield glass edge along face and edge of windshield glass to cut the adhesive layer. CAUTION: Do not twist windshield knife. Cutting of adhesive layer shall be started with wider gap between windshield glass and body. WINDSHIELD GLASS NOTE: ecause matching pins are bonded to the corners of glass, use piano wire to cut the pin. G5M USING PIANO WIRE 1) Remove cowl panel. <Ref. to EI-17, REMOVAL, Cowl Panel.> 2) Remove roof molding and upper front molding. 3) Tape the body side of the circumference of windshield glass for protection. 4) Make a hole in adhesive layer using drill or knife. 5) Pass piano wire through the hole, and attach securely both the wire ends to pieces of wood. G5M0418 G5M0494 6) Pull the wire ends alternately to cut off the adhesive layer. CAUTION: Do not tightly pull the piano wire against the windshield glass edge. e careful not to damage interior and exterior parts. When removal is made with area close to instrument panel, place a protection plate over it. Pay particular attention to the removal. Do not cross piano wires. Otherwise they may be cut. GW-35

38 : INSTALLATION 1) Clean external circumference of windshield glass with alcohol or white gasoline. 2) Remove adhesive layer on the body using cutter knife to obtain smooth face 2 mm (0.08 in) thick. CAUTION: e careful not to damage the body and paint surface. WINDSHIELD GLASS 8) Fit molding mark () to notch (A). G5M0553 3) Clean body with alcohol or white gasoline to remove thoroughly chips, dusts, and dirts from body face. 4) Place glass on body. 5) Adjust glass position to make uniform clearance between body and glass in four corners. 6) Place matching pins and body on glass. O0270 9) Apply primer to adhesive layer of glass using sponge. 10) Apply primer to adhesive layer of body. CAUTION: Primer once attached to the painted surface of the body and internal trim is hard to wipe off. Mask the circumference of such areas. Let primer dry for about ten minutes before installing the glass. Do not touch surface coated with primer. 7) Remove glass from body. G5M0407 G5M ) Cut off cartridge nozzle tip and set it in sealant gun as shown. GW-36 G5M0408

39 WINDSHIELD GLASS 12) Apply adhesive to glass end surface as shown. 13) Fit matching pins using suction rubber cup to install windshield glass. G5M ) Lightly press windshield glass for tight fit. 15) Make adhesive surface flush using spatula. CAUTION: When door is opened/closed after glass is bonded, always lower door glass and then open/close it carefully. Move vehicle slowly. 16) After completion of all work, allow vehicle to stand for about 24 hours. NOTE: For minimum drying time and time the vehicle must be left standing before driving after bonding, follow instructions or instruction manual from the adhesive manufacturer. 17) After curing of adhesive, pour water on external surface of vehicle to check that there are no water leaks. CAUTION: When a vehicle is returned to the user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days. 18) Install cowl panel. <Ref. to EI-17, INSTALLA- TION, Cowl Panel.> GW-37

40 REAR GATE GLASS 10.Rear Gate Glass A: REMOVAL 1) Remove rear wiper motor. <Ref. to WW-21, RE- MOVAL, Rear Wiper Motor.> 2) Remove electrical connector from rear defogger terminal. 3) Remove glass in the same procedure as for windshield glass. <Ref. to GW-35, REMOVAL, Windshield Glass.> : INSTALLATION 1) Apply adhesive evenly to the glass attachment area. 2) Insert the glass clip pin into the rear gate hole, and after pushing on the area around the clip pin to secure it, push lightly all around the area to seal it. 3) About one hour after installation, conduct a leak test. CAUTION: When a vehicle is returned to the user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days. 5) Connect rear defogger terminals. 6) Install rear wiper. <Ref. to WW-21, INSTALLA- TION, Rear Wiper Motor.> S5M0209A CAUTION: When door is opened/closed after glass is bonded, always lower door glass and then open/close it carefully. Move vehicle slowly. 4) After completion of all work, allow vehicle to stand for about 24 hours. NOTE: For minimum drying time and time the vehicle must be left standing before driving after bonding, follow instructions or instruction manual from the adhesive manufacturer. GW-38

41 11.Rear Quarter Glass A: REMOVAL REAR QUARTER GLASS 1. SEDAN Remove glass in the same procedure as for windshield glass. <Ref. to GW-35, REMOVAL, Windshield Glass.> Matching pin C-C A Matching pin Rear gate glass Molding A C Adhesive Rear quarter glass C Molding A-A - Dam rubber Adhesive Matching pin Rear quarter glass Molding Adhesive Molding Rear quarter glass 2. WAGON Remove glass in the same procedure as for windshield glass. <Ref. to GW-35, REMOVAL, Windshield Glass.> : INSTALLATION 1) Cut off nozzle tip as shown in the figure. G5M0414 2) Install glass in the same procedure as for windshield glass. <Ref. to GW-36, INSTALLATION, Windshield Glass.> CAUTION: When door is opened/closed after glass is bonded, always lower door glass and then open/close it carefully. GW-39 O0210 Move vehicle slowly. 3) After completion of all work, allow vehicle to stand for about 24 hours. NOTE: For minimum drying time and time the vehicle must be left standing before driving after bonding, follow instructions or instruction manual from the adhesive manufacturer. 4) After curing of adhesive, pour water on external surface of vehicle to check that there are no water leaks. CAUTION: When a vehicle is returned to the user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days.

42 12.Rear Window Glass A: REMOVAL 1) Disconnect electrical connectors from rear defogger terminals. 2) Remove glass in the same procedure as for windshield glass. <Ref. to GW-35, REMOVAL, Windshield Glass.> : INSTALLATION 1) ond dam rubber and matching pin. REAR WINDOW GLASS CAUTION: When a vehicle is returned to the user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days (0.571) Matching pin Fastener Dam rubber 8 (0.315) R20 22 (0.866) Unit: mm (in) O0271 2) Install glass in the same procedure as for windshield glass. <Ref. to GW-36, INSTALLATION, Windshield Glass.> 3) Connect rear defogger terminals. CAUTION: When door is opened/closed after glass is bonded, always lower door glass and then open/close door carefully. Move vehicle slowly. 4) After completion of all work, allow vehicle to stand for about 24 hours. NOTE: For minimum drying time and time the vehicle must be left standing before driving after bonding, follow instructions or instruction manual from the adhesive manufacturer. 5) After curing of adhesive, pour water on external surface of vehicle to check that there are no water leaks. GW-40

43 ROOF WINDOW GLASS 13.Roof Window Glass A: REMOVAL <Ref. to SR-6, REMOVAL, Sunroof Lid.> : INSTALLATION <Ref. to SR-6, INSTALLATION, Sunroof Lid.> C: ADJUSTMENT <Ref. to SR-6, ADJUSTMENT, Sunroof Lid.> GW-41

44 INNER REARVIEW MIRROR 14.Inner Rearview Mirror A: REMOVAL NOTE: The spring cannot be reused. Prepare a new spring before removal. 1) Turn mirror base 90 degrees clockwise or counterclockwise to remove it. 2) Remove spring from mirror base. 5M1059 CAUTION: e careful not to damage the mirror surface. : INSTALLATION Install in the reverse order of removal. C: INSPECTION Do not let mirror be damaged. Do not let spring deteriorate. 5M1060 GW-42

45 POWER WINDOW CONTROL SWITCH 15.Power Window Control Switch A: REMOVAL 2. SU-SWITCH 1) Remove switch panel. 2) Disconnect the connector. 1. MAIN SWITCH 1) Loosen screw to remove power window main switch. 2) Disconnect the connector. O0102 : INSTALLATION 1. MAIN SWITCH Install in the reverse order of removal. 2. SU-SWITCH Install in the reverse order of removal. O0101 C: INSPECTION 1. MAIN SWITCH LHD MODEL Check continuity between connector terminals. Driver's switch: Switch position Tester connection Specified condition AUTO UP 13 2, 1 5 Continuity UP 13 2, 1 5 Continuity OFF Continuity DOWN 13 1, 2 5 Continuity AUTO DOWN 13 1, 2 5 Continuity Front passenger's switch: Switch position Tester connection Specified condition UP 13 6, 7 5 Continuity OFF Continuity DOWN 13 7, 6 5 Continuity Rear left switch: Switch position Tester connection Specified condition UP 10 13, 9 5 Continuity OFF Continuity DOWN 13 9, 10 5 Continuity GW-43

46 POWER WINDOW CONTROL SWITCH Rear right switch: Switch position Tester connection Specified condition UP 13 16, 15 5 Continuity OFF Continuity DOWN 13 15, 16 5 Continuity If NG, replace the main switch. 2. MAIN SWITCH RHD MODEL Check continuity between connector terminals. Driver s switch: Switch position Tester connection Specified condition AUTO UP 12 6, 7 1 Continuity UP 12 6, 7 1 Continuity OFF Continuity DOWN 12 7, 6 1 Continuity AUTO DOWN 12 7, 6 1 Continuity Front passenger s switch: Switch position Tester connection Specified condition UP 12 3, 2 1 Continuity OFF Continuity DOWN 12 2, 3 1 Continuity Rear left switch: Switch position Tester connection Specified condition UP 12 10, 9 1 Continuity OFF Continuity DOWN 12 9, 10 1 Continuity Rear right switch: Switch position Tester connection Specified condition UP 12 14, 1 13 Continuity OFF Continuity DOWN 12 13, 14 1 Continuity If NG, replace the main switch. 3. SU-SWITCH Check continuity between connector terminals. Front passenger's door switch and rear door switch: Switch position Tester connection Specified condition UP 8 5, 6 7 Continuity OFF 4 5, 6 7 Continuity DOWN 8 7, 4 5 Continuity If NG, replace the sub-switch. GW-44

47 16.Rear Window Defogger A: INSPECTION CAUTION: When wiping stain on glass off with cloth, use a dry and soft cloth and move it in the direction of the heat wire extension to avoid damage to the heat wire. 1) Turn ignition switch to ON. 2) Turn defogger switch to ON. 3) Wrap tips of tester pins with aluminum foil to avoid damage to heat wire. REAR WINDOW DEFOGGER : REPAIR 1) Clean broken portion with alcohol or white gasoline. 2) Mask both side of wire with thin film. 3) Apply conductive silver composition (DUPONT No. 4817) to broken portion. 4) After repair, check wire. G6M0138 G6M0136 4) Measure voltage at wire center with DC voltmeter. Standard voltage: Approx. 6 volts 5M1053A Voltage Approx. 6 V Approx. 12 V or 0 V Criteria OK roken NOTE: If the measured value is 12 volts, heat wire is open between wire center and positive (+) end. If zero volt, heat wire is open between wire center and ground. 5) Apply positive lead of voltmeter to positive terminal of voltmeter, and then move negative lead along the wire up to the negative terminal end. If voltage changes from zero to several volts during movement of lead, heat wire is open at the voltage change point. GW-45

48 17.Outer Mirror Assembly A: REMOVAL 1) Remove door trim. <Ref. to EI-20, REMOVAL, Front Door Trim.> 2) Remove mirror gusset cover. : Hook OUTER MIRROR ASSEMLY : INSTALLATION Install in the reverse order of removal. O0099 3) Disconnect the mirror connector. 4) Loosen screws to remove mirror assembly. O0100 GW-46

49 OUTER MIRROR ASSEMLY C: INSPECTION Check to ensure that rearview mirror moves properly when battery voltage is applied to terminals. Mirror heater not-equipped model: Switch position Terminal connection OFF UP 4 (+) 6 ( ) DOWN 6 (+) 4 ( ) LEFT 5 (+) 6 ( ) RIGHT 6 (+) 5 ( ) If NG, replace the mirror. Mirror heater equipped model: Switch position Terminal connection OFF UP 6 (+) 8 ( ) DOWN 8 (+) 6 ( ) LEFT 7 (+) 8 ( ) RIGHT 8 (+) 7 ( ) If NG, replace the mirror. GW-47

50 18.Outer Mirror A: REPLACEMENT 1) Remove the door mirror assembly. <Ref. to GW- 46, REMOVAL, Outer Mirror Assembly.> 2) Warm the area around the mirror holder with a hair drier until the edges of the mirror holder become soft (about 2 or 3 minutes with a 1,000 W drier.) 3) Use a flat-bladed screwdriver without sharp edges to lift the mirror out of the mirror holder. (Also remove the connector from the back of mirrors with heaters.) OUTER MIRROR 5M1144A 4) Warm the area around the mirror holder with a hair drier until the edges of the mirror holder become soft (about 2 or 3 minutes with a 1,000 W drier.) 5) Remove the backing of the new two-sided tape, and push the mirror in to install it. CAUTION: Unless the mirror holder is warmed sufficiently, the mirror holder edges may be damaged or the mirror cracked. GW-48

51 REMOTE CONTROL MIRROR SWITCH 19.Remote Control Mirror Switch A: REMOVAL 1) Remove console cover. 2) Disconnect the connector. : INSTALLATION Install in the reverse order of removal. O0103 GW-49

52 REMOTE CONTROL MIRROR SWITCH C: INSPECTION Move rearview mirror switch to each position and check continuity between terminals. Change over switch left position: Change over switch right position: If NG, replace the switch. 5M1132 Switch position Tester connection Specified condition OFF No continuity UP 4 6, 2 1 Continuity DOWN 6 2, 4 1 Continuity LEFT 4 8, 2 1 Continuity RIGHT 8 2, 4 1 Continuity Switch position Tester connection Specified condition OFF No continuity UP 4 7, 2 1 Continuity DOWN 7 2, 4 1 Continuity LEFT 4 9, 2 1 Continuity RIGHT 9 2, 4 1 Continuity GW-50

53 ODY STRUCTURE S Refer to G1831GE SUPPLEMENT for this section. Page

54 ODY STRUCTURE S-2