Daihatsu Terios J100 Service Manual
Daihatsu Terios J100 Service Manual

Daihatsu Terios J100 Service Manual

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NOTE:
· When the tightening torque values are not given, refer to the tightening torque table for general standard bolts to find the re-
quired tightening torque values.
DAIHATSU
J100
TO INDEX
BODY
Alignment Adjustments ................... BO– 2
FRONT BUMPER ........................................ BO– 7
FRONT FENDER ........................................ BO–11
REAR BUMPER .......................................... BO–13
FENDER LINER .......................................... BO–16
HOOD & HOOD LOCK CONTROL
CABLE .................................................... BO–18
FUEL LID OPENER .................................... BO–22
ROOF DRIP MOLDING ............................... BO–24
ROOF RAIL & ROOF END SPOILER ......... BO–25
REMOVABLE ROOF ................................... BO–28
INSTRUMENT PANEL ................................ BO–30
FRONT SEAT .............................................. BO–37
REAR SEAT ................................................ BO–39
SEAT BELT ................................................. BO–40
FRONT DOOR ............................................ BO–44
REAR DOOR ............................................... BO–52
BACK DOOR ............................................... BO–59
TRIM & GARNISH ....................................... BO–64
WINDOWS ................................................... BO–70
FUEL TANK ................................................ BO–82
ACCELERATOR PEDAL ............................. BO–91
EXHAUST PIPE .......................................... BO–93
ENGINE MOUNTING INSULATOR ............. BO–94
Tightening Torque .............................. BO–96
JBO00001-00000
NO. 9710-JE
BO

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Summary of Contents for Daihatsu Terios J100

  • Page 1 DAIHATSU J100 TO INDEX BODY ALIGNMENT ADJUSTMENTS ....BO– 2 FRONT BUMPER ........BO– 7 FRONT FENDER ........BO–11 REAR BUMPER .......... BO–13 FENDER LINER .......... BO–16 HOOD & HOOD LOCK CONTROL CABLE ............ BO–18 FUEL LID OPENER ........BO–22 ROOF DRIP MOLDING .......
  • Page 2 BO–2 ALIGNMENT ADJUSTMENTS q Specified value y Specified value 4.4 ± 1.5 mm 5.2 ± 1.5 mm Gap: Gap: Lateral deviation: Not to exceed 1.5 mm Lateral deviation: Not to exceed 1.5 mm 5.9 ± 1.5 mm Difference between right and left sides: Difference in height: u Specified value Not to exceed 1.5 mm...
  • Page 3 BO–3 1. Gap adjustment Engine hood (1) Loosen the bolts attaching the engine hood to the en- gine hood hinge and adjust the engine hood alignment to the specified value mentioned below. Specified Value: 4.4 ± 1.5 mm Gap: Difference Between Right and Left Sides: Not to exceed 1.5 mm Lateral Deviation: Not to exceed 1.5 mm...
  • Page 4 BO–4 2. Adjustment of difference in height Front (1) Front/Rear door hinge side. q Loosen the bolts attaching the door to the door hinges. w Perform the adjustment by changing the attaching position of the front door to the door hinges. e Tighten the bolts attaching the door to the door hinge.
  • Page 5 BO–5 ADJUSTMENT OF BACK DOOR ALIGNMENT q Specified value Door hinge section 10.4 ± 2.0 mm Gap: Lateral deviation: Not to exceed 2.0 mm 1.8 ± 2.0 mm Difference in height: w Specified value 2.0 ± 1.5 mm Gap: Lateral deviation: Not to exceed 1.5 mm 1.5 ±...
  • Page 6 BO–6 2. Adjustment of difference in height (1) Remove the rear bumper. (Refer to the rear bumper section.) (2) Remove the right hand side rear combination lamp. (3) Remove the rear bumper filler by removing the attach- ing bolts. (4) Loosen the attaching bolts of the back door lock strik- (5) Adjust the difference in height by changing the attach- ing position of the back door lock striker.
  • Page 7 BO–7 FRONT BUMPER COMPONENTS q Front bumper cover !1 Front turn signal lamp lens w Front bumper guard base No. 1 bracket !2 Bulb e Front bumper guard right bracket !3 Front fog & turn lamp assembly r Front bumper guard left bracket !4 Turn cord t No.
  • Page 8 BO–8 REMOVAL 1. Removal of front fog & turn signal lamp assembly (Only for front bumper guard garnish equipped model.) (1) Remove the fog lamp attaching screws. (2) Remove the fog lamps by disconnecting its connec- tors. JBO00015-00015 2. Remove the under fender bracket by removing the attach- ing tapping screw and clip.
  • Page 9 BO–9 5. Remove the attaching bolts of the front bumper cover. (On model without the front bumper guard garnish.) 6. Remove the front bumper cover. (On model without the front bumper guard garnish.) 7. Remove the front bumper bar reinforcement by removing the attaching bolts.
  • Page 10 BO–10 7. Installation of radiator grill (1) Ensure that the clips and retainer are installed properly. Also, ensure that no damage exists. If any damage exists or the clip or retainer is missing, replace the clips or retainer with a new one. (2) Install the radiator grill by connecting the retainer and four clips.
  • Page 11 BO–11 FRONT FENDER COMPONENTS q Hood subassembly w Hood silencer e Clip r Headlamp cover to hood seal (R, L) t Clip y Hood to front end panel seal u Hood front protector i Front fender subassembly (R, L) o Front fender liner !0 Clip !1 Over fender JBO00024-00023...
  • Page 12 BO–12 4. Remove the over fender from the fender panel by discon- necting the retainers while retracting the lock section, using a nosepliers or the like. 5. Remove the side turn signal lamp. 6. Remove the front fender subassembly by removing the five attaching bolts.
  • Page 13 BO–13 REAR BUMPER COMPONENTS !0 !1 q Rear bumper cover u Quarter panel mudguard subassembly w License plate bracket base i Back-up lamp and/or rear fog lamp e Rear bumper filler o Rear combination lamp socket r Rear bumper right protector !0 Bulb t Lower back panel cover !1 Rear lamp lens...
  • Page 14 BO–14 4. Remove the license plate lamps by retracting the lock sections of the license plate lamps from the rear bumper cover. 5. Disconnect the license plate lamps from the connectors. JBO00031-00029 6. Remove the rear bumper cover and license plate bracket base (when equipped) by removing the eight attaching bolts.
  • Page 15 BO–15 INSTALLATION NOTE: · Basically the installation procedure is reverse to the removal procedure. Therefore, illustrations are not given in this installation procedure. Refer to the illustrations in the removal procedure in cases where any difficulty is encountered. 1. Install the rear bumper filler with the two attaching bolts. 2.
  • Page 16 BO–16 FENDER LINER COMPONENTS q Front fender liner w Clip e Front fender mudguard subassembly r Grommet t Front bumper bracket JBO00037-00034 REMOVAL 1. Remove the front fender mudguard subassembly by re- moving the three attaching bolts. JBO00038-00035 2. Remove the under fender bracket by removing the grom- met and tapping bolt.
  • Page 17 BO–17 3. Remove the screw grommet for the tapping bolts by cut- ting off the hem section of the grommet as shown. Screw grommet JBO00040-00037 4. Remove the ten screw type grommets by screwing them out. 5. Remove the front fender liner. JBO00041-00038 INSTALLATION NOTE:...
  • Page 18 BO–18 HOOD & HOOD LOCK CONTROL CABLE COMPONENTS q Hood lock control cable assembly w Hood lock assembly e Hood hinge assembly (R, L) r Hood support rod t Hood support clamp y Clip JBO00043-00039 Removal of engine hood 1. Disconnect the window washer hose from the window washer nozzle(s), clamps of the engine hood and clamp.
  • Page 19 BO–19 3. Remove the insulator, the hood-to-front end panel seal and the head lamp cover-to-hood seal by removing the attach- ing retainers. JBO00046-00042 4. Place cloths under the engine hood in order to prevent the painted surface from being damaged. 5.
  • Page 20 BO–20 Removal of hood lock and hood lock control cable 1. Remove the radiator grill. (Refer to the front bumper section.) 2. Remove the front fender liner. (Refer to the front fender liner section.) 3. Removal of hood lock assembly (1) Remove the three attaching bolts of the hood lock as- sembly.
  • Page 21 BO–21 Installation of hood lock and hood lock control cable NOTE: · Basically the installation procedure is reverse to the removal procedure. Therefore, illustrations are not given in this installation procedure. Refer to the illustrations in the removal procedure in cases where any difficulty is encountered.
  • Page 22 BO–22 FUEL LID OPENER COMPONENTS A or B section A (RHD) Right Front B (LHD) Floor carpet Center pillar lower garnish Harness Right Inside Front G sectional view E sectional view Front Right Harness Harness Front F section K and L C and D sectional view sectional view...
  • Page 23 BO–23 REMOVAL 1. Remove the front driver’s seat. (Refer to the front seat sec- tion.) 2. Remove the rear seat. (Refer to the rear seat section.) (Left hand drive vehicle only.) 3. Remove the right side rear door scuff plate assembly. (Refer to the trim &...
  • Page 24 BO–24 ROOF DRIP MOLDING COMPONENTS q Roof drip side finish right molding w Roof drip side finish left molding JBO00059-00053 REMOVAL 1. Remove the rear combination lamp. Retainer 2. Removal of roof drip molding Pull up the roof drip molding from the rear side gradually. Then remove the molding by pulling it backward to disen- gage the retainer on the molding from the pin on the roof panel.
  • Page 25 BO–25 ROOF RAIL & ROOF END SPOILER COMPONENTS q Right roof rack assembly w Clip e Rear right roof rack assembly r Clip t Left roof rack assembly y Rear spoiler subassembly u Stop center lamp assembly i Rear spoiler No. 1 cover JBO00062-00055 REMOVAL Hexagon wrench...
  • Page 26 BO–26 : Tightening torque Unit : N·m (kgf-m) Vehicles not equipped with roof end spoiler q Roof rack subassembly (front side) w Roof rear rack subassembly e Roof rack assembly 7.1 ± 1.1 (0.7 ± 0.1) Vehicles equipped with roof end spoiler q Roof rear rack subassembly w Rear spoiler subassembly e Roof rack assembly...
  • Page 27 BO–27 INSTALLATION NOTE: · Basically the installation procedure is reverse to the removal procedure. Therefore, illustrations are not given in this installation procedure. Refer to the illustrations in the removal procedure in cases where any difficulty is encountered. 1. Install the three clips to the rear spoiler subassembly. (Model equipped with rear spoiler.) 2.
  • Page 28 BO–28 REMOVABLE ROOF COMPONENTS q Removable roof rock garnish w Removable roof rock handle assembly e Removable roof rock base assembly r Removable roof panel assembly t Removable roof auxiliary left director catch assembly y Roof window deflector panel assembly u Sunroof opening trim molding i Removable roof inner weatherstrip o Removable roof trim...
  • Page 29 BO–29 INSTALLATION NOTE: · Basically the installation procedure is reverse to the removal procedure. Therefore, illustrations are not given in this installation procedure. Refer to the illustrations in the removal procedure in cases where any difficulty is encountered. 1. Install the removable roof hinge case with the attaching screws. 2.
  • Page 30 BO–30 INSTRUMENT PANEL COMPONENTS !5 !6 q Instrument panel subassembly !8 Shifting hole flame w Instrument panel center register assembly !9 Console panel e Instrument panel hole No. 3 cover @0 Rear console box assembly r Instrument panel hole No. 2 cover @1 Rear console box support bracket t Instrument panel hole No.
  • Page 31 BO–31 REMOVAL 1. Disconnect the battery ground cable terminal from the negative terminal of the battery. 2. Remove the front seats. (Refer to the front seat section.) 3. Removal of console box assembly (1) Remove the rear console box assembly by removing the two attaching screws.
  • Page 32 BO–32 10. Removal of combination meter assembly (1) Remove the three attaching bolts. JBO00076-00066 (2) Gradually raise the combination meter assembly. (3) Disconnect the connectors and speedometer cable from the combination meter assembly. NOTE: · Refer to the BE section for more details. (4) Remove the combination meter.
  • Page 33 BO–33 13. Remove the three attaching screws of the heater control panel assembly. 14. Disconnect the connector of the wire harness from the radio tuner or cassette player. 15. Disconnect the antenna cable from the radio tuner. 16. Remove the radio tuner opening cover, radio tuner or cas- sette player by removing the attaching screws.
  • Page 34 BO–34 21. Remove the instrument panel subassembly by removing the attaching bolts. If any difficulty is encountered in removing the attaching bolt of the rear hood lock control handle attaching bracket of the instrument panel, prior to the removal of the instru- ment panel, remove the hood lock control handle bracket by removing the two attaching bolts.
  • Page 35 BO–35 26. Remove the register assembly No. 2 of the instrument panel by unlocking the lock section on the instrument panel assembly. CAUTION: · Do not enlarge the attaching portion of the instrument panel more than necessary to remove the register. 27.
  • Page 36 BO–36 9. Connect the connector of the wire harness to the connector of the front passenger airbag. WARNING: · Be sure to refer to the instruction in the BE section. Failure to observe this warning may lead to seri- ous trouble or malfunction. 10.
  • Page 37 BO–37 FRONT SEAT COMPONENTS : Tightening torque Unit : N·m (kgf-m) Right side 25.4 ± 4.9 (2.5 ± 0.5) JBO00094-00082 REMOVAL 1. Disconnect the seat belt warning light switch connector. (Only for seat belt warning-equipped vehicle) 2. Move the front seat to the most rearward position. 3.
  • Page 38 BO–38 INSTALLATION 1. Place the front seat on the attaching surface on the floor while aligning the protrusions of the front seat with the holes on the floor panel. 2. Install the attaching bolts temporarily. 3. Move the front seat to the most forward position and tighten the attaching bolts temporarily. CAUTION: ·...
  • Page 39 BO–39 REAR SEAT COMPONENTS : Tightening torque Unit : N·m (kgf-m) 19.5 ± 4.5 (2.0 ± 0.5) 5.5 ± 1.5 (0.6 ± 0.2) 19.5 ± 4.5 (2.0 ± 0.5) 19.5 ± 4.5 (2.0 ± 0.5) JBO00098-00085 REMOVAL 1. Remove the rear seat cushion by removing the two attaching bolts. 2.
  • Page 40 BO–40 SEAT BELT FRONT SEAT BELT 9 ± 2 (0.9 ± 0.2) : Tightening torque Unit : N·m (kgf-m) 40.5 ± 12.5 (4.2 ± 1.3) 2.5 ± 1.0 (0.3 ± 0.1) öŸ If the threaded portion is damaged, øŸ use an oversized ET screw. 40.5 ±...
  • Page 41 BO–41 INSPECTION 1. Ensure that the seat belt will not be locked until the seat 45¡ belt retractor is tilted more than 15 degrees in all direc- tions from the installed angle. Also, ensure that the locked state is retained when the re- tractor is tilted 45 degrees or more.
  • Page 42 BO–42 REAR SEAT BELT : Tightening torque 40.5 ± 12.5 (4.2 ± 1.3) Unit : N·m (kgf-m) 40.5 ± 12.5 (4.2 ± 1.3) 40.5 ± 12.5 (4.2 ± 1.3) Turning-preventive beads 40.5 ± 12.5 (4.2 ± 1.3) öŸ Tightening should be made, aligning øŸ...
  • Page 43 BO–43 INSPECTION 1. Ensure that the seat belt will not be locked until the seat 45¡ belt retractor is tilted more than 15 degrees in all direc- tions. Also, ensure that the locked state is retained when the re- tractor is tilted 45 degrees or more. 2.
  • Page 44 BO–44 FRONT DOOR COMPONENTS : Non-reusable parts POWER WINDOW POWER LOCK q Front door glass subassembly @0 Front door glass outer weatherstrip w Front door glass run @1 Front door outside handle assembly e Front door outside panel @2 Front door lock link No 1 silencer r Front door panel subassembly @3 Front door open control link assembly t Front door front lower frame subassembly...
  • Page 45 BO–45 DISASSEMBLY 1. Unlock the shaft snap ring of the front door window handle assembly by inserting a piece of cloth between the handle and the door vent window control handle plate. Then, pull the inserted cloth alternately so as to unlock the shaft snap ring.
  • Page 46 BO–46 13. Remove the front door inside handle subassembly by dis- connecting the front door open control link. 14. Remove the door trim bracket by removing the attaching screws. 15. Remove the speaker by removing the three attaching screws. (Only when equipped.) 16.
  • Page 47 BO–47 23. Remove the front door glass subassembly. JBO00121-00103 24. Disconnect the connector of the front door wire harness from the power window motor. (For model equipped with power window) 25. Remove the front door window regulator subassembly by removing the attaching bolts. 26.
  • Page 48 BO–48 30. Remove the cowl side trim board. (Refer to the trim & gar- nish section.) 31. Disconnect the connector of the wire harness (cowl wire) from the connector of the wire harness (front door wire). 32. Disconnect the various clamps of the wire harness from the front door.
  • Page 49 BO–49 ASSEMBLY NOTE: · Basically the assembling procedure is reverse to the disassembling procedure. Therefore, illustra- tions are not mentioned in this assembling procedure. Refer to the illustrations in the disassembling procedure in cases where any difficulty is encountered. 1. Install the front door upper and lower hinges to the front door with the attaching bolts. 2.
  • Page 50 BO–50 19. Install the power window control switch by installing the attaching bolt. (For power window-equipped model.) 20. Install the door control lock knob holder to the front door trim panel assembly. JBO00130-00000 21. Installation of front door service hole cover (1) Affix a butyl tape at the groove provided around the front door panel, as shown.
  • Page 51 BO–51 22. Install the door trim bracket with the attaching screws. 23. Connect the front door inside handle subassembly to the front door open control link. 24. Installation of outside rear view mirror (1) Install the outside rear view mirror with the three attaching nuts. (2) Connect the connector of the front door wire harness to the connector of the remote control mirror.
  • Page 52 BO–52 REAR DOOR COMPONENTS : Non-reusable parts POWER LOCK q Rear door glass subassembly !7 Rear door locking control link subassembly w Rear door glass outer weatherstrip !8 Rear door locking link clamp e Rear door glass run !9 Rear door locking silencer r Rear door outside panel @0 Rear door lock link clamp t Rear door panel subassembly...
  • Page 53 BO–53 DISASSEMBLY Removal of rear door trim panel assembly 1. Unlock the shaft snap ring of the rear door window regula- tor handle assembly by inserting a piece of cloth between the rear door window regulator handle and the door vent window control handle plate.
  • Page 54 BO–54 14. Disconnect the rear door harness clamp from the door panel. (For the central door lock and/or speaker-equipped vehi- cle.) 15. Disconnect the connector of the rear door wire harness from the door control motor assembly. (For the central door lock and/or speaker-equipped vehi- cle.) JBO00139-00118 16.
  • Page 55 BO–55 20. Remove the rear door glass outer weatherstrip from the rear door panel by disconnecting the rear door glass weatherstrip clip from the rear door panel. 21. Remove the rear door glass run. 22. Remove the rear door window regulator handle assembly by removing the attaching bolts.
  • Page 56 BO–56 31. Remove the center pillar lower garnish. (Refer to the trim & garnish section.) (Only for model equipped with central door lock and/or speaker.) 32. Disconnect the connector of the rear door wire from the wire harness. (Only for model equipped with central door lock and/or speaker.) 33.
  • Page 57 BO–57 15. Install the rear door glass outer weatherstrip to the rear door panel by connecting the rear door glass weatherstrip clip to the rear door panel. 16. Install the rear door regulator subassembly with the attaching bolts. 17. Install the rear door window regulator handle temporarily. 18.
  • Page 58 BO–58 27. Install the door trim No. 1 bracket with the attaching bolts. 28. Connect the rear door inside handle subassembly to the rear door open control link assembly. 29. Ensure that the retainers are installed on the back side of the rear door trim panel assembly properly. 30.
  • Page 59 BO–59 BACK DOOR COMPONENTS : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 19.6 - 29.4 (2.0 - 3.0) 6.9 - 15.7 (0.7 - 1.6) q Back door weatherstrip !7 Back door handle assembly w Retainer !8 Back door lock assembly e Back door trim board !9 Door lock striker plate assembly r Back door service hole cover...
  • Page 60 BO–60 DISASSEMBLY 1. Removal of spare wheel (1) Remove the spare wheel by removing the attaching bolts. (2) Remove the spare wheel cover tray by removing the four attaching bolts. (For model equipped with spare wheel carrier.) JBO00154-00131 (3) Remove the spare wheel carrier assembly by remov- ing the four attaching bolts.
  • Page 61 BO–61 5. Disconnect the connectors of the rear wiper motor and door lock control switch. (Only for models equipped with such equipment. Refer to the BE section for the removal procedure.) 6. Remove the rear wiper motor by removing the attaching bolts.
  • Page 62 BO–62 19. Remove the back door check assembly by removing the attaching bolts. JBO00164-00141 20. Remove the right hand side rear combination lamp and rear bumper filler. (Refer to the rear bumper section) 21. Remove the back door by removing the attaching bolts of the back door hinge.
  • Page 63 BO–63 15. Install the rear wiper motor with the attaching bolts. (Only for rear wiper-equipped model. Refer to the BE section for the installation procedure.) 16. Connect the connectors of the rear wiper motor and door lock control switch. (Only for models equipped with such equipment. Refer to the BE section for the installation procedure.) JBO00166-00000 17.
  • Page 64 BO–64 TRIM & GARNISH COMPONENTS !5 (CL) !5 (CX) q Front pillar garnish (R, L) !1 Center pillar lower garnish (R, L) w Retainer !2 Rear door scuff plate assembly (R, L) e Center pillar upper garnish (R, L) !3 Deck side trim (R, L) r Roof side inner garnish (R, L) !4 Lower back trim t Clip...
  • Page 65 BO–65 REMOVAL 1. Remove the front and rear seats. (Refer to the front and rear seat section.) 2. Removal of front door scuff plate (1) Disconnect the four retainers provided under the scuff plate by pulling them up straight. (2) Remove the front scuff plate. JBO00170-00145 3.
  • Page 66 BO–66 8. Removal of front pillar garnish (1) Disconnect the clips provided on the back side of the front pillar garnish, using a clip remover or the like. (2) Remove the front pillar garnish. JBO00175-00150 9. Removal of lower back trim (1) Unlock the clips by pushing the central part of the clips one notch.
  • Page 67 BO–67 15. Removal of inner rear-view mirror assembly and visor as- sembly (1) Disconnect the visor assembly from the visor holder. (2) Remove the visor assembly by removing the two at- taching screws. (3) Remove the visor holder by removing the attaching screws.
  • Page 68 BO–68 INSTALLATION NOTE: · Basically the assembling procedure is reverse to the disassembling procedure. Therefore, some il- lustrations are not mentioned in this assembling procedure. Refer to the illustrations in the disassem- bling procedure in cases where any difficulty is encountered. 1.
  • Page 69 BO–69 11. Install the deck board assembly by installing the attaching bolts. 12. Installation of lower back trim (1) Place the lower back trim in position. (2) Push back the central part of the retainer one click from the position where the central part is flush with the outer part.
  • Page 70 BO–70 WINDOWS COMPONENTS q Windshield glass dam w Windshield glass e Windshield outside molding r Cowl top ventilator louver (R, L) t Hood to cowl top weatherstrip y Windshield glass stopper JBO00184-00157 REMOVAL 1. Preparation prior to removal (1) Remove the front pillar garnish & roof headlining. (Refer to the trim & garnish section.) (2) Remove the instrument panel.
  • Page 71 BO–71 2. Cut off the windshield glass adhesive by a cutter knife or the like to make a small hole, in order to pass a piano wire through the hole. CAUTION: · Be very careful not to damage the paint surface and windshield by the cutter knife or the like.
  • Page 72 BO–72 INSTALLATION 1. Affix locating stoppers to the windshield glass as shown in the figure below. Align both ends with cut-out sections. Unit: mm JBO00190-00162 Affix a windshield glass dam of the windshield glass to the position shown in the figure below. 3.
  • Page 73 BO–73 5. Install the glass, using suction rubbers. Push the entire glass surface lightly so that the glass may fit completely. NOTE: · At this time, assembling should be performed while the marks of the tinted section of the glass are aligned with the windshield glass stoppers.
  • Page 74 BO–74 QUARTER WINDOW GLASS COMPONENTS : Non-reusable parts q Quarter window glass w Quarter window glass molding e Quarter window glass clip r Quarter window glass spacer JBO00195-00166 REMOVAL Protective 1. Preparation prior to removal tape (1) Remove the roof side inner garnish. (Refer to the trim &...
  • Page 75 BO–75 3. Pass a piano wire through the adhesive agent. 4. Hold both ends of the piano wire by pliers or the like and cut off the adhesive by pulling the piano wire one side to the other. NOTE: · Some parts are hard to be cut off, because spacers or retainers are built in between the glass and the body panel.
  • Page 76 BO–76 2. Affix the quater window glass molding to the quater window with a two-faced tape. 3. Affix the spacers in position as shown in the figure below. 4. Apply the primer for the window frame or window to under the adhesive agent applying portion if the adhesive agent has been removed completely.
  • Page 77 BO–77 BACK DOOR WINDOW COMPONENTS : Non-reusable parts Back door trim board Back door hinge cover Back door glass r-1 Back door glass adhesive dam (On vehicles without spoiler) r-2 Back door upper weatherstrip (On vehicles with spoiler) Back window glass clip Back window glass spacer JBO00203-00173 REMOVAL...
  • Page 78 BO–78 (6) Protection for paint surface around windows Protective tape Protect the paint surface around the windows by ap- plying a protective tape or the like. CAUTION: · To protect the paint surface, be sure to apply a protec- tive tape to the inside of the edge (groove around the window attaching surface) as far as it will go.
  • Page 79 BO–79 INSTALLATION 1. Affix the clips of the back door window glass as follows. (1) Install the clips to the holes on the back door panel. (2) Remove the protective sheet of the clip. (3) Place the back door window glass to the body in such a location as shown. (4) Ensure that the clips are sticked to the back door window glass.
  • Page 80 BO–80 2. Affix the spacers in position as shown in the figure below. 3. Affix the dam in position as shown in the figure below. 4. Apply the primer for the window frame and/or window to under the adhesive agent applying portion if the adhesive agent has been removed completely.
  • Page 81 BO–81 9. Install the roof side inner garnish. (Refer to the trim & garnish section of the service manual.) 10. Ensure that no water leakage exists. If any water leakage is found, repair it, as required, or refit the quarter window glass. NOTE: ·...
  • Page 82 BO–82 FUEL TANK COMPONENTS 2.5 - 5.0 (0.25 - 0.5) : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 2.5 - 5.0 (0.25 - 0.5) 2.5 - 5.0 (0.25 - 0.5) q Drain plug w Fuel tube (emission) e Fuel tube (return) r Fuel tube (main) t Fuel tank sub inlet hose y Breather hose...
  • Page 83 BO–83 (4) Install the fuel drain plug with new gasket interposed and tighten it to specified tightening torque. (When fuel tank is reused.) Tightening torque: 65 N·m (0.66 kgf-m) Gasket CAUTION: · Be sure to clean the gasket attaching surface of fuel tank and fuel drain plug before installation.
  • Page 84 BO–84 9. Disconnect the connector of the wire harness from the fuel pump with motor and bracket located upper side of fuel tank while unlocking the lock on the connector. JBO00223-00190 10. Support the fuel tank with suitable jack or bench. 11.
  • Page 85 BO–85 13. Remove the fuel pump assembly and gasket by removing the attaching screws evenly CAUTION: · Never reuse the removed gasket again. Failure to ob- serve this caution may cause to fire. JBO00228-00195 14. Remove the fuel hose from the check valve by removing the hose clamp.
  • Page 86 BO–86 2. Inspection of the check valve (1) Connect the suitable rubber hose to check valve. (2) Ensure that the air continuity is exists when check valve in installed angle. If no air continuity is exists, replace the check valve with new one.
  • Page 87 BO–87 7. Connection of the fuel hoses to fuel pump assembly (1) Connection of the fuel main tube q Clean the fuel main pipe on the fuel pump assem- bly. w Apply the few drops of engine oil to the fuel pipe. e Connect the new fuel hose to the fuel pipe until clicking sounds emits from the retainer.
  • Page 88 BO–88 t Hold the checker as shown and connect the nail sections of checker to the quick connector. y Ensure that the connector is connected properly by pull the connector from the fuel pipe lightly. (4) Connect the fuel return tube to the fuel pipe clamps installed on the fuel tank securely.
  • Page 89 BO–89 13. Install the shut valve to the fuel inlet securely. 14. Connect the fuel tank sub inlet hose with new hose band to the fuel tank temporary. 15. Install the fuel tank to the floor panel with the four attach- ing bolts and tighten the attaching bolts to specified tight- ening torque evenly while supporting the fuel tank with suitable stand or the like.
  • Page 90 BO–90 REMOVAL OF FUEL INLET CAUTION: · Be sure to drain the fuel from the fuel tank before re- moving the fuel inlet when fuel filled-up more than half in the fuel tank. 1. Remove the fuel tank cap assembly. 2.
  • Page 91 BO–91 ACCELERATOR PEDAL COMPONENTS q Accelerator cable w Accelerator pedal e Accelerator pedal support bracket r Bush t Accelerator link rod return spring y Cushion u Clamp i Clamp o Clamp JBO00248-00214 INSPECTION OF ACCELERATOR PEDAL Ensure that the accelerator pedal operates smoothly without being caught or interference. If any problem is found, replace the damaged accelerator pedal related part, as required.
  • Page 92 BO–92 INSTALLATION 1. Install the accelerator cable assembly and connect the cable to the throttle body side (Refer to the EM section of the service manual.) 2. Install the accelerator pedal assembly to the floor panel with attaching bolts and tighten the attaching bolts to the specified tightening torque.
  • Page 93 BO–93 EXHAUST PIPE COMPONENTS : Tightening torque Unit : N·m (kgf-m) : Non-reusable parts 24.0 - 56.4 (2.45 - 5.75) q Tail pipe assembly w Exhaust front pipe assembly e Exhaust pipe support bracket No. 1 15.2 - 22.8 r Exhaust pipe gasket (1.6 - 2.3) t Muffler support No.
  • Page 94 BO–94 ENGINE MOUNTING INSULATOR COMPONENTS : Tightening torque Unit : N·m (kgf-m) 34.3 - 61.8 34.3 - 61.8 (3.5 - 6.3) 7 ± 3 mm (3.5 - 6.3) RH 7.5 –2.5 LH 5.5 –2.5 21.6 - 39.2 (2.2 - 4.0) 21.6 - 39.2 (2.2 - 4.0) REAR...
  • Page 95 BO–95 INSPECTION Ensure that the clearance of each mounting is within the specified value, as shown in the figure. If the clearance fails meet with the specified value mentioned in the figure, replace the part with a new one or adjust the clearance by changing the attaching position. REMOVAL/INSTALLATION 1.
  • Page 96 BO–96 TIGHTENING TORQUE Tightening torque determination procedure for general standard bolts and nuts 1. Tightening torque determination procedure for bolts Determine the strength division of the bolt concerned from the table below. Then, locate the tightening torque in the tightening torque table. 2.

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