GLASS/WINDOWS/MIRRORS GW
Page 1. General Description ...... 2 2. Power Window System ...... 6 3. Power Window Control Switch ...... 7 4. Remote Control Mirror System...... 10 5. Outer Mirror Assembly ...... 11 6. Outer Mirror...... 13 7. Remote Control Mirror Switch ...... 14 8. Front Door Glass...... 16 9. Front Regulator and Motor Assembly ...... 20 10. Rear Door Glass ...... 21 11. Rear Regulator and Motor Assembly ...... 23 12. Windshield Glass ...... 24 13. Inner Rearview Mirror...... 27 14. Rear Gate Glass ...... 28 15. Rear Window Defogger System...... 29 16. Rear Window Defogger...... 30 17. Rear Quarter Glass ...... 31 18. Roof Window Glass...... 32 GENERAL DESCRIPTION GLASS/WINDOWS/MIRRORS 1. General Description A: COMPONENT 1. FIXED GLASS
(6)
(2) (4) (3) (10) (1) (5)
(6)
(9)
(8)
(7) (3) (8)
(8) (8)
(11)
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(1) Windshield glass (5) Locate pin (9) Rear gate glass (2) Dam rubber (6) Fastener (10) Spring (3) Molding (7) Rear quarter glass (11) Cover C pillar (4) Rearview mirror mount (8) Locate pin
GW-2 GENERAL DESCRIPTION GLASS/WINDOWS/MIRRORS 2. FRONT DOOR GLASS
(1)
(4) T1
T1
(3) (2)
T2 (5) T1 T2 (6)
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(1) Glass (4) Regulator ASSY Tightening torque: N·m (kgf-m, ft-lb) (2) Door sash (Front) (5) Motor ASSY T1: 7.4 (0.75, 5.5) (3) Door sash (Rear) (6) Guide rail T2: 13.7 (1.4, 10.1)
GW-3 GENERAL DESCRIPTION GLASS/WINDOWS/MIRRORS 3. REAR DOOR GLASS
(2)
(3)
T2
T1 (4) (1)
T1
T2 (5)
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(1) Door sash (Front) (4) Regulator ASSY Tightening torque: N·m (kgf-m, ft-lb) (2) Glass (5) Motor ASSY T1: 7.4 (0.75, 5.5) (3) Door sash (Rear) T2: 13.7 (1.4, 10.1)
GW-4 GENERAL DESCRIPTION GLASS/WINDOWS/MIRRORS 4. MIRRORS
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(1) Outer mirror (3) Mount (5) Mirror (2) Inner rearview mirror (4) Spring B: PREPARATION TOOL
TOOL NAME REMARKS Circuit Tester Used for checking voltage and continuity. Piano Wire Used for window glass removal. Windshield Knife Used for window glass removal.
GW-5 POWER WINDOW SYSTEM GLASS/WINDOWS/MIRRORS 2. Power Window System A: SCHEMATIC 1. POWER WINDOW (LHD MODEL)
Symptom Repair order (1) Fuse (SBF-6) (2) Power window circuit breaker All power windows does not operate. (3) Power window relay (4) Wire harness (1) Power window main switch (2) Power window sub switch One window does not operate. (3) Power window motor (4) Wire harness “Window Lock” does not operate. (1) Power window main switch
GW-6 POWER WINDOW CONTROL SWITCH GLASS/WINDOWS/MIRRORS 3. Power Window Control 3) Remove the switch panel. Switch A: REMOVAL 1. MAIN SWITCH 1) Disconnect the ground cable from battery. 2) Using a flat tip screwdriver, remove the screw cover.
GW-00008 4) Disconnect the connector. B: INSTALLATION 1. MAIN SWITCH Install in the reverse order of removal. 2. SUB-SWITCH GW-00005 Install in the reverse order of removal. 3) Loosen the screw to remove the power window main switch.
GW-00006 4) Disconnect the connector. 2. SUB-SWITCH 1) Disconnect the ground cable from battery. 2) Remove the screw which secures switch panel.
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GW-7 POWER WINDOW CONTROL SWITCH GLASS/WINDOWS/MIRRORS C: INSPECTION 1. MAIN SWITCH Measure the switch resistance. • LHD model Driver's switch: Switch position Terminal No. Standard AUTO UP 13 and 1, 2 and 5 Less than 1 Ω UP 13 and 1, 2 and 5 Less than 1 Ω 1 and 2 OFF 1 and 5 Less than 1 Ω 2 and 5 DOWN 13 and 2, 1 and 5 Less than 1 Ω AUTO DOWN 13 and 2, 1 and 5 Less than 1 Ω Front passenger's switch: Switch position Terminal No. Standard UP 13 and 7, 6 and 5 Less than 1 Ω 5 and 6 OFF 5 and 7 Less than 1 Ω 6 and 7 DOWN 13 and 6, 7 and 5 Less than 1 Ω Rear left switch: Switch position Terminal No. Standard UP 13 and 11, 10 and 1 Less than 1 Ω 1 and 11 OFF 1 and 10 Less than 1 Ω 11 and 10 DOWN 13 and 11, 10 and 5 Less than 1 Ω Rear right switch: Switch position Terminal No. Standard UP 13 and 16, 15 and 1 Less than 1 Ω 1 and 15 OFF 1 and 16 Less than 1 Ω 15 and 16 DOWN 13 and 15, 16 and 1 Less than 1 Ω If NG, replace the main switch. • RHD model Driver's switch: Switch position Terminal No. Standard AUTO UP 12 and 7, 6 and 1 Less than 1 Ω UP 12 and 7, 6 and 1 Less than 1 Ω 1 and 6 OFF 1 and 7 Less than 1 Ω 6 and 7 DOWN 12 and 6, 7 and 1 Less than 1 Ω AUTO DOWN 12 and 6, 7 and 1 Less than 1 Ω
GW-8 POWER WINDOW CONTROL SWITCH GLASS/WINDOWS/MIRRORS
Front passenger's switch: Switch position Terminal No. Standard UP 12 and 2, 3 and 1 Less than 1 Ω 1 and 2 OFF 1 and 3 Less than 1 Ω 2 and 3 DOWN 12 and 3, 2 and 1 Less than 1 Ω Rear left switch: Switch position Terminal No. Standard UP 12 and 10, 9 and 1 Less than 1 Ω 1 and 9 OFF 1 and 10 Less than 1 Ω 9 and 10 DOWN 12 and 9, 10 and 1 Less than 1 Ω Rear right switch: Switch position Terminal No. Standard UP 12 and 14, 13 and 1 Less than 1 Ω 1 and 13 OFF 1 and 14 Less than 1 Ω 13 and 14 DOWN 12 and 13, 14 and 1 Less than 1 Ω If NG, replace the main switch. 2. SUB-SWITCH Measure the switch resistance. Front passenger's door switch and rear door switch: Switch position Terminal No. Standard UP 8 and 5, 7 and 4, 1 and 8, 1 and 5 Less than 1 Ω OFF 6 and 5, 4 and 7 Less than 1 Ω DOWN 8 and 7, 5 and 6, 1 and 8, 1 and 7 Less than 1 Ω If NG, replace the sub-switch.
GW-9 REMOTE CONTROL MIRROR SYSTEM GLASS/WINDOWS/MIRRORS 4. Remote Control Mirror System A: SCHEMATIC 1. REMOTE CONTROL MIRROR
Symptom Repair order (1) Fuse (F/B No. 4) (F/B No. 13) (F/B No. 17: LHD model) (F/B No. 18) All function does not operate. (2) Mirror switch (3) Wire harness (1) Mirror switch One side of the mirror motor does not operate. (2) Mirror motor (3) Wire harness (1) Mirror switch Mirror heater does not operate. (2) Mirror heater (3) Wire harness
GW-10 OUTER MIRROR ASSEMBLY GLASS/WINDOWS/MIRRORS 5. Outer Mirror Assembly B: INSTALLATION A: REMOVAL Install in the reverse order of removal. 1) Remove the door trim.
: (1)
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(1) Hook 3) Disconnect the mirror connector. 4) Remove the grommet, and loosen the screws to remove mirror assembly.
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GW-11 OUTER MIRROR ASSEMBLY GLASS/WINDOWS/MIRRORS C: INSPECTION Check to ensure that the rearview mirror moves properly when battery voltage is applied to terminals. Mirror heater not-equipped model: Switch position Terminal No. OFF — UP 1 (+) and 3 (−) DOWN 3 (+) and 1 (−) LEFT 2 (+) and 3 (−) RIGHT 3 (+) and 2 (−) If NG, replace the mirror. Mirror heater equipped model: Switch position Terminal No. OFF — UP 2 (+) and 4 (−) DOWN 4 (+) and 2 (−) LEFT 3 (+) and 2 (−) RIGHT 4 (+) and 3 (−) If NG, replace the mirror.
GW-12 OUTER MIRROR GLASS/WINDOWS/MIRRORS 6. Outer Mirror A: REPLACEMENT 1) Remove the door mirror assembly.
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(1) Mirror holder 4) When installing the mirror, warm the area around the mirror holder with a hair drier until the edges of the mirror holder become soft again (about 2 or 3 minutes with a 1,000 W drier.) 5) Remove the backing of the new double-stick tape, and push the mirror in to install it. NOTE: Unless the mirror holder is warmed sufficiently, the mirror holder edges may be damaged or the mirror cracked.
GW-13 REMOTE CONTROL MIRROR SWITCH GLASS/WINDOWS/MIRRORS 7. Remote Control Mirror Switch A: REMOVAL Refer to Power Window Control Switch, because the remote control mirror switch is integrated with power window control switch.
GW-14 REMOTE CONTROL MIRROR SWITCH GLASS/WINDOWS/MIRRORS C: INSPECTION Move the rearview mirror switch to each position and check continuity between terminals.
10 9 8 7 6 5 4 3 2 1
GW-00012 Change over switch right position: Switch position Terminal No. Standard OFF — More than 1 MΩ UP 8 and 3, 6 and 7 Less than 1 Ω DOWN 8 and 6, 3 and 7 Less than 1 Ω LEFT 8 and 2, 6 and 7 Less than 1 Ω RIGHT 8 and 6, 2 and 7 Less than 1 Ω Change over switch left position: Switch position Terminal No. Standard OFF — More than 1 MΩ UP 8 and 4, 6 and 7 Less than 1 Ω DOWN 8 and 6, 4 and 7 Less than 1 Ω LEFT 8 and 5, 6 and 7 Less than 1 Ω RIGHT 8 and 6, 5 and 7 Less than 1 Ω If NG, replace the switch.
GW-15 FRONT DOOR GLASS GLASS/WINDOWS/MIRRORS 8. Front Door Glass 7) Remove the rear end of door weatherstrip and weatherstrip outer. A: REMOVAL 1) Remove the front door trim.
GW-00017 9) Take out the door glass. NOTE: • Do not turn the regulator in closing direction after removal of the glass. Otherwise gear may be disen- gaged.
GW-00013 6) Remove the stabilizers.
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GW-16 FRONT DOOR GLASS GLASS/WINDOWS/MIRRORS B: INSTALLATION 4) For adjustment of clearance between front door 1) Install in the reverse order of removal. glass and center pillar cover, loosen the nuts (A), and move the rear sash back and forward until CAUTION: clearance becomes the value shown. (Difference Make sure that the glass stay is placed securely between upper side and lower side must be within in sash. 1.5 mm (0.059 in).) 2) Adjust the front door glass.
(A)
(B)
GW-00063 GW-00021 (1) Full close (2) Stabilizer (3) 10 — 15 mm (0.39 — 0.59 in)
GW-17 FRONT DOOR GLASS GLASS/WINDOWS/MIRRORS
6) Adjust so that the upper and lower ends of cen- For preventing wind noise, adjust the glass at the ter pillar are the same size. position where tip of gusset is raised up a little.
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(A) 0 — 1.5 mm (0 — 0.059 in) 8) After stabilizer adjustment, carry out the glass crimp adjustment. First, visually ensure positional relationship between retainer & molding and glass of the roof side, and then begin with rear sash ad- justment. Adjust two adjusting bolts alternately step by step to obtain dimensions shown below (cross- section A). NOTE: GW-00139 If two nuts are loosened at the same time, sash moves back and forth. Therefore, when one nut is (1) Narrow adjusted, secure the other. (2) Wide 9) Make the same adjustment of two adjusting bolts (3) Glass tilts too far rearward of rear sash. (4) Glass tilts too far forward (5) Raise B channel (6) Lower B channel (1)
7) For glass stroke adjustment, close the door, A raise glass until positional relationship between glass and weatherstrip becomes as shown. And secure the glass so that the upper stopper lightly A touches the glass holder.
(2)
(1) GW-00066
A (1) 3.5±0.8 mm (0.137±0.031 in) (2) 9.5±1 mm (0.374±0.039 in)
A
(2)
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(1) 3.5±0.8 mm (0.137±0.031 in) (2) 9.5±1 mm (0.374±0.039 in)
GW-18 FRONT DOOR GLASS GLASS/WINDOWS/MIRRORS
NOTE: Do not tilt the sash bracket to inner panel during ad- justment. Otherwise smooth regulator operation cannot be achieved.
(A)
(C) (D)
(B) (E) GW-00026
(A) Sash bracket (B) Rear sash (C) Adjust a line parallel (D) Sash (E) Innter panel 10) Make adjustment of front sash in the same manner as that of rear sash. NOTE: Although front and rear sashes must, as a rule, be adjusted in the same manner, in some door instal- lation, 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 re- sult in application of excessive load to regulator. 11) After adjustments, tighten the nuts. 12) After adjustment to glass, close the door. If there is even a little gap between outer lip of gusset and glass surface, adjust the gap with adjusting nut (A) in lower fitting part of the gusset to prevent gen- eration of wind noise. 13) During adjustments, loosen the other three clamping screws.
(A)
GW-00056 14) After adjustment, tighten the bolts and nuts.
GW-19 FRONT REGULATOR AND MOTOR ASSEMBLY GLASS/WINDOWS/MIRRORS 9. Front Regulator and Motor B: INSTALLATION Assembly 1) Install in the reverse order of removal. 2) Adjust the front door glass.
GW-00027 3) Disconnect the motor connector. 4) Loosen the four bolts and two nuts to remove regulator assembly.
GW-00028 5) Loosen the screw to remove motor assembly.
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GW-20 REAR DOOR GLASS GLASS/WINDOWS/MIRRORS 10.Rear Door Glass 6) Loosen the two screws to remove the weather strip outer. A: REMOVAL 1) Remove the rear door trim.
GW-00030 5) Remove the door weather strip.
GW-00032 7) Operate the power window switch to remove glass as shown in the figure, and then remove two nuts.
GW-00031 8) Take out the door glass.
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GW-21 REAR DOOR GLASS GLASS/WINDOWS/MIRRORS B: INSTALLATION 2) Adjust the crimp of glass using the following di- 1) Install in the reverse order of removal. mensions as a guide line. CAUTION: Make sure that the glass stay is placed securely (1) in sash. A 2) Adjust the rear door glass.
(1) (1)
A A
A-A
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(1) 12±1 mm (0.472±0.039 in)
NOTE: • If the dimensions are smaller than the given di- mensions, glass may get caught in weatherstrip during lifting/lowering operation. In the worst case, it may cause the glass not to be opened fully. • After adjustment, move the glass up and down to check whether it is caught.
GW-22 REAR REGULATOR AND MOTOR ASSEMBLY GLASS/WINDOWS/MIRRORS 11.Rear Regulator and Motor As- sembly A: REMOVAL 1) Remove the door glass.
GW-00035 5) Loosen the screws to remove motor assembly.
GW-00036 B: INSTALLATION 1) Install in the reverse order of removal. 2) Adjust the rear door glass.
GW-23 WINDSHIELD GLASS GLASS/WINDOWS/MIRRORS
12.Windshield Glass NOTE: Because the matching pins are bonded to the cor- A: REMOVAL ners of glass, use piano wire to cut the pin. 1. USING WINDSHIELD KNIFE 1) Remove the cowl panel.
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(1) Putty knife 6) Pull the wire ends alternately to cut off the adhe- (2) Protective tape sive layer. (3) Matching pin (4) Windshield glass knife
GW-24 WINDSHIELD GLASS GLASS/WINDOWS/MIRRORS B: INSTALLATION 5) Remove the backing of double-faced adhesive 1) Clean the external circumference of windshield tape (C) and then align the molding mark (B) to glass with alcohol or white gasoline. notch (A). Attach the molding around the edge of 2) Remove the adhesive layer on the body using glass, and then press it evenly to fit. cutter knife to obtain smooth face 2 mm (0.08 in) thick. ( A )
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(1) Adhesive ( B ) (2) 2 mm (0.08 in) (3) Dam rubber (4) Glass 3) Clean the body with alcohol or white gasoline to remove thoroughly chips, dusts, and dirts from body face. ( C ) GW-00042 4) Apply the dam rubber to back of glass. 6) Apply primer to the adhesive layer of glass using sponge. 7) Apply primer to the adhesive layer of body. Primer once attached to the painted surface of the body and internal trim is hard to wipe off. Mask the (4) circumference of such areas. Let the primer dry for about ten minutes before in- (1) (3) stalling the glass.
(2)
(4)
(4)
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(1) Application of primer (2) Glass side GW-00072 (3) Body side
(1) Matching pin (2) Dam rubber (3) Fastener (4) 13 mm (0.512 in)
GW-25 WINDSHIELD GLASS GLASS/WINDOWS/MIRRORS
8) Cut off the cartridge nozzle tip and set it in seal- ant gun as shown.
(2)
(1)
(3)
(4)
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(1) 10 — 13 mm (0.39 — 0.51 in) (2) 13 mm (0.51 in) (3) 10 mm (0.39 in) (4) 15 mm (0.59 in) 9) Apply adhesive to the glass end surface as shown. 10) Fit the matching pins using suction rubber cup to install the windshield glass.
GW-00045 11) Lightly press the windshield glass for tight fit. 12) After completion of all work, allow the 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 adhe- sive manufacturer. 13) After curing of adhesive, pour water on external surface of vehicle to check that there are no water leaks. NOTE: 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. 14) Install the cowl panel.
GW-26 INNER REARVIEW MIRROR GLASS/WINDOWS/MIRRORS 13.Inner Rearview Mirror A: REMOVAL NOTE: The spring cannot be reused. Prepare a new spring before removal. 1) Turn the mirror base 90 degrees clockwise or counterclockwise to remove it.
GW-00046 2) Remove the spring from mirror base.
GW-00047 CAUTION: Be careful not to damage the mirror surface. B: INSTALLATION Install in the reverse order of removal. C: INSPECTION Do not let the mirror be damaged. Do not let the spring deteriorate.
GW-27 REAR GATE GLASS GLASS/WINDOWS/MIRRORS 14.Rear Gate Glass 2) Install the glass in same procedure as for wind- shield glass.
(3) A (2) A
(1)
(3)
A - A
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(1) Body panel A) Upper side (2) Glass B) Left and right side (3) Matching pin (1) Adhesive (2) Strip rubber B: INSTALLATION (3) Glass 1) Install a new rubber strip (A) by aligning it with (4) Primer the end of the rear gate glass (B). (5) 12 mm (0.47 in) (6) 14 mm (0.55 in) (7) 10 — 13 mm (0.39 — 0.51 in) (8) 15 mm (0.31 in) (9) 12 mm (0.47 in) 3) About one hour after installation, conduct a leak test. 4) After completion of all work, allow the vehicle to stand for about 24 hours.
GW-00049 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. • 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 the rear defogger terminals. 6) Install the rear gete garnish.
GW-28 REAR WINDOW DEFOGGER SYSTEM GLASS/WINDOWS/MIRRORS 15.Rear Window Defogger Sys- tem A: SCHEMATIC 1. REAR WINDOW DEFOGGER
Symptom Repair order (1) Fuse (M/B No. 1) (F/B No. 17) (2) Rear defogger relay (3) Rear defogger timer Rear window defogger does not operate. (4) Defogger switch (5) Rear defogger condenser (6) Defogger wire (7) Wire harness
GW-29 REAR WINDOW DEFOGGER GLASS/WINDOWS/MIRRORS 16.Rear Window Defogger movement of lead, heat wire is open at the voltage change point. A: INSPECTION B: REPAIR 1) Turn the ignition switch to ON. 2) Turn the defogger switch to ON. 1) Clean the broken portion with alcohol or white gasoline. 3) Wrap the tips of tester pins with aluminum foil to 2) Mask both side of wire with thin film. avoid damage to heat wire. 3) Apply conductive silver composition (DUPONT No. 4817) to broken portion.
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GW-00078 (1) Tester probe (2) Tin foil (1) Broken portion (3) Heat wire (2) Masking thin film (4) PRESS (3) Broken wire 4) Measure the voltage at wire center with DC volt- (4) Conductive silver composition meter. 4) After repair, check the wire. Standard voltage: Approx. 6 V
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(1) Center
Voltage Criteria Approx. 6 V OK Approx. 12 V or 0 V Broken
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 cen- ter and ground. 5) Apply positive lead of voltmeter to positive termi- nal of heat wire, and then move the negative lead along the wire up to negative terminal end. If volt- age changes from zero to several volts during
GW-30 REAR QUARTER GLASS GLASS/WINDOWS/MIRRORS 17.Rear Quarter Glass A: REMOVAL Remove the glass in the same procedure as for windshield glass.
A A-A D-D
(1) (4) (3) (2) (4) (2) B C (3) (1)
D (5)
B-B (2) C-C (6)
(3) (2) (3) (1) (7) (5) (8)
(5)
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(1) Molding (4) Locating pin (7) Weatherstrip (2) Adhesive (5) Body (8) Rear door glass (3) Interior trim (6) Cover C pillar B: INSTALLATION 2) Install the glass in the same procedure as for 1) Cut off the nozzle tip as shown in the figure. windshield glass.
(1) Molding NOTE: When a vehicle is returned to the user, tell him or (2) Matching pin her that the vehicle should not be subjected to (3) Adhesive heavy impact for at least three days. (4) 10 mm (0.39 in) (5) 15 mm (0.59 in) (6) 10 — 13 mm (0.39 — 0.51 in)
GW-31 ROOF WINDOW GLASS GLASS/WINDOWS/MIRRORS 18.Roof Window Glass A: REMOVAL
GW-32 BODY STRUCTURE BS
Page Refer to G8071GZ SUPPLEMENT for this section. BODY STRUCTURE
BS-2