Field-Fix Procedures

1. Remove the Roofside Rail Weatherstrip.





2. Remove the Windshield Side Molding and the Screw Grommets.





3. Remove the Door Trim Panel and Mirror Cover.





4. Remove outer Rear View Mirror





5. Remove the Door Glass.





6. Remove the outside Door Glass Run.





7. Remove the Door Opening Weatherstrip.





8. Using round pieces of clay approximately the size of a quarter, measure the gap between the door frame and the door opening flange by placing clay at the following four (4) locations:

A & C - Notched area in flange.
B - In line with top windshield molding.
D - 150 mm down toward the cowl from C.

Close the door slowly, with both hands on the belt molding, until the 2nd click is heard from the latch mechanism.





Open the door and cut clay at the raised indentation approximately in the middle of each clay, perpendicular to the door flange.

Measure and record the height of clay at each location and then remove clay.





9. Install new Door Opening Weatherstrip.








10. Install shims (400 x 10 x 0.5) to the "A" pillar area between the door opening flange and the Door Opening Weatherstrip. These shims, should narrow the gap to approximately 10.5 mm.

NOTE:
Shim material can be cut.





11. Install new Windshield Side Molding Screw Grommets.





12. Install Windshield Side Molding.

NOTE:
The black screw (P/N 90167-40027) goes in the top hole. The 2 chrome screws (P/N 90168-40027) go in the bottom 2 holes.





13. Confirm Cowl to Fender Seal is properly positioned so that the leading edge is parallel to the Windshield Side Molding.





14. Install Roofside Rail Weatherstrip.





15. Install foam tape (300 x 5 x 5, 5 pieces per door) to inside of door glass black rubber molding trim below and under the chrome.

NOTE:
Place the pieces of foam tape end to end. Do NOT put foam tape on the chrome.





16. Install and wrap foam (160 x 30 x 5) to inner side of division bar next to door inner panel.





17. Install Glass Run Weatherstrip.





18. Install glass to regulator.





19. Measure glass depth to glass run. Close the front door glass. Mark the door glass at points (A) and (B) against the glass run weatherstrip as shown.


NOTE:
Use a piece of masking tape over the edge of the window.





20. With the glass down about 30 mm, measure the difference between the glass edge and marked point on the tape at (A) and (B). The measurements should be greater than 3 mm at each point, and the difference between the measurements at (A) and (B) should be less than 3 mm.

If the measurements are not within specification, replace the front door window regulator.





21. Confirm that sponge is present under the joint between the belt molding and mirror base chrome. If not, add sponge (15 x 8 x 8 mm).





22. Add sponge sealer (40 x 25 x 5 mm) over the joint between the belt molding and the mirror base chrome.

NOTE:
Clean off surface dirt before applying sponge sealer.





23. Add round foam sponge (12 x 300 mm) to the area as shown.





24. Remove old foam from Mirror Base Gasket.





25. Add foam to mirror base as shown:

A) 122 x 100 x 10 mm - Triangular piece with hole in center.
B) 55 x 40 x 5 mm - Small Triangle
C) 75 x 5 x 5 mm





26. Install mirror to door frame.





27. Add foam to inner door panel below mirror base attachment bolts to seal the mirror wire to the door.

A) 90 x 25 x 5 mm

B) 110 x 25 x 5 mm

Foam "B" goes on top of Foam "A" and under the mirror wire.





28. Add butyl sealer to top of watershield plastic in areas as shown.

NOTE:
Verify that all of the watershield plastic edges are secured tightly to the door.





29. Check door frame to body gap:

a. Adjust door frame at the top of the door frame to the roof panel to provide a gap of 6.5 mm (+/- 1.5).
b. Adjust door frame to the "A" pillar or windshield side molding area to provide a gap of 7 mm (+/- 1.5).





3O. Install Door Trim Panel and Mirror Cover.