2006帕杰罗维修手册-BODY.pdf

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1、42-1 GROUP 42 BODY CONTENTS HOOD. . . . . . . . . . . . . . . . . . . . .42-3 HOOD DIAGNOSIS . . . . . . . . . . . .42-3 INTRODUCTION TO HOOD DIAGNOSIS42-3 HOOD DIAGNOSTIC TROUBLESHOOTING STRATEGY . . . . . . . . . . . . . . . . . . . . . . 42-3 SYMPTOM CHART . . . . . . . . . . . .42-3 SYMPTOM PROC

2、EDURES. . . . . .42-3 HOOD. . . . . . . . . . . . . . . . . . . . . . .42-5 REMOVAL AND INSTALLATION . . . . . 42-5 INSPECTION. . . . . . . . . . . . . . . . . . . . . 42-7 FENDER. . . . . . . . . . . . . . . . . . .42-7 REMOVAL AND INSTALLATION .42-7 FUEL FILLER LID . . . . . . . . . . .42-8 REMOVA

3、L AND INSTALLATION .42-8 WINDOW GLASS . . . . . . . . . . .42-10 GENERAL DESCRIPTION . . . . . .42-10 WINDOW GLASS DIAGNOSIS. . .42-12 INTRODUCTION TO WINDOW GLASS DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . 42-12 WINDOW GLASS DIAGNOSTIC TROUBLESHOOTING STRATEGY . . . 42-12 SYMPTOM CHART .

4、. . . . . . . . . . .42-12 SYMPTOM PROCEDURES. . . . . .42-12 SPECIAL TOOL . . . . . . . . . . . . . . .42-12 WINDSHIELD . . . . . . . . . . . . . . . . .42-13 REMOVAL AND INSTALLATION. . . . . . 42-13 QUARTER WINDOW GLASS . . . .42-16 REMOVAL AND INSTALLATION. . . . . . 42-16 BACK DOOR WINDOW GLASS

5、 . .42-18 REMOVAL AND INSTALLATION. . . . . . 42-18 DOOR. . . . . . . . . . . . . . . . . . . . 42-20 GENERAL DESCRIPTION. . . . . . .42-20 CENTRAL DOOR LOCKING SYSTEM DIAGNOSIS . . . . . . . . . .42-20 POWER WINDOW DIAGNOSIS. . .42-20 DOOR DIAGNOSIS . . . . . . . . . . . .42-20 INTRODUCTION TO GLAS

6、S AND DOOR DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 42-20 GLASS AND DOOR DIAGNOSTIC TROUBLESHOOTING STRATEGY. . . . 42-20 SYMPTOM CHART. . . . . . . . . . . . .42-21 SYMPTOM PROCEDURES . . . . . .42-21 HOW TO LOCATE WIND NOISES.42-24 SPECIAL TOOLS . . . . . . . . . . . . . .42-25 Contin

7、ued on next page 42-2 ON-VEHICLE SERVICE. . . . . . . . .42-26 DOOR FIT ADJUSTMENT. . . . . . . . . . . 42-26 DOOR WINDOW GLASS ADJUSTMENT42-28 DOOR INSIDE HANDLE PLAY CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . 42-29 DOOR OUTSIDE HANDLE PLAY CHECK42-29 CIRCUIT BREAKER (INCORPORATED IN THE PO

8、WER WINDOW MOTOR) INSPECTION. . . . . . . . . . . . . . . . . . . . . 42-29 DOOR ASSEMBLY . . . . . . . . . . . .42-30 REMOVAL AND INSTALLATION . . . . . 42-30 INSPECTION. . . . . . . . . . . . . . . . . . . . . 42-31 DOOR TRIM AND WATERPROOF FILM. . . . . . . . . . . . . . . . . . . . . . . .42-32

9、REMOVAL AND INSTALLATION . . . . . 42-32 INSPECTION. . . . . . . . . . . . . . . . . . . . . 42-37 DOOR GLASS AND REGULATOR42-38 REMOVAL AND INSTALLATION . . . . . 42-38 INSPECTION. . . . . . . . . . . . . . . . . . . . . 42-40 DOOR HANDLE AND LATCH. . . .42-41 REMOVAL AND INSTALLATION . . . . . 42-

10、41 INSPECTION. . . . . . . . . . . . . . . . . . . . . 42-43 WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP42-45 REMOVAL AND INSTALLATION . . . . . 42-45 BACK DOOR ASSEMBLY . . . .42-49 BACK DOOR DIAGNOSIS . . . . . .42-49 INTRODUCTION TO BACK DOOR DIAGNOSIS. . . . . . . . . . . . . . . . . .

11、 . . . . 42-49 BACK DOOR DIAGNOSTIC TROUBLESHOOTING STRATEGY . . . 42-49 SYMPTOM CHART . . . . . . . . . . . .42-49 SYMPTOM PROCEDURES. . . . . .42-49 SPECIAL TOOL. . . . . . . . . . . . . . .42-50 ON-VEHICLE SERVICE. . . . . . . . .42-50 BACK DOOR FIT ADJUSTMENT . . . . . 42-50 BACK DOOR HANDLE PLA

12、Y CHECK . 42-51 BACK DOOR ASSEMBLY . . . . . .42-51 REMOVAL AND INSTALLATION . . . . . 42-51 INSPECTION. . . . . . . . . . . . . . . . . . . . . 42-52 BACK DOOR TRIM AND WATERPROOF FILM. . . . . . . . . . .42-53 REMOVAL AND INSTALLATION. . . . . . 42-53 BACK DOOR HANDLE AND LATCH42-54 REMOVAL AND IN

13、STALLATION. . . . . . 42-54 INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-55 KEYLESS ENTRY SYSTEM . . 42-55 GENERAL DESCRIPTION. . . . . . .42-55 KEYLESS ENTRY SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . .42-55 SPECIAL TOOLS . . . . . . . . . . . . . .42-56 ON-VEHICLE SERVICE . . .

14、. . . . . .42-57 HOW TO REPLACE THE TRANSMITTER BATTERY. . . . . . . . . . . . . . . . . . . . . . . . 42-57 ENABLING/DISABLING THE ANSWERBACK FUNCTION . . . . . . . . . 42-57 HOW TO REGISTER SECRET CODE . 42-59 SUNROOF ASSEMBLY. . . . . . 42-62 GENERAL DESCRIPTION. . . . . . .42-62 SUNROOF DIAGNOSI

15、S. . . . . . . . .42-62 SPECIAL TOOL . . . . . . . . . . . . . . .42-62 ON-VEHICLE SERVICE . . . . . . . . .42-63 WATER TEST . . . . . . . . . . . . . . . . . . . . 42-63 SUNROOF FIT ADJUSTMENT . . . . . . . 42-63 OPERATION CHECK. . . . . . . . . . . . . . . 42-63 SUNROOF ASSEMBLY . . . . . . . . .4

16、2-66 REMOVAL AND INSTALLATION. . . . . . 42-66 INSPECTION . . . . . . . . . . . . . . . . . . . . . 42-69 DISASSEMBLY AND ASSEMBLY. . . . . 42-70 SPECIFICATIONS . . . . . . . . . . 42-73 FASTENER TIGHTENING SPECIFICATIONS . . . . . . . . . . . . .42-73 SERVICE SPECIFICATIONS . . . . .42-73 SEALANTS.

17、 . . . . . . . . . . . . . . . . . .42-74 COMPONENT IDENTIFICATION. .42-74 HOOD TSB Revision BODY 42-3 HOOD HOOD DIAGNOSIS INTRODUCTION TO HOOD DIAGNOSIS M1421005800040 Wind noise at the hood may be caused by improper hood adjustment. HOOD DIAGNOSTIC TROUBLESHOOTING STRATEGY M1421005900036 Use these

18、 steps to plan your diagnostic strategy. If you follow them carefully, you will be sure that you have exhausted most of the possible ways to find a hood fault. 1. Gather information from the customer. 2. Verify that the condition described by the customer exists. 3. Find the malfunction by following

19、 the Symptom Chart. 4. Verify malfunction is eliminated. SYMPTOM CHART M1421006000337 SYMPTOMINSPECTION PROCEDURE REFERENCE PAGE Difficult locking and unlocking1 P.42-3 Uneven body clearance2 P.42-4 Uneven height3 P.42-4 SYMPTOM PROCEDURES INSPECTION PROCEDURE 1: Difficult Locking and Unlocking DIAG

20、NOSIS STEP 1. Check the release cable routing condition. Q: Is the release cable routing condition good? YES : Go to Step 2. NO : Repair the release cable, then go to Step 4. STEP 2. Check the engagement of the hood latch and hood striker. Q: Are the hood latch and hood striker engaged correctly? YE

21、S : Go to Step 3. NO : Adjust the hood latch (Refer to P.42-5). Then go to Step 4. STEP 3. Check for proper lubrication of release cable. Q: Is the release cable properly lubricated? YES : Go to Step 4. NO : Lubricate, then go to Step 4. STEP 4. Retest the system. Q: Does the hood lock operate easil

22、y? YES : The procedure is complete. NO : Return to Step 1. HOOD TSB Revision BODY 42-4 INSPECTION PROCEDURE 2: Uneven Body Clearance DIAGNOSIS STEP 1. Check the hood installation condition. Q: Is the hood installation in good condition? YES : Go to Step 2. NO : Adjust the hood (Refer to P.42-5). The

23、n go to Step 2 . STEP 2. Retest the system. Q: Is the clearance with the body even? YES : The procedure is complete. NO : Return to Step 1. INSPECTION PROCEDURE 3: Uneven Height DIAGNOSIS STEP 1. Check the hood bumper height. Q: Is the hood bumper height proper? YES : Go to Step 2. NO : Adjust the h

24、ood bumper (Refer to P.42-5). Then go to Step2. STEP 2. Retest the system. Q: Are the hood and body height even? YES : The procedure is complete. NO : Return to Step 1. HOOD TSB Revision BODY 42-5 HOOD REMOVAL AND INSTALLATION M1421001600226 ACX01958 A18C0021AW0381AU 22 4 Nm 16 3 ft-lb 9.0 2.0 Nm 79

25、 18 in-lb 2 1 3 4 5 6 7 8 9 7 7 5 7 5.0 1.0 Nm 44 9 in-lb 1 2 AB 10 HOOD LATCH REMOVAL STEPS RADIATOR GRILL (REFER TO GROUP 51 FRONT BUMPER P.51- 3.) 1.HOOD LATCH HOOD LOCK RELEASE CABLE REMOVAL STEPS 2.HOOD LOCK RELEASE HANDLE 3.HOOD LOCK RELEASE CABLE HOOD AND HOOD HINGE REMOVAL STEPS 4.HOOD INSUL

26、ATOR 5.HOOD WEATHERSTRIP WASHER HOSE (REFER TO GROUP 51 WINDSHIELD WIPER AND WASHER P.51-23.) 6.HOOD 7.BUMPER A 8.HOOD SUPPORT ROD FRONT DECK GARNISH (REFER TO GROUP 51 WINDSHIELD WIPER AND WASHER P.51-23.) 9.HOOD HINGE 10. HOOD SWITCH HOOD AND HOOD HINGE REMOVAL STEPS (Continued) ACX00459 AC203663

27、AX0385CA AW0382AL AX0423CA AX0424CA ADJUSTMENT OF CLEARANCE AROUND HOOD ADJUSTMENT OF HOOD AND HOOD STRIKER ENGAGEMENT SECTION A ASECTION B B 6 7 6 7 B B A A 15 0.5 mm 0.59 0.02 in 20 0.5 mm 0.78 0.02 in CLIP POSITIONSSECTION A A A A 6 CLIP 4 4 6 : CLIP POSITION AB ADJUSTMENT OF HEIGHT AROUND HOOD H

28、OOD TSB Revision BODY 42-6 FENDER TSB Revision BODY 42-7 INSPECTION M1421001700182 HOOD SWITCH CONTINUITY CHECK 12 ACX02415 SWITCH POSITION TESTER CONNECTION SPECIFIED CONDITION Hood switch unpressed 1 2Less than 2 ohms Hood switch depressed Open circuit FENDER REMOVAL AND INSTALLATION M142100190072

29、2 Pre-removal and Post-installation Operation Front Bumper Removal and Installation (Refer to GROUP 51, Front Bumper P.51-3.) Front Mud Guard Removal and Installation (Refer to GROUP 51, Front Mud Guard P.51-17.) Front Wheel Cut Molding Removal and Installation (Refer to GROUP 51, Front Wheel Cut Mo

30、lding P.51-10.) AC203222 AC500083 CLIP 1 3 1 2 AB SECTION A A A A 3 REMOVAL STEPS 1. SPLASH SHIELD FRONT DOOR ASSEMBLY (REFER TO P.42-30.) 2. FENDER REAR PROTECTOR 3. FENDER FUEL FILLER LID TSB Revision BODY 42-8 FUEL FILLER LID REMOVAL AND INSTALLATION M1421002500318 Pre-removal and Post-installati

31、on Operation Quarter Trim Lower Removal and Installation (Refer to GROUP 52A, Trims P.52A-8.) Center Pillar Trim Lower Removal and Installation (Refer to GROUP 52A, Trims P.52A-8.) X0181CA AC101963 3 5 3 2 4 1 AB REMOVAL STEPS A RIVET REMOVAL AC100411AY RIVET DRILL FUEL FILLER LID ASSEMBLY Use a dri

32、ll 6.5 7.5 mm (0.25 0.29 inch) to break the rivet by drilling a hole, and remove the rivet. INSTALLATION SERVICE POINT . A BAAA WINDSHIELD REMOVAL 1. To protect the body (paint surface), apply cloth tape to all body areas around the installed windshield. ACX00474AB 2. Using a sharp-point drill, make

33、 a hole in the windshield adhesive. 3. Pass the piano wire from the inside of the vehicle through the hole. CAUTION Do not let the piano wire touch the edge of the windshield. 4. Pull the piano wire alternately from the inside and outside along the windshield to cut the adhesive. 5. Make mating mark

34、s on the windshield and body. ACX00475AB MB990480 6. Use special tool MB990480 to remove the windshield. CAUTION Be careful not to remove more adhesive than is neces- sary. Be careful also not to damage the paintwork on the body surface with the knife. If the paintwork is dam- aged, repair the damag

35、ed area with repair paint or anti- rust agent. 7. Use a knife to cut away the remaining adhesive so that the thickness is within 2 mm (0.08 inch) around the entire circumference of the body flange. 8. Finish the flange surfaces so that they are smooth. CAUTION Allow the cleaned area to dry for at le

36、ast three minutes. Do not touch any surface that has been cleaned. ACX00476AB 9. When reusing the windshield, remove the adhesive still adhering to the windshield, and clean with 3M AAD Part number 8880 or equivalent. 10.Clean the body side in the same way. INSTALLATION SERVICE POINTS . AB A A QUART

37、ER WINDOW GLASS/QUARTER WINDOW MOLDING REMOVAL Remove the quarter window glass using the same procedure as for windshield removal (Refer to P.42-13). INSTALLATION SERVICE POINT . A AAAA BACK DOOR WINDOW GLASS REMOVAL Remove the back door window glass using the same proce- dure as for the windshield

38、(Refer to P.42-13). REMOVAL STEPS (Continued) WINDOW GLASS TSB Revision BODY 42-19 INSTALLATION SERVICE POINT . A 1 4 2 3 5 6 7 8 9 10 27 5 Nm 20 4 ft-lb 21 4 Nm 16 2 ft-lb 21 4 Nm 16 2 ft-lb 5, 6 11 2 Nm 98 17 in-lb 11 2 Nm 98 17 in-lb AB DOOR ASSEMBLY REMOVAL STEPS 1.HARNESS CONNECTOR 2.DOOR CHECK

39、 CONNECTING BOLT 3.DOOR ASSEMBLY 4.FENDER REAR PROTECTOR 5.DOOR UPPER HINGE 6.DOOR LOWER HINGE STRIKER REMOVAL STEPS 7.STRIKER 8.STRIKER SHIM DOOR SWITCH REMOVAL STEPS 9.DOOR SWITCH CAP 10. DOOR SWITCH X1085CA AC400085 AC400225 AC205357 4, 5 27 5 Nm 20 4 ft-lb 21 4 Nm 16 2 ft-lb 21 4 Nm 16 2 ft-lb 1

40、1 2 Nm 98 17 in-lb 3 4 5 6 7 8 9 AB 1 2 11 2 Nm 98 17 in-lb DOOR ASSEMBLY REMOVAL STEPS 1.HARNESS CONNECTOR 2.DOOR CHECK CONNECTING BOLT 3.DOOR ASSEMBLY 4.DOOR UPPER HINGE 5.DOOR LOWER HINGE STRIKER REMOVAL STEPS 6.STRIKER 7.STRIKER SHIM DOOR SWITCH REMOVAL STEPS 8.DOOR SWITCH CAP 9.DOOR SWITCH DOOR

41、 TSB Revision BODY 42-31 INSPECTION M1421007600343 DOOR SWITCH CONTINUITY CHECK 1 2 3 ACX01865AB ON OFF SWITCH POSITION TESTER CONNECTION SPECIFIED CONDITION Released (ON)1 switch body, 2 switch body Less than 2 ohms Depressed (OFF)Open circuit DOOR TSB Revision BODY 42-32 DOOR TRIM AND WATERPROOF F

42、ILM REMOVAL AND INSTALLATION M1423004300275 X0083CA AC313612 AC400206 X0084CA 1 3 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 17 SEALANT: 3M AAD NO. 8633 OR EQUIVALENT AB REMOVAL STEPS 1.POWER WINDOW SWITCH AND POWER WINDOW SWITCH PANEL ASSEMBLY 2.POWER WINDOW SWITCH PANEL 3.POWER WINDOW SWITCH 4.DELTA CO

43、VER, INNER 5.DOOR LIGHT ASSEMBLY 6.DOOR INSIDE HANDLE COVER AND DOOR TRIM ASSEMBLY 7.DOOR BELT LINE MOLDING ASSEMBLY 8.DOOR TRIM 9.FRONT ARM RESTRAINT COVER 10. DOOR INSIDE HANDLE COVER 11. DOOR GRIP 12. GRIP BRACKET 13. DOOR GRIP UPPER RETAINER 14. DOOR GRIP LOWER BRACKET 15. SPEAKER 16. DOOR INSID

44、E HANDLE A VIEW A VIEW B B D D B A A C C NOTE : CLIP POSITIONS : CLAW POSITIONS AC400088X0650CAAC400089 AC400222 X0089CA X0090CA X1179CAW0737CA X0092CA X0094CA X0900CA VIEW AVIEW B DOOR LIGHT LENSPOWER WINDOW SWITCH PANEL ASSEMBLY DELTA COVER, INNER SECTION A ASECTION B BSECTION C C SECTION E ESECTI

45、ON F FSECTION G G FRONT ARM RESTRAINT COVER DOOR TRIM DOOR TRIM DOOR TRIM CLIP DOOR LIGHT LENS DOOR LIGHT LENS COVER SECTION D D CLAW POWER WINDOW SWITCH PANEL ASSEMBLY AB CLIP CLIP DOOR TRIM POWER WINDOW SWITCH PANEL ASSEMBLY CLIP DELTA COVER, INNER CLIP E E FF FF FF FF G G G G POWER WINDOW SWITCH

46、PANEL ASSEMBLY X1084CA AC313613 AC400207 X0128CA AB 2 3 1 4 5 6 7 8 9 10 11 12 14 13 16 16 15 SEALANT: 3M AAD NO. 8633 OR EQUIVALENT REMOVAL STEPS 1.POWER WINDOW SWITCH AND POWER WINDOW SWITCH PANEL ASSEMBLY 2.POWER WINDOW SWITCH PANEL 3.POWER WINDOW SWITCH 4.DOOR LIGHT ASSEMBLY 5.DOOR INSIDE HANDLE

47、 COVER AND DOOR TRIM ASSEMBLY 6.DOOR BELT LINE MOLDING ASSEMBLY 7.DOOR TRIM 8.DOOR INSIDE HANDLE COVER 9.DOOR GRIP 10. REAR ARM RESTRAINT COVER 11. DOOR GRIP BRACKET 12. DOOR GRIP UPPER RETAINER 13. DOOR GRIP LOWER BRACKET 14. SPEAKER ASSEMBLY 15. DOOR INSIDE HANDLE A B B A A NOTE : CLIP POSITIONS :

48、 CLAW POSITIONS X0650CA AC400223 X0089CA X0090CA X0092CA X0094CA X0900CA AC400090 VIEW AVIEW B DOOR LIGHT LENS SECTION A A SECTION B BSECTION C CSECTION D DSECTION E E FRONT ARM RESTRAINT COVER DOOR TRIM DOOR TRIM DOOR TRIM CLIP DOOR LIGHT LENS DOOR LIGHT LENS COVER CLAW POWER WINDOW SWITCH PANEL AS

49、SEMBLY AB CLIP CLIP DOOR TRIM POWER WINDOW SWITCH PANEL ASSEMBLY C C DD DD E E POWER WINDOW SWITCH PANEL ASSEMBLY DOOR TSB Revision BODY 42-36 REMOVAL SERVICE POINTS . POWER WINDOW SWITCH ASSEMBLY REMOVAL Y0066CA ACX00524 POWER WINDOW SWITCH PANEL ASSEMBLY MB990784 AC There is a clip (drivers side) or a claw (other sides) on the front of the power window switch assembly. Work from the front side using special tool MB990784. . DOOR