BO–1 - UNIGEobswildif/cars/docs/MR2_Spyder/00 - Body.pdf · 2020. 10. 9. · 2000 MR2 (RM760U)...
Transcript of BO–1 - UNIGEobswildif/cars/docs/MR2_Spyder/00 - Body.pdf · 2020. 10. 9. · 2000 MR2 (RM760U)...
BO0ZO–06
V00005
Shape (Example) Removal/Installation
Clip Remover
Pliers
Screwdriver
Scraper
–BODY CLIPBO–1
1201Author�: Date�:
2000 MR2 (RM760U)
CLIPREPLACEMENTThe removal and installation methods of typical clips used in body parts are shown in the table below.HINT:If the clip is damaged during the operation, always replace it with a new clip.
V00012
Shape (Example) Removal/Installation
Removal Installation
Removal Installation
BO–2–BODY CLIP
1202Author�: Date�:
2000 MR2 (RM760U)
BO0ZP–04
–BODY SRS AIRBAGBO–3
1203Author�: Date�:
2000 MR2 (RM760U)
SRS AIRBAGPRECAUTIONThe MR2 is equipped with an SRS (Supplemental Restraint System) such as the driver airbag, front passen-ger airbag and seat belt pretensioner. Failure to carry out service operation in the correct sequence couldcause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before serv-icing (including removal or installation of parts, inspection or replacement), be sure to read the precautionarynotices in the RS section.
BO1DG–03
H13942: Specified torqueN·m (kgf·cm, ft·lbf)
Front Bumper Reinforcement
Front Bumper Cover
Side Marker
22 (220, 16)
Side Marker
5.5 (56, 48 in.·lbf)
Licence Garnish
Radiator Grille
BO–4–BODY FRONT BUMPER
1204Author�: Date�:
2000 MR2 (RM760U)
FRONT BUMPERCOMPONENTS
BO1DH–03
H13944
: Specified torqueN·m (kgf·cm, ft·lbf)
Rear BumperReinforcement
Rear Combination Light
Rear Bumper Cover
Rear Combination Light
20 (200, 14)
License PlateLight
Rear BumperUpper Retainer
Rear BumperPlate
–BODY REAR BUMPERBO–5
1205Author�: Date�:
2000 MR2 (RM760U)
REAR BUMPERCOMPONENTS
BO2NB–02
H13943
Headlight
Headlight
: Specified torqueN·m (kgf·cm, ft·lbf)
Tool Box
Luggage Compartment Trim Box Cover
x18
5.5 (56, 48in.·lbf)
Front Bumper Cover
BO–6–BODY HEADLIGHT
1206Author�: Date�:
2000 MR2 (RM760U)
HEADLIGHTCOMPONENTS
BO2NC–02
H14003
H14004
–BODY HEADLIGHTBO–7
1207Author�: Date�:
2000 MR2 (RM760U)
REMOVAL1. REMOVE FRONT BUMPER COVER
(See page BO–4)2. REMOVE LUGGAGE COMPARTMENT TRIM BOX
COVER3. REMOVE TOOL BOX
4. REMOVE HEADLIGHT(a) Remove the 2 bolts and nut.(b) Disconnect the connectors, then remove the headlight as
shown in the illustration.(c) Employ the same manner described above to the other
side.
HINT:At the time of installation, please refer to the following item.If the shown part of the headlight is damaged, the headlight canbe reinstalled to the body by installing a bracket to it.
BO2ND–01
BO–8–BODY HEADLIGHT
1208Author�: Date�:
2000 MR2 (RM760U)
INSTALLATIONInstallation is in the reverse order of removal (See page BO–6).
H14538
Centering Bolt Standard Bolt
BO2NE–03
H14005
H14087
H14006
–BODY HOODBO–9
1209Author�: Date�:
2000 MR2 (RM760U)
HOODADJUSTMENTHINT:Since the centering bolt is used as the hood hinge and lock setbolt, the hood cannot be adjusted with it. Substitute the stan-dard bolt for the centering bolt.
1. ADJUST HOOD IN FORWARD/REARWARD ANDLEFT/LIGHT DIRECTIONS
(a) Adjust the hood by loosening the hood side hinge bolts.(b) Tighten the loosened bolts again.
Torque:Centering bolt: 13 N·m (130 kgf·cm, 9 ft·lbf)Standard bolt: 12 N·m (120 kgf·cm, 9 ft·lbf)
2. ADJUST FRONT EDGE OF HOOD IN VERTICALDIRECTION
Adjust the hood by turning the cushions.
3. ADJUST HOOD LOCK(a) Remove the front bumper (See page BO–4).(b) Adjust the hood lock by loosening the bolts.(c) Tighten the loosened bolts again.
Torque:Centering bolt: 8.0 N·m (80 kgf·cm, 70 in.·lbf)Standard bolt: 7.0 N·m (70 kgf·cm, 60 in.·lbf)
(d) Reinstall the removed parts.
H14538
Centering Bolt Standard Bolt
BO34Y–01
H14150
H14151
H14152
BO–10–BODY ENGINE HOOD
1210Author�: Date�:
2000 MR2 (RM760U)
ENGINE HOODADJUSTMENTHINT:Since the centering bolt is used as the hood hinge and lock setbolt, the hood cannot be adjusted with it. Substitute the stan-dard bolt for the centering bolt.
1. ADJUST HOOD IN FORWARD/REARWARD ANDLEFT/ LIGHT DIRECTIONS
(a) Adjust the hood by loosening the hood side hinge bolts.(b) Tighten the loosened bolts again.
Torque:Centering bolt: 8.0 N·m (80 kgf·cm, 70 in.·lbf)Standard bolt: 7.0 N·m (70 kgf·cm, 60 in.·lbf)
2. ADJUST FRONT EDGE OF HOOD IN VERTICALDIRECTION
Adjust the hood by turning the cushions.
3. ADJUST HOOD LOCK(a) Adjust the hood lock by loosening the bolts.(b) Tighten the loosened bolts again.
Torque: 17.5 N·m (180 kgf·cm, 13 ft·lbf)
BO1DJ–03
H14548
Door GlassFemale Stabilizer Key Cylinder
Outside Handle Door Glass Outer Rear View Mirror
Tweeter Speaker
Door Lock Link ClampDoor LockStriker
Window Regulator Motor
Cover Plate
Front LowerFrame
Door HingeSetting Nut
Lower Plate
Window Regulator
Power Door Lock�
Front DoorWeatherstrip
Door Check
Front Door Belt Moulding
Upper Window Stoper
No. 2 Door Inside Handle Bezel
Door Trim
Plug Hole Cover
Speaker
Door Inside Handle
Service Hole Cover
Front DoorInner Weatherstrip
Shim
: Specified torqueN·m (kgf·cm, ft·lbf)
� Precoated Part
5.4 (55, 48 in.·lbf)
23 (230, 17)
5.5 (55, 49 in.·lbf)
26 (260, 19)
Door Assist Grip
Assist Grip Cover
Door Assist Cover
Tweeter Speaker Coverw/ Tweeter Speaker
w/ Tweeter Speaker
13 (130, 10)
5 (50, 44 in.·lbf)
8 (80, 70 in.·lbf)
7 (70, 60 in.·lbf)
40 (410, 29)
5 (50, 44 in.·lbf)
26 (260, 19)
–BODY FRONT DOORBO–11
1211Author�: Date�:
2000 MR2 (RM760U)
FRONT DOORCOMPONENTS
BO34J–01
H13936
H139357 Clips
Door Armrest Cover
Assist Grip Cover
Plug Hole Cover
H13938
BO–12–BODY FRONT DOOR
1212Author�: Date�:
2000 MR2 (RM760U)
DISASSEMBLY1. REMOVE NO. 2 DOOR INSIDE HANDLE BEZEL(a) Using a screwdriver, remove the No. 2 door inside handle
bezel.HINT:Tape the screwdriver tip before use.(b) Remove the screw.(c) Using a screwdriver, remove the inside handle bezel as
shown in the illustration.HINT:Tape the screwdriver tip before use.
2. REMOVE DOOR TRIM(a) w/ Tweeter speaker:
Using a screwdriver, remove the tweeter speaker cover.HINT:Tape the screwdriver tip before use.(b) Using a screwdriver, remove the plug hole cover and
screw.HINT:Tape the screwdriver tip before use.(c) Using a screwdriver, remove the door armrest cover and
assist grip cover.HINT:Tape the screwdriver tip before use.(d) Remove the 2 screws.(e) Insert a screwdriver between the door panel and door trim
to pry the trim out.HINT:Tape the screwdriver tip before use.
(f) Pull the trim upward to remove it, then disconnect thelocking cable and open cable from the door inside handle.
HINT:At the time of reassembly, please refer to the following items.� Check that a ball at the end of the locking cable is pressed
(The cable should be locked.).� Turn the locking knob of the inside handle fully to the lock
side and install the locking cable.(g) Remove the screw and door inside handle from the door
trim.
H14101Clip
H13939
15 Clips
H13940
Protective Tape
Clip
–BODY FRONT DOORBO–13
1213Author�: Date�:
2000 MR2 (RM760U)
(h) Using a screwdriver, remove the front door inner weather-strip from the door trim.
3. w/ Tweeter speaker:REMOVE TWEETER SPEAKER
4. REMOVE SERVICE HOLE COVERRemove the 3 clips and service hole cover.NOTICE:Do not tear the cover.HINT:At the time of reassembly, please refer to the following item.Bring out the 2 cables and wire harness through the slits of ser-vice hole cover.
5. REMOVE FRONT DOOR WEATHERSTRIP(a) Using a clip remover, remove the 6 clips.(b) Using a screwdriver, remove the front door weatherstrip.HINT:Tape the screwdriver tip before use.
6. REMOVE FRONT DOOR BELT MOULDING(a) Using a clip remover, remove the clip.(b) Using a moulding remover, remove the front door belt
moulding.HINT:Apply protective tape to the outer surface to keep the surfacefrom being scratched.
H13941
H14010
H14007
Lower Plate
Setting Nut
Snap Lower Plate
Snap
H14142
BO–14–BODY FRONT DOOR
1214Author�: Date�:
2000 MR2 (RM760U)
7. REMOVE UPPER WINDOW STOPSRemove the 2 bolts and 2 upper window stops.
Torque: 13 N·m (130 kgf·cm, 10 ft·lbf)
8. REMOVE DOOR GLASS(a) Close the door glass until the nuts appear in the service
hole.(b) Remove the nut and 2 bolts.
Torque:Nut: 8 N·m (80 kgf·cm, 70 in.·lbf)Bolt: 7 N·m (70 kgf·cm, 60 in.·lbf)
(c) Take the door glass out of the panel carefully.NOTICE:Be careful not to drop the door glass.HINT:At the time of reassembly, please refer to the following item.Insert a shop rag inside the panel to prevent the glass from be-ing scratched.
9. REMOVE WINDOW REGULATOR(a) Remove the bolt of lower plate.
Torque: 5 N·m (50 kgf·cm, 44 in.·lbf)(b) Unlock the snap by pulling the lower plate.(c) Remove the snap and lower plate from the stud bolt of
lower bracket.(d) Remove the setting nut.(e) Disconnect the connector.(f) Remove the 2 nuts and window regulator.
Torque: 5.5 N·m (55 kgf·cm, 48 in.·lbf)10. If replacing window regulator:
REMOVE WINDOW REGULATOR FROM MOTOR(a) Remove the 2 screws and cover plate.(b) Using needle nose pliers, remove the drum and wire
guide from the motor.NOTICE:Do not use a screwdriver etc. to remove them.
H14008
H14009
H14141
–BODY FRONT DOORBO–15
1215Author�: Date�:
2000 MR2 (RM760U)
11. REMOVE SPEAKER(a) Remove the 3 bolts and speaker.(b) Disconnect the connector.
12. REMOVE DOOR GLASS FEMALE STABILIZERRemove the screw and door glass female stabilizer.
Torque: 13 N·m (130 kgf·cm, 10 ft·lbf)
13. REMOVE FRONT LOWER FRAME(a) Remove the bolt and nut.(b) Disengage the clamp of door wire harness from the front
lower frame.(c) Remove the front lower frame through the service hole.(d) Remove the door glass run from the lower frame.
14. REMOVE DOOR LOCK(a) Disconnect the 2 links from the outside handle and key
cylinder.(b) Disconnect the connector and remove the 3 screws.
Torque: 5 N·m (50 kgf·cm, 44 in.·lbf)HINT:� At the time of reassembly, please refer to the following
item.� Apply adhesive to 3 screws.
Adhesive: Part No. 08833–00070, THREE BOND 1324or equivalent
(c) Remove the door lock through the service hole.(d) Remove the door lock link clamp.
H14139
BO–16–BODY FRONT DOOR
1216Author�: Date�:
2000 MR2 (RM760U)
HINT:� At the time of reassembly, please refer to the following
item.� Apply MP grease to the sliding and rotating parts of the
door lock.15. REMOVE OUTER MIRROR(a) Remove the 2 nuts.(b) Remove the connector and mirror.16. REMOVE OUTSIDE HANDLE(a) Remove the 2 bolts and outside handle with key cylinder.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)(b) Remove the bolt and key cylinder from the outside han-
dle.Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
BO1DL–03
H14242
b – bc – c
a – a
a
b
cbc
3.5 mm(0.138 in.)
1.7 mm (0.067 in.)
13.3 mm (0.524 in.)
7.4 mm(0.291 in.)
11.4 mm(0.449 in.)
13.3 mm (0.524 in.)
a
AA: 70 mm (2.756 in.)
–BODY FRONT DOORBO–17
1217Author�: Date�:
2000 MR2 (RM760U)
INSPECTIONINSPECT FRONT DOOR GLASSCheck the following. If the conditions are not met, readjust theglass.
(1) When you close the door with the glass fully closed,the a–a, b–b, c–c sections are in the same conditionas shown in the illustration.
(2) When you close the door with the glass fully closed,check that the weatherstrip is not pinched and thatthe door glass is not in contact with the roof dripmoulding.
(3) When the door glass is fully closed, check that theoutside edge of the door glass is in contact with theweatherstrip at the front pillar and roof side and thatthe edge of the glass cannot be seen.
(4) Check that the door glass is not loose when it is halfopen.
(5) When the door glass is rising up, check that the doorglass and roof side weatherstrip are parallel andthat the door glass contacts the 2 upper stops.
(6) Check that the door glass moves up and downsmoothly over all areas.
BO1DM–03
H14538
Centering Bolt Standard Bolt
H14088
SST
H14089
SST
N17571
H14018
BO–18–BODY FRONT DOOR
1218Author�: Date�:
2000 MR2 (RM760U)
ADJUSTMENT1. FRONT DOOR ADJUSTMENTHINT:Since the centering bolt is used as the door side hinge bolt, thedoor hinge cannot be adjusted with it. Substitute the standardbolt for the centering bolt.
(a) Adjust the front door in forward/rearward and verticaldirections.Using SST, adjust the door by loosening the body sidehinge bolts.SST 09812–00010Torque:Upper bolt: 40 N·m (410 kgf·cm, 29 ft·lbf)Lower bolt: 26 N·m (270 kgf·cm, 19 ft·lbf)
(b) Adjust the front door in left/right and vertical directions.Adjust the door by loosening the door side hinge bolts.Torque: 26 N·m (270 kgf·cm, 19 ft·lbf)
(c) Adjust the front door lock striker.(1) Check the door fit and that door lock linkages are
adjusted correctly.(2) Adjust the striker position by slightly loosening the
striker mounting screws and hitting the striker witha hammer.
(3) Tighten the striker mounting screws again.Torque: 23 N·m (230 kgf·cm, 17 ft·lbf)
2. ADJUST FRONT DOOR GLASS(a) Adjust the upper part of the glass inward/outward.
(1) Remove the bolt and lower plate.(2) Pull the lower plate so that the snap is unlocked.(3) Remove the snap and lower plate.(4) Adjust the glass by turning the setting nut.(5) Reinstall the lower plate, snap and bolt.Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf)
H14019
H14020
H14021
–BODY FRONT DOORBO–19
1219Author�: Date�:
2000 MR2 (RM760U)
(b) Adjust the lower part of the glass inward/outward.(1) Loosen the 2 nuts on the top of the window regula-
tor.(2) Insert the shim to adjust the glass position (inside/
outside).Shim thickness:1.0 mm (0.039 in.)2.0 mm (0.079 in.)(3) Tighten the 2 nuts.Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf)
(c) Adjust the glass to the proper position (forward/rearward).Loosen the 3 nuts of the carrier plate for adjustment.
(d) Adjust the glass to the proper position vertically (With theglass fully closed).Adjust the door window upper stops.Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
BO2OK–02
BO–20–BODY FRONT DOOR
1220Author�: Date�:
2000 MR2 (RM760U)
REASSEMBLYReassembly is in the reverse order of disassembly (See page BO–12).
BO1DT–03
H14024
Wiper Arm
Wiper Motor
Wiper Link Assembly: Specified torqueN·m (kgf·cm, ft·lbf)
Wiper Arm Head Cap
20 (200, 15)
20 (200, 15)
5.4 (55, 48 in.·lbf)
5.4 (55, 48 in.·lbf)Washer Nozzle
Luggage Compartment Trim Box Cover
Tool Box
x18
–BODY FRONT WIPER AND WASHERBO–21
1221Author�: Date�:
2000 MR2 (RM760U)
FRONT WIPER AND WASHERCOMPONENTS
BO2NG–02
H14022
6 Clips
H14050
H14023
H00575
BO–22–BODY FRONT WIPER AND WASHER
1222Author�: Date�:
2000 MR2 (RM760U)
REMOVAL1. REMOVE WIPER ARMSRemove the 2 wiper arm head caps, 2 nuts and 2 wiper arms.
2. REMOVE COWL TOP VENTILATOR LOUVER(a) Remove the 6 clips and 5 screws.(b) Using a screwdriver, remove the cowl top ventilator lou-
ver.HINT:Tape the screwdriver tip before use.3. REMOVE LUGGAGE COMPARTMENT TRIM BOX
COVER4. REMOVE TOOL BOX
5. REMOVE WIRER MOTOR ASSEMBLY(a) Disconnect the connector.(b) Remove the 4 bolts and disconnect the wiper motor as-
sembly.(c) Disconnect the wiper link from the wiper motor assembly.
6. REMOVE WIPER LINK ASSEMBLYRemove 6 bolts and wiper link.
7. REMOVE WINDOW WASHER NOZZLE(a) Remove the hose from the nozzle.(b) Using a screwdriver, remove the nozzle.HINT:Tape the screwdriver tip before use.(c) Employ the same manner described above to the other
side.
BO2NH–02
H14470
C
A
BF
E
G
H
II
JJ
D
–BODY FRONT WIPER AND WASHERBO–23
1223Author�: Date�:
2000 MR2 (RM760U)
INSPECTIONINSPECT WASHER NOZZLEWhile operating the washer, check that points where the wash-er fluid from the nozzles hits the windshield and applies greatamount on certain area is within the range indicated by thehatched line, the washer nozzle is operating normally.
A: 263.2 mm (10.362 in.)B: 256.7 mm (10.106 in.)C: 379.2 mm (14.929 in.)D: 150.4 mm (5.921 in.)E: 405.2 mm (15.952 in.)F: 201.6 mm (7.937 in.)G: 182.2 mm (7.173 in.)H: 406.5 mm (16.003 in.)I: 150.0 mm (5.905 in.)J: 50 mm (1.968 in.)
BO1DW–03
BE3367
2.0 – 2.5 mm(0.079 – 0.098 in.)
0.70 – 0.75 mm(0.028 – 0.030 in.)
BO–24–BODY FRONT WIPER AND WASHER
1224Author�: Date�:
2000 MR2 (RM760U)
ADJUSTMENTADJUST FRONT WASHER NOZZLEUsing a tool like the one shown in the illustration, change thedirection of the nozzle hole to adjust the point where washerfluid hits the windshield.
BO34K–01
H14023
H14022
6 Clips
H12666
AA
–BODY FRONT WIPER AND WASHERBO–25
1225Author�: Date�:
2000 MR2 (RM760U)
INSTALLATION1. INSTALL WINDOW WASHER NOZZLE
2. INSTALL WIPER LINK ASSEMBLYInstall the wiper link with the 6 bolts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)3. INSTALL WIPER MOTOR(a) Install the wiper motor with the 4 bolts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)(b) Connect the wiper link to the wiper motor.(c) Connect the connector.4. INSTALL LUGGAGE COMPARTMENT TRIM BOX
COVER5. INSTALL TOOL BOX
6. INSTALL COWL TOP VENTILATOR LOUVERInstall the cowl top ventilator louver with the 5 screws and 6clips.HINT:Check that the 6 clips on the back side of the cowl top ventilatorlouver are surely fixed to the body.7. INSTALL WIPER ARMS(a) Operate the wipers once and turn the wiper switch OFF.(b) Install the wiper arms and tighten the nuts by hand.
(c) Adjust the installation positions of the wiper arms to thepositions as shown in the illustration.A: 25 – 40 mm (0.98 – 1.57 in.)
(d) Torque the nuts.Torque: 20 N·m (200 kgf·cm, 15 ft·lbf)
(e) Install the wiper arm head cap.
BO2NL–02
H14090
Front Convertible Roof Weatherstrip
Roof Drip Side MouldingRoof Drip Side Moulding
BO–26–BODY ROOF DRIP SIDE MOULDING
1226Author�: Date�:
2000 MR2 (RM760U)
ROOF DRIP SIDE MOULDINGCOMPONENTS
BO2NM–02
H14091
H14092
–BODY ROOF DRIP SIDE MOULDINGBO–27
1227Author�: Date�:
2000 MR2 (RM760U)
REMOVAL1. REMOVE FRONT CONVERTIBLE ROOF WEATH-
ERSTRIP(a) Using a clip remover, remove the 6 clips.(b) Remove the front convertible roof weatherstrip.
2. REMOVE ROOF DRIP SIDE MOULDINGSRemove the 3 screws and roof drip side moulding. Remove theLH and RH mouldings.
BO34L–01
H14092
BO–28–BODY ROOF DRIP SIDE MOULDING
1228Author�: Date�:
2000 MR2 (RM760U)
INSTALLATION1. CLEAN BODY MOUNTING SURFACE(a) Using a heat light, heat the body mounting surface to 40
– 60°C (104 – 140°F).NOTICE:Do not heat the body excessively.(b) Remove the adhesive tape from the body.(c) Wipe off stains with cleaner.2. If reusing the moulding:
CLEAN MOULDING(a) Using a heat light, heat the moulding to 20 – 30°C (68 –
86°F).NOTICE:Do not heat the moulding excessively.(b) Remove the adhesive tape from the moulding.(c) Wipe off stains with cleaner.(d) Apply a new adhesive tape to the moulding.
3. INSTALL ROOF DRIP SIDE MOULDINGInstall the roof drip side moulding with the 3 screws.
H14237H14091 H14387
Butyl Tape
Butyl Tape
–BODY ROOF DRIP SIDE MOULDINGBO–29
1229Author�: Date�:
2000 MR2 (RM760U)
4. INSTALL FRONT CONVERTIBLE ROOF WEATH-ERSTRIP
Install the front convertible roof weatherstrip with the 6 clips asshown in the illustration.
BO1E9–03
H14094
Map Light Assembly
Sun Visor
Map Light CoverSun Visor
No. 1 Stopper
Dam
Front Pillar Garnish
Windshield Outside Moulding
Wiper Arm
Wiper Arm Head Cap
Front Pillar Garnish
Cowl Top Ventilator Louver
Windshield Glass No. 2 Stopper
Removable Roof Hook
�
�
�
�
: Specified torque� Non–reusable partN·m (kgf·cm, ft·lbf)
20 (200, 15)
Removable Roof Hook
Front Roof Headlining Trim
No. 1 Stopper�
BO–30–BODY WINDSHIELD
1230Author�: Date�:
2000 MR2 (RM760U)
WINDSHIELDCOMPONENTS
BO34M–01
H14022
: 6 Clips
H14012
: 2 Clips
H14013
H14014: 2 Clips
–BODY WINDSHIELDBO–31
1231Author�: Date�:
2000 MR2 (RM760U)
REMOVAL1. REMOVE WIPER ARMSRemove the wiper arm head cap, 2 nuts and 2 wiper arms.
2. REMOVE COWL TOP VENTILATOR LOUVER(a) Remove the 5 screws and 6 clips.(b) Using a screwdriver, remove the cowl top ventilator lou-
ver.HINT:Tape the screwdriver tip before use.3. REMOVE REMOVABLE ROOF HOOKRemove the 2 screws and removable roof hook.
4. REMOVE FRONT PILLAR GARNISHS(a) Using a screwdriver, remove the front pillar garnish.HINT:Tape the screwdriver tip before use.(b) Employ the same manner described above to the other
side.5. REMOVE SUN VISORSRemove the 4 screws and sun visors.
6. REMOVE MAP LIGHT ASSEMBLY(a) Using a screwdriver, remove the map light cover.HINT:Tape the screwdriver tip before use.(b) Remove the 2 screws and map light assembly, then dis-
connect the connector.
7. REMOVE FRONT ROOF HEADLINING TRIMUsing a screwdriver, remove the front roof headlining.HINT:Tape the screwdriver tip before use.8. REMOVE INNER REAR VIEW MIRROR ASSEMBLY
H14011
BO5232
BO1689
Plastic Sheet
Protective Tape
BO–32–BODY WINDSHIELD
1232Author�: Date�:
2000 MR2 (RM760U)
9. REMOVE WINDSHIELD OUTSIDE MOULDING(a) Using a knife, cut off the moulding as shown in the illustra-
tion.NOTICE:Do not damage the body with the knife.(b) Remove the remaining moulding.
10. REMOVE WINDSHIELD GLASS(a) Insert a piano wire between the body and glass, let it pass
through.(b) Tie both wire ends to wooden blocks or similar objects.NOTICE:Be careful not to damage the wire harness.
(c) Cut the adhesive by pulling the piano wire around it.NOTICE:When separating the glass, take care not to damage thepaint and exterior ornaments. To prevent the safety padfrom being scratched when removing the windshield,place a plastic sheet between the piano wire and safetypad.HINT:Apply protective tape to the outer surface to keep the surfacefrom being scratched.(d) Remove the glass.NOTICE:Leave the adhesive on the body as much as possible whencutting off the glass.
BO4420
Adhesive
BO34N–01
BO5231
H14015
15 mm (0.59 in.)
Stopper
H14016
B
A – A
B – B
A
A
B
7 mm (0.28 in.)18.6 mm (0.73 in.)
BB
Dam
–BODY WINDSHIELDBO–33
1233Author�: Date�:
2000 MR2 (RM760U)
INSTALLATION1. CLEAN AND SHAPE CONTACT SURFACE OF BODY(a) Using a knife, cut away any rough areas on the body.HINT:Leave the adhesive on the body as much as possible.(b) Clean the cut surface of the adhesive with a shop rag sat-
urated in cleaner.HINT:Even if all the adhesive has been removed, clean the body.
2. CLEAN REMOVED GLASS(a) Remove the damaged the No. 2 stoppers and dams.(b) Using a scraper, remove the adhesive sticking to the
glass.(c) Clean the glass with cleaner.NOTICE:� Be careful not to damage the glass.� Do not touch the glass face after cleaning it.
3. INSTALL NEW NO. 1 STOPPERSAttach new stoppers to the glass so that the ceramic notcheson the glass will align with the stoppers as shown in the illustra-tion.HINT:Make sure that the stoppers are installed facing the correctdirection.
4. INSTALL NEW DAMSInstall new dams with double–stick tape as shown in the illustra-tion.
H04300Reference Marks
BO4421
H02865
Primer M
Adhesive
Primer M
H00471
Primer G
BO–34–BODY WINDSHIELD
1234Author�: Date�:
2000 MR2 (RM760U)
5. POSITION GLASS(a) Place the glass in the correct position.(b) Check that all contacting parts of the glass rim are set per-
fectly even.(c) Place reference marks on the glass and body.(d) Remove the glass.
6. CLEAN CONTACT SURFACE OF GLASSUsing a cleaner, clean the contact surface which is black–col-ored area around the entire glass rim.NOTICE:Do not touch the glass face after cleaning it.
7. COAT CONTACT SURFACE OF BODY WITH PRIMER”M”
Using a brush, apply Primer M to the exposed part of the bodyon the vehicle side.NOTICE:� Allow 3 minutes or more to dry the primer coated sur-
face.� Do not apply Primer M to the adhesive.� Do not keep any of the opened Primer M for later use.
8. COAT CONTACT SURFACE OF GLASS WITH PRIMER”G”
(a) Using a brush or sponge, coat the edge of the glass andthe contact surface with Primer G as shown in the illustra-tion.
(b) When the primer is applied inappropriaely to the area oth-er than the specified, wipe it off with a clean shop rag be-fore the primer dries.
NOTICE:� Allow 3 minutes or more to dry the primer coated sur-
face.� Do not keep any of the opened Primer G for later use.
9. APPLY ADHESIVE(a) Cut off the tip of the cartridge nozzle.
Part No. 08850–00801 or equivalentHINT:After cutting off the tip, use all adhesive within the time de-scribed in the table on next page.
H00464
A
BDam
Adhesive
BO2821Reference Marks
H00679
H14017
Windshield GlassWindshieldMoulding
Body
–BODY WINDSHIELDBO–35
1235Author�: Date�:
2000 MR2 (RM760U)
Temperature Tackfree time
35°C (95°F) 15 minutes
20°C (68 F) 100 minutes
5°C (41°F) 8 hours
(b) Load the cartridge into the sealer gun.
(c) Coat the glass with adhesive as shown in the illustration.A: 12.5 mm (0.492 in.)B: 8.0 mm (0.315 in.)
10. INSTALL WINDSHIELD GLASS AND MOULDING(a) Install the glass, aligning the reference marks using a suc-
tion rubber.HINT:Check to see that the stoppers are attached to the body correct-ly.(b) Lightly press the glass front surface for close contact.
(c) Correct insufficient or protruded adhesive agent using aspatula.
HINT:Apply the adhesive agent up to the windshield glass edge.
(d) Install a new windshield moulding to the windshield glassbefore the adhesive agent hardens.
HINT:Install the moulding, aligning the center of moulding with thecenter of the body.(e) Remove any excessive adhesive agent before it hardens.(f) Hold the glass and moulding in place securely with a pro-
tective tape or equivalent until the adhesive hardens.
H12666
A A
BO–36–BODY WINDSHIELD
1236Author�: Date�:
2000 MR2 (RM760U)
NOTICE:Take care not to drive the vehicle during the time describedin the table below.
Temperature Minimum time prior to driving the vehicle
35°C (95°F) 1.5 hours
20°C (68°F) 5 hours
5°C (41°F) 24 hours
11. INSPECT FOR LEAK AND REPAIRNOTICE:Conduct a leak test after the hardening time has elapsed.12. INSTALL INNER REAR VIEW MIRROR13. INSTALL FRONT ROOF HEADLINING TRIM14. INSTALL MAP LIGHT ASSEMBLY15. INSTALL SUN VISORS16. INSTALL FRONT PILLAR GARNISHS17. INSTALL COWL TOP VENTILATOR LOUVERHINT:Check that the 6 clips on the back side of the cowl louver aresurely fixed to the body.18. INSTALL WIPER ARMS(a) Operate the wiper motor once and turn the wiper switch
OFF.(b) Install the wiper arms and tighten the nuts by hand.
(c) Adjust the installation positions A of the wiper arms to thepositions as shown in the illustration.A: 25 – 40 mm (0.98 – 1.57 in.)
(d) Torque the nuts.Torque: 20 N·m (200 kgf·cm, 15 ft·lbf)
(e) Install the wiper arm head cap.
BO34O–01
H14026
Passenger Airbag Cutoff Switch
Glove CompartmentDoor
Knob
Steering Wheel
Front Pillar Garnish
Hood ReleaseLever
Combination Meter
Column UpperCover
Instrument PanelLower Pad Insert
Instrument Cluster Finish Panel
Front Pillar Garnish
Column LowerCover
Steering Wheel Pad
RemovableRoof Hook
L
C
C
O
Door Scuff Plate
Cowl SideTrim
Door Scuff Plate
Cowl SideTrim
C
: Specified torqueN·m (kgf·cm, ft·lbf)
L
F
F
F
No.1 Instrument PanelLower mount Bracket
34 (350, 25)
Instrument Panel
20 (205, 15)
20 (205, 15)
Front Passenger AirBag Assembly
N
ReinforcementM
MB
M
M
F
C
Heater Control Assembly
Center Instrument Cluster Finish Panel
O
–BODY INSTRUMENT PANELBO–37
1237Author�: Date�:
2000 MR2 (RM760U)
INSTRUMENT PANELCOMPONENTS
H14472
No. 2 Instrument PanelBrace Outer Cover
Ash ReceptacleOuter Case
Ash Receptacle Box
Cup HolderNo. 3 Instrument PanelBrace Inner Cover
No. 3 Instrument PanelBrace Inner Cover
No. 1 InstrumentPanel Brace
Ash ReceptacleRetainer
M
F
F
Stereo Player Finish Panel
No. 1 Instrument PanelBrace Outer CoverNo. 1 Instrument
Panel Brace
M
F
No. 2 Instrument PanelBrace Outer Cover
No. 1 Instrument PanelBrace Outer Cover
Stereo Player
F
BO–38–BODY INSTRUMENT PANEL
1238Author�: Date�:
2000 MR2 (RM760U)
H14053
K
K
K
Defroster NozzleNo. 2 Heater to Register Duct
No. 3 Register
No. 2 Register
Light ControlRheostat
No. 1 Register
No. 1 Heater to Register Duct
Console Box
Shifting Hole Cover
Power WindowSwitch
Console BoxHole Cover
Remote ControlMirror Switch
Fuse Box OpeningCover
Window LockSwitch
Door LockSwitch
Coin Holder
Center InstrumentPanel Bracket
K
K
K
KKK
KK
K
K
K
KK
F
FF
–BODY INSTRUMENT PANELBO–39
1239Author�: Date�:
2000 MR2 (RM760U)
H14402
Shape Size Shape Size Shape Size
ø = 8(0.32)L = 16(0.63)
ø = 8(0.32)L = 15(0.59)
ø = 6(0.24)L = 22(0.87)
ø = 6(0.24)L = 16(0.63)
ø = 6(0.24)L = 18(0.71)
ø = 5.22(0.2055)L = 16(0.63)
ø = 8(0.32)
ø = 6(0.24)
mm (in.)
ø =5.22(0.2055)L = 16(0.63)
ø = 5(0.20)L = 18(0.71)
ø = 5(0.20)L = 16(0.63)
ø = 5(0.20)L = 16(0.63)
ø = 5(0.20)L = 14(0.55)
ø = 4(0.16)L = 16(0.63)
ø = 6(0.24)L = 20(0.78)
BO–40–BODY INSTRUMENT PANEL
1240Author�: Date�:
2000 MR2 (RM760U)
HINT:Screw shapes and sizes are indicated in the table below. The codes (”A” – ”O”) correspond to those indicatedon the previous page.
BO34P–01
H140274 Clips
H140284 Clips
H14029
–BODY INSTRUMENT PANELBO–41
1241Author�: Date�:
2000 MR2 (RM760U)
REMOVAL1. REMOVE STEERING WHEEL PAD AND STEERING
WHEEL (See page SR–10)2. REMOVE DOOR SCUFF PLATES3. REMOVE COWL SIDE TRIMS
4. REMOVE NO. 1 LOWER FINISH PANEL(a) Remove the bolt, screw and DLC3.(b) Using a screwdriver, remove the No. 1 lower finish panel.HINT:Tape the screwdriver tip before use.5. REMOVE INSTRUMENT PANEL LOWER PAD INSERT6. REMOVE COLUMN COVERSRemove 3 screws and upper and lower column covers.7. REMOVE SPIRAL CABLE (See page SR–10)8. REMOVE WIPER AND WASHER SWITCH AND LIGHT
CONTROL SWITCH AND HEADLIGHT DIMMERSWITCH (See page SR–10)
9. REMOVE INSTRUMENT CLUSTER FINISH PANELUsing a screwdriver, remove the cluster finish panel.HINT:Tape the screwdriver tip before use.
10. REMOVE COMBINATION METER(a) Remove the 3 screws and combination meter.(b) Disconnect the connectors.
I16284
I156564 Cips
H144953 Clips
H14048
BO–42–BODY INSTRUMENT PANEL
1242Author�: Date�:
2000 MR2 (RM760U)
11. REMOVE GLOVE COMPARTMENT DOOR(a) Open the glove compartment door.(b) Push both sides inward and pull out the glove compart-
ment door.12. REMOVE PASSENGER AIRBAG ASSEMBLY
(See page RS–26)13. REMOVE PASSENGER AIRBAG MANUAL ON–OFF
SWITCH (See page RS–26)14. REMOVE HOOD RELEASE LEVER
15. REMOVE CENTER INSTRUMENT CLUSTER FINISHPANEL
(a) Remove the 4 knobs.(b) Remove the 2 screws.(c) Using a screwdriver, remove the center cluster finish pan-
el.HINT:Tape the screwdriver tip before use.(d) Disconnect the clock connector from the clock.
16. REMOVE ASH RECEPTACLE OUTER CASE AND STE-REO PLAYER FINISH PANEL
(a) Remove the ash receptacle box.(b) Remove the 2 bolts ash receptacle retainer.(c) Using a screwdriver, remove the ash receptacle outer
case.HINT:Tape the screwdriver tip before use.(d) Using a screwdriver, remove the stereo finish panel.HINT:Tape the screwdriver tip before use.
17. REMOVE NO. 1 AND NO. 2 INSTRUMENT PANELBRACE OUTER COVERS AND NO.3 INSTRUMENTPANEL BRACE INNER COVERS
(a) Using a screwdriver, remove the No. 2 instrument panelbrace outer covers and No. 3 instrument panel brace in-ner covers.
HINT:Tape the screwdriver tip before use.
I15657
H14012:2 Clips
H14051
H14052
–BODY INSTRUMENT PANELBO–43
1243Author�: Date�:
2000 MR2 (RM760U)
(b) Remove the 4 screws and No. 1 instrument panel braceouter covers.
(c) Remove the 4 screws and stereo.18. DISCONNECT HEATER CONTROL CABLES
(See page AC–83)NOTICE:When the air mix damper control cables are disconnected,be careful not to bend the cables.
19. REMOVE HEATER CONTROL ASSEMBLY(a) Remove the 4 screws and control assembly.(b) Disconnect the 2 connectors.20. REMOVE STEERING COLUMN (See page SR–10)
21. REMOVE FRONT PILLAR GARNISHS(a) Remove the 2 screws and removable roof hook.(b) Using a screwdriver, remove the front pillar garnish.HINT:Tape the screwdriver tip before use.(c) Employ the same manner described above to the other
side.
22. REMOVE INSTRUMENT PANEL(a) Remove the nut, screw and No. 1 instrument panel lower
mount bracket.(b) Remove the 2 screws and center instrument panel brack-
et.(c) Disconnect the connectors.(d) Disengage the wire harness clamps.(e) Remove the 5 bolts, nut, screw and instrument panel.23. REMOVE NO. 1 AND NO. 2 BRACES
24. REMOVE REINFORCEMENT(a) Disconnect the connector.(b) Disengage the wire harness clamps.(c) Remove the 3 bolts, 5 nuts and reinforcement.
H14054
Side BrakeCover
BO–44–BODY INSTRUMENT PANEL
1244Author�: Date�:
2000 MR2 (RM760U)
25. REMOVE CONSOLE BOX(a) Remove the seat (See page BO–49).(b) Remove the shift knob.(c) Remove the side brake cover.(d) Remove the 4 screws and console box.(e) Disconnect the power window switch connector.
BO2O6–02
–BODY INSTRUMENT PANELBO–45
1245Author�: Date�:
2000 MR2 (RM760U)
DISASSEMBLY1. REMOVE INSTRUMENT PANEL WIRE2. REMOVE NO. 1 HEATER TO REGISTER DUCT3. REMOVE NO. 2 HEATER TO REGISTER DUCT4. REMOVE NO. 3 HEATER TO REGISTER DUCT5. REMOVE NO. 1 INSTRUMENT PANEL RESISTER6. REMOVE NO. 2 INSTRUMENT PANEL RESISTER7. REMOVE NO. 3 INSTRUMENT PANEL RESISTER8. REMOVE LIGHT CONTROL RHEOSTAT9. REMOVE WINDOW LOCK SWITCH10. REMOVE CONTROL MIRROR SWITCH
BO2O7–02
BO–46–BODY INSTRUMENT PANEL
1246Author�: Date�:
2000 MR2 (RM760U)
REASSEMBLYReassembly is in the reverse order of disassembly (See page BO–45).
BO2O8–02
–BODY INSTRUMENT PANELBO–47
1247Author�: Date�:
2000 MR2 (RM760U)
INSTALLATIONInstallation is in the reverse order of removal (See page BO–41).
BO1F6–03
H14227
Seatback Pad
Seatback Cover
Seatback Frame
Hog Ring
Seat Cushion Cover
Seat Cushion Pad
Seat Cushion Frame
Reclining Connecting Pipe
Front Seat Cushion Inner Shield
Front Seat Inner Belt
E–Ring
Inner Track
Seat Track Handle Outer Track
Reclining Adjuster Release Handle
Front Seat Cushion Inner Shield
Reclining Connecting Pipe
Front Seat Cushion Shield
Reclining Adjuster Release HandleOuter Track
Seat Track Handle
Front Seat Inner Belt
w/o Vertical adjuster
w/ Vertical adjuster
21 (210, 15) 43 (440, 32)
21 (210, 15)
37 (375, 27)
43 (440, 32)
21 (210, 15)
43 (440, 32)
21 (210, 15)
43 (440, 32)
37 (375, 27)�
Hog Ring�
Front Seat Cushion Shield
: Specified torque� Non–reusable partN·m (kgf·cm, ft·lbf)
37 (375, 27)
Vertical Adjuster Knob
42 (430, 30)
42 (430, 30)
37 (375, 27)
Inner Track
Clip
BO–48–BODY FRONT SEAT
1248Author�: Date�:
2000 MR2 (RM760U)
FRONT SEATCOMPONENTS
BO1F7–03
–BODY FRONT SEATBO–49
1249Author�: Date�:
2000 MR2 (RM760U)
REMOVALREMOVE FRONT SEAT(a) Remove the 4 bolts.(b) Disconnect the connectors.(c) Remove the front seat.NOTICE:Be careful not to damage the body.
BO34Q–01
H14096
H14097
H14098
BO–50–BODY FRONT SEAT
1250Author�: Date�:
2000 MR2 (RM760U)
DISASSEMBLY1. w/ Vertical adjuster:
REMOVE VERTICAL ADJUSTER KNOBUsing a screwdriver, remove the clip and vertical adjuster knob.HINT:Tape the screwdriver tip before use.
2. REMOVE RECLINING ADJUSTER RELEASE HANDLEUsing a screwdriver, remove the reclining adjuster release han-dle.HINT:Tape the screwdriver tip before use.
3. REMOVE FRONT SEAT CUSHION SHIELDRemove the front seat cushion shield as shown in the illustra-tion.
4. REMOVE FRONT SEAT CUSHION INNER SHIELDRemove the screw and front seat cushion inner shield as shownin the illustration.5. REMOVE FRONT SEAT INNER BELT(a) Cut off the clamp and connector.(b) Remove the bolt and front seat inner belt.6. REMOVE SEAT CUSHION ASSEMBLY(a) Remove the 4 bolts and seat cushion assembly.(b) Remove the hog rings.(c) Disengage that seat cushion cover hooks and remove the
seat cushion frame.(d) Remove the hog rings between the seat cushion cover
and seat cushion pad.(e) Remove the seat cushion cover from the seat cushion
pad.7. REMOVE SEATBACK ASSEMBLY(a) Remove the hog rings.(b) Turn over the seatback cover.(c) Remove the 4 bolts and seatback assembly
H14100
–BODY FRONT SEATBO–51
1251Author�: Date�:
2000 MR2 (RM760U)
(d) Remove the hog rings between the seat back cover andthe seatback pad.
(e) Remove the seatback cover and the seatback pad fromthe seatback frame.
8. REMOVE SEAT TRACK HANDLEUsing a screwdriver, remove the seat track handle.HINT:Tape the screwdriver tip before use.9. REMOVE RECLINING CONNECTING PIPE10. DISASSEMBLE OUTER AND INNER TRACK(a) Using a screwdriver, remove the E–ring.(b) Disassemble the outer track and inner track.
BO1F9–03
BO–52–BODY FRONT SEAT
1252Author�: Date�:
2000 MR2 (RM760U)
INSPECTIONINSPECT RECLINING LOCK POSITION AND SLIDING LOCK POSITION SLIPPING OFF(a) When reclining the seat, inspect that the outer and inner recliners are released at the same time.HINT:When the reclining lock position slips off, disassemble the seat to adjust the position.(b) When sliding the seat, inspect that the outer and inner tracks are locked at the same time.HINT:When sliding lock positions slip off, loosen the bolts to adjust the position.(c) After adjusting the position, tighten the bolt.
BO34R–01
H14100
H14099
Wire Harness Protector
–BODY FRONT SEATBO–53
1253Author�: Date�:
2000 MR2 (RM760U)
REASSEMBLY1. ASSEMBLE OUTER TRACK AND INNER TRACKAssemble the outer track and inner track with a new E–ring.2. INSTALL SEAT TRACK HANDLE
3. INSTALL RECLINING CONNECTING PIPE(a) Adjust the reclining lock positions of the seat adjusters.(b) Slide the seat adjusters to the most front position.(c) Place the adjusters on a spacer to adjust the seat rail in
parallel and install the connecting pipe.HINT:When installing the connecting pipe while raising up the adjust-ers, the lock position adjusted in step–(a) may become de-tached. When this happens, locking cannot be done properly.
4. INSTALL FRONT SEAT INNER BELT(a) Pass the wire harness of the front seat inner belt through
the wire harness protector of the seat cushion assemblyand install the front seat inner belt.Torque: 42 N·m (430 kgf·cm, 30 ft·lbf)
(b) Install the front seat inner belt wire harness to the seatcushion frame.
5. INSTALL SEATBACK COVER(a) Install the seatback pad to the seatback frame.(b) Install the seatback cover to the seatback pad with new
hog rings.HINT:When installing the hog rings, take care not to have wrinkles onthe cover as much as possible.6. INSTALL SEAT CUSHION ASSEMBLY(a) Install the seat cushion cover to the seat cushion pad with
new hog rings.HINT:When installing the hog rings, take care not to have wrinkles onthe cover as much as possible.(b) Install the seat cushion frame to the seat cushion cover
with pad.(c) Engage the seat cushion hooks and install new hog rings.HINT:When installing the hog rings, take care not to have wrinkles onthe cover as much as possible.(d) Install the seat cushion assembly with the 4 bolts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
BO–54–BODY FRONT SEAT
1254Author�: Date�:
2000 MR2 (RM760U)
7. INSTALL SEAT BACK ASSEMBLY(a) Install the seatback assembly with the 4 bolts.
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)(b) Pull down the seatback cover closed.(c) Install new hog rings.HINT:When installing the hog rings, take care not to twist them asmuch as possible.8. INSTALL FRONT SEAT CUSHION INNER SHIELD9. INSTALL FRONT SEAT CUSHION SHIELD10. INSTALL RECLINING ADJUSTER RELEASE HANDLE11. w/ Vertical adjuster:
INSTALL VERTICAL ADJUSTER KNOB
BO1FB–03
–BODY FRONT SEATBO–55
1255Author�: Date�:
2000 MR2 (RM760U)
INSTALLATIONINSTALL FRONT SEAT(a) Mount the front seat to the vehicle.NOTICE:Be careful not to damage the body.(b) Connect the connectors.(c) Slide the front seat to the front most position.(d) Tighten the bolts on the rear side temporarily, starting from the bolt on the inner side, then tighten them
completely.Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
(e) Slide the seat to the rear most position to install the bolts on the front side.Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
(f) Install the seat track covers.
BO1FH–03
H14095: Specified torqueN·m (kgf·cm, ft·lbf)
42 (420, 30)Front Seat Inner Belt
42 (420, 30)
42 (420, 30)
42 (420, 30)
Door Scuff Plate 7.5 (80, 69 in.·lbf)
Quarter Trim Panel
Front SeatOuter Belt
Luggage Compartment Box
Luggage CompartmentLidLower Rear No.1 Separator
Trim Cover
Front Seat Cushion Inner Shield
BO–56–BODY SEAT BELT
1256Author�: Date�:
2000 MR2 (RM760U)
SEAT BELTCOMPONENTS
BO1FI–03
BO0632
BO0633
15°
45°
–BODY SEAT BELTBO–57
1257Author�: Date�:
2000 MR2 (RM760U)
INSPECTIONCAUTION:Replace the seat belt assembly (outer belt, inner belt, boltsand nuts) if it has been used in a severe impact. The entireassembly should be replaced even if damage is not ob-vious.1. RUNNING TEST (IN SAFE AREA)(a) Fasten the front seat belts.
(b) Drive the car at 16 km/h (10 mph) and slam on the brakes.Check that the belt locks and cannot be extended at thistime.
HINT:Conduct this test in a safe area. If the belt does not lock, removethe belt mechanism assembly and conduct the following staticcheck. Also, whenever installing a new belt assembly, verify theproper operation before installation.2. Driver’s seat belt (ELR):
STATIC TEST(a) Make sure that the belt locks when pulled out quickly.(b) Remove the locking retractor assembly.(c) Tilt the retractor slowly.
(d) Make sure that the belt can be pulled out at a tilt of 15 de-grees or less, and cannot be pulled out over 45 degreesof tilt.
If a problem is found, replace the assembly.3. Passenger ’s seat belt (ELR/ALR):
STATIC TEST(a) Make sure that the belt locks when pulled out quickly.(b) Remove the locking retractor assembly.(c) Pull out the whole belt and measure the length of the
whole belt.Then retract the belt slightly and pull it out again.
(d) Make sure that the belt cannot be extended further.If a problem is found, replace the assembly.
N10070
Full Belt Length Minus200 mm (7.87 in.)
BO0633
15°
45°
BO–58–BODY SEAT BELT
1258Author�: Date�:
2000 MR2 (RM760U)
(e) Retract the whole belt, then pull out the belt until 200 mm(7.87 in.) of belt remains retracted.
(f) Tilt the retractor slowly.
(g) Make sure that the belt can be pulled out at a tilt of 15 de-grees or less, and cannot be pulled out at over 45 degreesof tilt.
If a problem is found, replace the assembly.
BO2OE–02
H14104
: 4 Clips
H14105
H14106
: 2 Clips
H14343
–BODY SEAT BELT PRETENSIONERBO–59
1259Author�: Date�:
2000 MR2 (RM760U)
SEAT BELT PRETENSIONERREMOVALNOTICE:� If the wiring connector of the seat belt pretensioner is
disconnected with the ignition switch at ON diagnos-tic trouble codes will be recorded.
� Never use seat belt pretensioner from another ve-hicle. When replacing parts, replace them with newparts.
1. REMOVE FRONT DOOR SCUFF PLATEUsing a screwdriver, remove the front door scuff plate.HINT:Tape the screwdriver tip before use.2. REMOVE LUGGAGE COMPARTMENT LIDSRemove 6 bolts and luggage compartment lids.
3. REMOVE LOWER REAR SEPARATOR TRIM COVER(a) Remove the screw and scrip(b) Using a screwdriver, remove the lower rear separator trim
cover.HINT:Tape the screwdriver tip before use.
4. REMOVE QUARTER TRIM PANEL(a) Remove the floor anchor mounting bolt and disconnect
the front seat outer belt.(b) Remove the 2 clips.(c) Using a screwdriver, remove the quarter trim panel.HINT:Tape the screwdriver tip before use.
5. REMOVE LUGGAGE COMPARTMENT BOX(a) Remove the 2 screws.(b) Using a screwdriver, remove the luggage compartment
box.HINT:Tape the screwdriver tip before use.6. REMOVE FRONT SEAT OUTER BELT(a) Remove the shoulder anchor mounting bolt and discon-
nect the front seat outer belt.
H14149
BO–60–BODY SEAT BELT PRETENSIONER
1260Author�: Date�:
2000 MR2 (RM760U)
(b) Disconnect the pretensioner connector as shown in theillustration.
NOTICE:When removing the seat belt pretensioner, work must bestarted 90 seconds after the ignition switch is turned to the”LOCK” position and the negative (–) terminal cable is dis-connected from the battery.(c) Remove the 2 bolts and retractor of front seat outer belt.(d) Only driver’s side:
Disconnect the connector of the retractor switch.
BO2OF–02
H14401
H14144
H14145
–BODY SEAT BELT PRETENSIONERBO–61
1261Author�: Date�:
2000 MR2 (RM760U)
INSPECTION1. PRETENSIONER IS NOT ACTIVATED(a) Perform a diagnostic system check (See page DI–237).
(b) Perform a visual check which includes the following itemswith the front seat outer belt removed from the vehicle.� Check for cuts and cracks in, or marked discolor-
ation on the quarter trim panel.� Check for cuts and cracks in wire harness, and for
chipping in connectors.� Check for deformation of the center floor No. 3
crossmember.
NOTICE:For removal and installation of the front seat outer belt, seepages BO–59 and BO–68.2. PRETENSIONER IS ACTIVATED(a) Perform a diagnostic system check (See page DI–237).
(b) Perform a visual check which includes the following itemswith the front seat outer belt removed from the vehicle.� Check for deformation of the center floor No. 3
crossmember.� Check for damage on the connector and wire har-
ness.
BO2OG–02
AB0152
SST
BO–62–BODY SEAT BELT PRETENSIONER
1262Author�: Date�:
2000 MR2 (RM760U)
DISPOSALHINT:When scrapping vehicles equipped with a seat belt pretension-er or disposing of a front seat outer belt (with seat belt preten-sioner) always first activate the seat belt pretensioner in accor-dance with the procedure described below. If any abnormalityoccurs in the seat belt pretensioner operation, contact the SER-VICE DEPT. of TOYOTA MOTOR SALES, U.S.A.,INC. Whendisposing of a front seat outer belt (with seat belt pretensioner)activated in a collision, follow the same procedure given in step1–(e) in ”DISPOSAL”.
NOTICE:� Never dispose of front seat outer belt which has an in-
activated pretensioner.� The seat belt pretensioner produces a sizeable ex-
ploding sound when it activates, so perform the op-eration out–of–door and where it will not disturbnearby residents.
� When activating the seat belt pretensioner, alwaysuse the specified SST. (SRS Airbag Deployment Tool)Perform the operation in a place away from electricalnoise.SST 09082–00700, 09082–00740
� When activating a front seat outer belt (with seat beltpretensioner), perform the operation at least 10 m (33ft) away from the front seat outer belt.
� Use gloves and safety glasses when handling a frontseat outer belt with activated pretensioner.
� Always wash your hands with water after completingthe operation.
� Do not apply water, etc. to a front seat outer belt withactivated pretensioner.
AB0158
SST
Battery
AB0152
SST
AB0158
SST
Battery
H01580
SST
–BODY SEAT BELT PRETENSIONERBO–63
1263Author�: Date�:
2000 MR2 (RM760U)
1. SEAT BELT PRETENSIONER ACTIVATION WHENSCRAPPING VEHICLE
HINT:Have a battery ready as the power source to activate the seatbelt pretensioner.
(a) Check functioning of SST.NOTICE:When activating the seat belt pretensioner, always use thespecified SST: SRS Airbag Deployment Tool.
SST 09082–00700, 09082–00740
(1) Connect the SST to the battery.Connect the red clip of the SST to the battery posi-tive (+) terminal and the black clip to the battery neg-ative (–) terminal.
HINT:Do not connect the yellow connector which will be connectedwith the seat belt pretensioner.
(2) Check functioning of SST.Press the SST activation switch, and check the LEDof the SST activation switch lights up.
NOTICE:If the LED lights up when the activation switch is not beingpressed, SST malfunction is probable, so definitely do notuse the SST.(b) Disconnect the pretensioner connector.
(1) Remove the door scuff plate.(2) Remove the luggage compartment lid.(3) Remove the lower rear separator trim cover.(4) Remove the floor anchor mounting bolt and discon-
nect the front seat outer belt.(5) Remove the quarter trim panel.(6) Remove the luggage compartment box.(7) Remove the shoulder anchor mounting bolt and dis-
connect the front seat outer belt.
H14149
H14146
SST
Battery
SST
R13455
10 m (33 ft) or more
BO–64–BODY SEAT BELT PRETENSIONER
1264Author�: Date�:
2000 MR2 (RM760U)
(8) Disconnect the pretensioner connector as shown inthe illustration.
(c) Install the SST.(1) Install the floor anchor of the seat belt.
(2) Connect the 2 SST, then connect them to the seatbelt pretensioner.
SST 09082–00700, 09082–00740NOTICE:To avoid damaging the SST connector and wire harness,do not lock the secondary lock of the twin lock.
(3) Move the SST to at least 10 m (33 ft) away from thefront of the vehicle.
(4) Close all the doors and windows of the vehicle.NOTICE:Take care not to damage the SST wire harness.
(5) Connect the SST red clip to the battery positive (+)terminal and the black clip to the negative (–) termi-nal.
(d) Activate the seat belt pretensioner.(1) Confirm that no one is inside the vehicle or within 10
m (33 ft) area around of the vehicle.(2) Press the SST activation switch and activate the
seat belt pretensioner.HINT:The seat belt pretensioner operates simultaneously as the LEDof the SST activation switch lights up.(e) Dispose of front seat outer belt (with seat belt pretension-
er).NOTICE:� The front seat outer belt is very hot when the seat belt
pretensioner is activated, so leave it alone for at least30 minutes after activation.
� Use gloves and safety glasses when handling a frontseat outer belt with activated seat belt pretensioner.
� Always wash your hands with water after completingthe operation.
� Do not apply water, etc. to a front seat outer belt withactivated seat belt pretensioner.
AB0158
SST
Battery
H14146
SST
Battery
SST
H14147SST SST
–BODY SEAT BELT PRETENSIONERBO–65
1265Author�: Date�:
2000 MR2 (RM760U)
HINT:When scrapping a vehicle, activate the seat belt pretensionerand scrap the vehicle with activated front seat outer belt stillinstalled.2. ACTIVATION WHEN DISPOSING OF FRONT SEAT
OUTER BELT ONLYNOTICE:� When disposing of the front seat outer belt (with seat
belt pretensioner) only, never use the customer’s ve-hicle to activate the seat belt pretensioner.
� Be sure to follow the procedure given on the nextpage when activating the seat belt pretensioner.
HINT:Have a battery ready as the power source when activating theseat belt pretensioner.(a) Remove the front seat outer belt (See page BO–59).HINT:Cut the belt near the seat belt retractor.
(b) Check functioning of SST (See step 1–(a)).SST 09082–00700, 09082–00740
(c) Install the SST.(1) Connect the 2 SST, then connect them to the seat
belt pretensioner.SST 09082–00700, 09082–00740
NOTICE:To avoid damaging the SST connector and wire harness,do not lock the secondary lock of the twin lock.
(2) Place the front seat outer belt on the ground andcover it with the disc wheel with tire.
NOTICE:Place the front seat outer belt as shown in the illustration.
(3) Move the SST as least 10 m (33 ft) away from thedisc wheel.
NOTICE:Take care not to damage the SST wire harness.
R05181
10 m (33 ft) or more
H14148
BO–66–BODY SEAT BELT PRETENSIONER
1266Author�: Date�:
2000 MR2 (RM760U)
(d) Activate the seat belt pretensioner.(1) Connect the SST red clip to the battery positive (+)
terminal and black clip to the battery negative (–)terminal.
(2) Check that no one is within 10 m (33 ft) area aroundthe disc wheel.
(3) Press the SST activation switch and activate theseat belt pretensioner.
HINT:The seat belt pretensioner operates simultaneously as the LEDof the SST activation switch lights up.
(e) Dispose of front seat outer belt (with seat belt pretension-er).
CAUTION:� The front seat outer belt is very hot when the seat belt
pretensioner is activated, so leave it alone for at least30 minutes after activation.
� Use gloves and safety glasses when handling a frontseat outer belt with activated seat belt pretensioner.
� Always wash your hands with water after completingthe operation.
� Do not apply water, etc. to a front seat outer belt withactivated seat belt pretensioner.(1) Remove the disc wheel and SST.(2) Place the front seat outer belt in a vinyl bag, tie the
end tightly and dispose of it in the same way as oth-er general parts.
BO2OH–02
–BODY SEAT BELT PRETENSIONERBO–67
1267Author�: Date�:
2000 MR2 (RM760U)
REPLACEMENTREPLACE REQUIREMENTSIn the following cases, replace the seat belt pretensioner.
� If the seat belt pretensioner has been activated.� If the seat belt pretensioner has been found to be faulty in troubleshooting.� If the front seat outer belt has been found to be faulty during checking item 1–(a) or 2–(b).� If the front seat outer belt has been dropped.
CAUTION:For removal and installation of the seat belt pretensioner, see pages BO–59 and BO–68.Be sure to follow the correct procedure.
BO2OI–02
H14149
BO–68–BODY SEAT BELT PRETENSIONER
1268Author�: Date�:
2000 MR2 (RM760U)
INSTALLATIONNOTICE:� Never use seat belt pretensioner from another ve-
hicle. When replacing parts, replace them with newparts.
� Make sure that the front seat outer belt is installedwith the specified torque.
� If the front seat outer belt has been dropped, or thereare cracks, dents or other defects in the case or con-nector, replace the front seat outer belt with a newone.
� When installing the front seat outer belt, take care thatthe wiring does not interfere with other parts and isnot pinched between other parts.
1. INSTALL RETRACTOR OF FRONT SEAT OUTER BELT(a) Install the retractor of the front seat outer belt with the 2
bolts.Torque:Upper bolt: 7.5 N·m (76 kgf·cm, 66 in.·lbf)Lower bolt: 43 N·m (440 kgf·cm, 32 ft·lbf)
(b) Connect the pretensioner connector as shown in the il-lustration.
(c) Only driver side:Connect the retractor switch connector.
2. INSTALL FRONT SEAT OUTER BELT SHOULDER AN-CHORTorque: 42 N·m (420 kgf·cm, 30 ft·lbf)
3. INSTALL LUGGAGE COMPARTMENT BOX4. INSTALL QUARTER TRIM PANEL5. INSTALL FRONT SEAT OUTER BELT FLOOR AN-
CHORTorque: 42 N·m (420 kgf·cm, 30 ft·lbf)
6. INSTALL LOWER REAR SEPARATOR TRIM COVER7. INSTALL LUGGAGE COMPARTMENT LID8. INSTALL FRONT DOOR SCUFF PLATE
BO34S–01
H14125
Tarpaulin Assembly
Luggage Compartment Cover
Rear Belt Moulding
Window DeflectorBoard
Pull handle
Cover
Window Deflector Cover
Upper LuggageCompartment Garnish
Package TrayTrim Panel
Room Partition Board
Luggage Compartment Lid
Luggage Compartment Box
Lower Rear SeparatorTrim Cover
Ouarter Trim Panel
Scuff Plate
Lower Rear SeparatorTrim Cover
Ouarter Trim Panel
Scuff Plate
Front Top and TarpaulinSupport Frame
Side BeltMoulding
–BODY SOFT TOPBO–69
1269Author�: Date�:
2000 MR2 (RM760U)
SOFT TOPCOMPONENTS
H14103
Front Roof SideRail Weatherstrip
Center Roof DripSide Finish Moulding
Rear Roof SideRail Weatherstrip
Tarpaulin Rear RailWeatherstrip
Tarpaulin Cover Side Retainer
Upper TarpaulinCover Retainer
Tail Gate ProtectorBracket
Tail Gate Lower Seal
Tarpaulin Lock
Center Tarpaulin BowStay Catch Handle
Set Plate
Tarpaulin Lock
Side Gate Seal
Tail Gate ProtectorBracket
Tarpaulin Rear RailWeatherstrip
Center RoofDrip SideFinish Moulding
Front RoofSideRailWeatherstrip
Rear Roof Drip SideFinish Moulding
Rear Roof SideRail Weatherstrip
Tarpaulin Cover Side Retainer
: Specified torqueN·m (kgf·cm, ft·lbf)� Precoated Part
�
�
11 (115, 8)
62 (630, 45)
Rear Roof Drip SideFinish Moulding
62 (630, 45)
11 (115, 8)
BO–70–BODY SOFT TOP
1270Author�: Date�:
2000 MR2 (RM760U)
H14153
Cloth of Main Body
Spring
Upper Cloth
Side Cloth
Side Cloth End Plate
Spring
Spring
–BODY SOFT TOPBO–71
1271Author�: Date�:
2000 MR2 (RM760U)
BO34T–01
H14104
: 4 Clips
H14105
H14106
: 2 Clips
H14343
BO–72–BODY SOFT TOP
1272Author�: Date�:
2000 MR2 (RM760U)
REMOVAL1. REMOVE DOOR SCUFF PLATES(a) Using a screwdriver, remove the door scuff plateHINT:Tape the screwdriver tip before use.(b) Employ the same manner described above to the other
side.
2. REMOVE LOWER REAR SEPARATOR TRIM COVERS(a) Remove the 2 clips.(b) Using a screwdriver, remove the separator trim cover.HINT:Tape the screwdriver tip before use.(c) Employ the same manner described above to the other
side.
3. REMOVE QUARTER TRIM PANELS(a) Remove the floor anchor mounting bolt and disconnect
the front seat outer belt.(b) Remove the 2 clips.(c) Using a screwdriver, remove the quarter trim panel.HINT:Tape the screwdriver tip before use.(d) Employ the same manner described above to the other
side.4. REMOVE LUGGAGE COMPARTMENT LIDSRemove 6 bolts and luggage compartment lids.
5. REMOVE LUGGAGE COMPARTMENT BOXS(a) Remove the 2 screws.(b) Using a screwdriver, remove the luggage compartment
box.HINT:Tape the screwdriver tip before use.(c) Employ the same manner described above to the other
side.
H14108
H14109
H14110
–BODY SOFT TOPBO–73
1273Author�: Date�:
2000 MR2 (RM760U)
6. DISCONNECT FRONT SEAT OUTER BELTRemove the shoulder anchor mounting bolt and disconnect thefront seat outer belt.
7. REMOVE WIND DEFLECTOR BOARD(a) Using a screwdriver, remove the window deflector cover.HINT:Tape the screwdriver tip before use.(b) Remove the 4 nuts and deflector board.
8. REMOVE PULL HANDLE(a) Using a screwdriver, remove the cover.HINT:Tape the screwdriver tip before use.(b) Remove the 2 screws and pull handle.
9. REMOVE UPPER LUGGAGE COMPARTMENT GAR-NISH
Remove the 8 clips and upper luggage compartment garnish.10. REMOVE LUGGAGE COMPARTMENT COVERS
H14506
H14507 H14544
H14111
H14112
H14113
BO–74–BODY SOFT TOP
1274Author�: Date�:
2000 MR2 (RM760U)
11. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY(a) Remove the 4 clips.(b) Remove the clip and button.(c) Remove the package tray trim suspender then remove
the package tray trim panel.(d) Employ the same manner described above to the other
side.
12. REMOVE FRONT TOP AND TARPAULIN SUPPORTFRAME
Remove the 2 bolts, 2 nuts and front top and tarpaulin supportframe.
13. REMOVE ROOM PARTITION BOARDUsing a clip remover, remove the 3 clips of room partition board.
14. REMOVE TARPAULIN COVER SIDE RETAINERS(a) Pull up the side cloth.(b) Remove the screw and wire(c) Remove the screw, 4 nuts and tarpaulin cover side retain-
er.(d) Employ the same manner described above to the other
side.15. REMOVE TAIL GATE LOWER SEAL
H14115
H14494Clip
Double–Stick Tape
H14353
H14116
–BODY SOFT TOPBO–75
1275Author�: Date�:
2000 MR2 (RM760U)
16. REMOVE UPPER TARPAULIN COVER RETAINERRemove the 7 nuts and upper tarpaulin cover retainer.
17. REMOVE SIDE BELT MOULDING(a) Using a screwdriver, remove the side belt moulding.HINT:Tape the screwdriver tip before use.(b) Employ the same manner described above to the other
side.18. REMOVE REAR BELT MOULDING ASSEMBLY(a) Remove the rear end of the tarpaulin from the stud bolt.NOTICE:Take care not to damage the glass.(b) Remove the 8 bolts.(c) Using a screwdriver, remove the rear belt moulding.HINT:Tape the screwdriver, tip before use.
19. REMOVE TARPAULIN ASSEMBLY(a) Remove the 3 clips then disconnect the side gate seal
partially.
(b) Remove the 6 bolts and tarpaulin assembly.
H14346
H14347
Hook
Drain Hose
BO–76–BODY SOFT TOP
1276Author�: Date�:
2000 MR2 (RM760U)
20. REMOVE DUST ROOF WEATHERSTRIPS(a) Using a screwdriver, remove the 3 clips and dust roof
weatherstrips.HINT:Tape the screwdriver tip before use.(b) Employ the same manner described above to the other
side.
21. REMOVE SIDE GATE SEALS(a) Remove the tail gate lower seal partially.(b) Unhook the center pillar hook partially.(c) Pull out the drain hose and remove the side gate seal.(d) Employ the same manner described above to the other
side.
BO34U–01
H14117
H14154
Marking
H14118
–BODY SOFT TOPBO–77
1277Author�: Date�:
2000 MR2 (RM760U)
DISASSEMBLY1. REMOVE TARPAULIN LOCKS(a) Remove the 3 screws and tarpaulin lock.(b) Remove the RH and LH locks.2. REMOVE CENTER TARPAULIN BOW STAY CATCH
HANDLERemove the 2 screws and center tarpaulin bow stay catch han-dle.3. REMOVE SET PLATERemove 6 screws and set plate.
4. REMOVE FRONT ROOF SIDE RAIL WEATHERSTRIPS(a) Remove the screw, 2 clips and roof side rail weatherstrip.(b) Remove the RH and LH weatherstrips.
5. REMOVE CENTER ROOF DRIP SIDE FINISH MOULD-INGS
(a) Remove the 4 screws and roof side finish moulding.(b) Employ the same manner described above to the other
side.NOTICE:Before removing the moulding, mark the positioning witha colored pencil on the installation holes.
6. REMOVE REAR ROOF SIDE RAIL WEATHERSTRIPS(a) Using a clip remover, remove the 2 clips and roof side rail
weather strip.HINT:Tape the screwdriver tip before use.(b) Employ the same manner described above to the other
side.
H14155
Marking
H14119
Tie Lap Band
H14120
Spring B
H14121
No.2 Bow
Upper Cloth
Cloth of theMain Body
BO–78–BODY SOFT TOP
1278Author�: Date�:
2000 MR2 (RM760U)
7. REMOVE REAR ROOF SIDE FINISH MOULDINGS(a) Remove the 4 screws and rear roof side finish moulding.(b) Employ the same manner described above to the other
side.CAUTION:Before removing the moulding, mark the positioning witha colored pencil on the installation holes.
8. REMOVE TARPAULIN COVER(a) Close the tarpaulin lightly and cut out the tie lap band.
(b) Remove the clip.(c) Pull up the spring cover and remove the spring B.
(d) By marking the tarpaulin assembly in a half–open condi-tion, remove the upper cloth from the No. 2 bow.
(e) Remove the cloth affixed on the No. 2 bow.(f) Remove the upper band.(g) Remove the inside cloth of the tarpaulin from the band as-
sembly.
H14498
End PlateNut
Plate
H14499
H14500
Velcro
Belt
No. 2 Bow
H14123
Caulking Part
H14501
–BODY SOFT TOPBO–79
1279Author�: Date�:
2000 MR2 (RM760U)
(h) By making the tarpaulin assembly in a full–open condi-tion, remove the nut and end plate.
NOTICE:Remove the plate pinched in the end plate before hand.
(i) Remove the 6 right and left screws of the tarpaulin coverat the link side.
(j) Remove the tarpaulin belt wrapped around the link side.(k) Remove the velcro holding both ends of No. 2 Bow.
(l) Pull up the cover at the link side and remove the caulkingof the wire using a screw driver.
(m) Remove the screw and spring.(n) Remove the front of the tarpaulin cover.
(o) Using a rivet cutter and a drill, drill out the rivets and re-move the band.
HINT:Even if flanges are taken off, continue drilling and push out re-maining flangments with the drill.(p) Remove the tarpaulin cover from the rear of the link to-
ward the front then take it out.NOTICE:Take out the cover so as not to damage the glass.
BO34V–01
H14235
Front of Moulding Back of Moulding
Horizontal Direction
Vertical Direction
1.5 mm or lessHorizontal Direction1.0 mm or less
Vertical Direction
1.5 mm or less
1.0 mm or less
Front of moulding Back of moulding
H14236
Tarpaulin
Lock Striker
A
B
BO–80–BODY SOFT TOP
1280Author�: Date�:
2000 MR2 (RM760U)
INSPECTION1. INSPECT WATER LEAKAGECheck from the outside of the vehicle that there is no water leak-age.
(1) In case of pouring water with hose, do not water withthe hose squeezed.
(2) There is a possibilty of water leakage even in a nor-mal condition if you water under the tarpaulin.
NOTICE:In case that the water leaks, Check and adjust the doorglass and the tarpaulin alignment.2. INSPECT TARPAULIN COVER FOR PROPER TEN-
SION AND CREASESTarpaulin cover tension checking.
By making the tarpaulin in a full–open condition, checkthe tension of the cover visually and by touching.
NOTICE:Depending on the tension or wrinkling condition, re–spread the cover.
3. INSPECT TARPAULIN COVER(a) Inspect the roof drip moulding gap.
Standard gap:
– Vertical direction Horizontal direction
Front moulding 1.5 mm (0.059 in) or less 1.5 mm (0.059 in) or less
Rear moulding 1.0 mm (0.039 in) or less 1.0 mm (0.039 in) or less
NOTICE:In case that it is out of the standard range, adjust or replacethe roof drip moulding.
(b) Inspect the roof header measurement.Standard measurement:A: 0 ± 2.0 mm (0.079 in.)B: 0 ± 2.0 mm (0.079 in.)
NOTICE:In case that it is out of the standard range, adjust the tar-paulin assembly.
BO34W–01
H14502
H02440Mandrel
Riveter
H02441
Riveter
Riveter
H02442
Riveter
–BODY SOFT TOPBO–81
1281Author�: Date�:
2000 MR2 (RM760U)
REASSEMBLY1. INSTALL TARPAULIN COVER(a) Set the tarpaulin cover on the link assembly.
(b) Rivet the band on the link using a pneumatic riveter orhand riveter.
NOTICE:� Do not prize a riveter, as riveter is damaged, it is not
tightened and the mandrel is bent.
� Do not tilt the riveter and disconnect the rivet from thematerial while operating a riveter otherwise, the ma-terials could not be tightened firmly.
� Install the rivet while attaching materials, as they arenot be tightened firmly.
(c) Apply the front part of the tarpaulin cover over the linkheader part.
(d) Put the front part of the tarpaulin cover over the link.NOTICE:Pull the both edges of the cover in order to preventwrinkles.
H14123
Caulking Part
H14500
Velcro
Belt
No. 2 Bow
H14499
H14498
End PlateNut
Plate
H14503
Inside Cover
BO–82–BODY SOFT TOP
1282Author�: Date�:
2000 MR2 (RM760U)
(e) Tighten the wire at the link side.(f) After caulking the wire, affix the butyl tape to that position.NOTICE:Failing to tighten the caulking part securely may cause abreak of the cover on the side.(g) install the spring with the screw.NOTICE:If the spring or the wire is leant toward either right or left,this may cause a wind noise.
(h) Retain the tarpaulin belt wound around the link side witha button.
(i) Wind the velcro of the tarpaulin.NOTICE:Secure the space for winding the cloth.
(j) Install the tarpaulin cover to the link side part with the 6screws.
NOTICE:Pay due attention, because the screws on the vehicle backend are short.(k) Install the set plate with the 6 screws.NOTICE:When installing, use the center screw first.
(l) Apply adhesive to 2 or 3 threads of the mounting nut.(m) Install the end plate.
Adhesive: Part No. 08833–00070, THREE BOND 1324or equivalent
NOTICE:Do not let the head of the bolt sticking up over the nut uppersurface. Pinch the plate, while taking care of the plate fac-ing direction.HINT:Over–tightening of the nut causes a wind noise.(n) Put the cloth for the inside tarpaulin cover into the inside.(o) Install the rear of the tarpaulin cover to the stud bolt on the
body side.NOTICE:Take care not to damage the glass.(p) Tighten the upper tarpaulin cover retainer with the 7 nuts.
H14229
No. 4 Bow
H14231
Butyl Tape
H14118
–BODY SOFT TOPBO–83
1283Author�: Date�:
2000 MR2 (RM760U)
(q) Affix the tailgate lower seal with velcro.NOTICE:Be careful that the inside cover or the tarpaulin is notcaught.(r) By making the tarpaulin assembly in a close condition,
lock it.
(s) Pull No. 4 bow as shown in the illustration.
(t) Install the center roof drip side finish mouldings.(1) Using a scraper, remove the adhesive sticking to
the finish moulding.(2) Clean the roof side rail finish moulding.(3) Apply butyl tape to the groove on the back of the
moulding.(4) Install the roof side rail finish moulding with the
screws by matching them with marking.(u) Employ the same manner described above to the other
side.(v) Install the rear roof side finish mouldings.
(w) Install the rear roof side rail weatherstrip with the 2 clips.(x) Employ the same manner described above to the other
side.
H14117
H14504
No. 4 Bow
Tip Lap Band
No. 3 Bow
H14120
Spring B
H14233
No. 2 Bow
Cloth of theMain Body
H14121
No. 2 Bow
Upper Cloth
Cloth of theMain Body
BO–84–BODY SOFT TOP
1284Author�: Date�:
2000 MR2 (RM760U)
(y) Install the front roof side rail weatherstrip with the screwand 2 clips.
(z) Employ the same manner described above to the otherside.
(aa) Affix the inside cover with velcro.
(ab) As shown in the illustration, put a cloth and a bandthrough No. 3 bow guide, and fix with a tie lap band.� Fix with a band while checking the tension at the tar-
paulin cover side.� After installing the band, cut it by 5 mm (0.20 in.) or
less.
(ac) Install the spring B.� Be sure to install the spring B securely to the
groove.� Check the tension of the link upper part of the tar-
paulin cover.� Check that the side of the cover is not caught in the
link when opening or closing the tarpaulin assem-bly.
(ad) Peel off the parting paper of the double adhesive tape,install the cloth of the main body side to No. 2 bow.
CAUTION:Install the cloth of the main body side while checking thatit is not streched too much.
(ae) By making the tarpaulin assembly in a half–open condi-tion, install the upper cloth by hanging it on the hook.
2. INSTALL CENTER TARPAULIN BOW STAY CATCHHANDLE
Install the center tarpaulin bow stay handle with the 2 screws.Torque: 62 N·m (630 kgf·cm, 45 ft·lbf)
–BODY SOFT TOPBO–85
1285Author�: Date�:
2000 MR2 (RM760U)
3. INSTALL TARPAULIN LOCKS(a) Apply adhesive to 2 or 3 threads of the mounting screw
end.Adhesive: Part No. 08833–00070, THREE BOND orequivalent
(b) Install the tarpaulin lock with the 3 screws.Torque: 62 N·m (630 kgf·cm, 45 ft·lbf)
(c) Employ the same manner described above to the otherside.
BO34X–01
H14348:Butyl Tape
Double–Stick Tape
H14349
Butyl Tape
H14116
A
BB
H14353
BO–86–BODY SOFT TOP
1286Author�: Date�:
2000 MR2 (RM760U)
INSTALLATION1. INSTALL SIDE GATE SEALS(a) Install the double–stick tape as shown in the illustration.(b) Apply butyl tape as shown in the illustration.(c) Insert the drain hose.(d) Insert the hook to the center pillar.(e) Peel off the separating sheet of the double adhesive tape
and affix the tape to the center pillar.(f) Employ the same manner described above to the other
side.
2. INSTALL DUST ROOF WEATHERSTRIPS(a) Along the groove of the weatherstrip, apply the butyl tape
on the weatherstrip.(b) Install the pillar seal with the 3 clips.HINT:Press the weatherstrip with a hand and securely affix the butyltape.(c) Employ the same manner described above to the other
side.
3. INSTALL TARPAULIN ASSEMBLY(a) Install the tarpaulin assembly with the 6 bolts.
Torque:A: 11 N·m (115 kgf·cm, 8 ft·lbf)B: 11 N·m (115 kgf·cm, 8 ft·lbf)
(b) Install side gate seal with the clip.4. INSTALL REAR BELT MOULDINGInstall the rear belt moulding with the 8 bolts.
H14493
Double–stick Tape
H14230
H14111
H14110
–BODY SOFT TOPBO–87
1287Author�: Date�:
2000 MR2 (RM760U)
5. INSTALL SIDE BELT MOULDINGInstall the new double–stick tape as shown in the illustration.6. INSTALL UPPER TARPAULIN COVER RETAINERInstall the upper tarpaulin cover retainer with the 7 nuts.7. INSTALL TAIL GATE LOWER SEAL
8. INSTALL TARPAULIN COVER SIDE RETAINERS(a) Install the tarpaulin cover side retainer with the 4 nuts and
screw.NOTICE:Tighten the side retainer and band assembly together se-curely.After opening the tarpaulin, tighten the head of the side re-tainer together with the side retainer itself.(b) Install the wire on the side retainer.NOTICE:After installation, be sure that the bracket on the wire tipmoves lightly.9. INSTALL ROOM PARTITION BOARD10. INSTALL PACKAGE TRAY TRIM PANEL
11. INSTALL FRONT TOP AND TARPAULIN SUPPORTFRAME
Install the front top and tarpaulin support frame with the 2 boltsand 2 nuts.12. INSTALL LUGGAGE COMPARTMENT COVERS
13. INSTALL UPPER LUGGAGE COMPARTMENT GAR-NISH
Install the upper luggage compartment garnish with the 6 clips.14. INSTALL PULL HANDLE(a) Install pull handle with the 2 screws.(b) Install the cover.15. INSTALL WIND DEFLECTOR BOARD(a) Install the deflector board with the 4 nuts.(b) Install the window deflector cover.
BO–88–BODY SOFT TOP
1288Author�: Date�:
2000 MR2 (RM760U)
16. CONNECT FRONT SEAT OUTER BELTSConnect the front seat outer belt with the shoulder anchormounting bolt.
Torque: 42 N·m (420 kgf·cm, 30 ft·lbf)17. INSTALL LUGGAGE COMPARTMENT BOXS18. INSTALL QUARTER TRIM PANELS19. CONNECT FRONT SEAT OUTER BELTSConnect the front seat outer belt with the floor anchor mountingbolt.
Torque: 42 N·m (420 kgf·cm, 30 ft·lbf)20. INSTALL LOWER REAR NO.1 SEPARATOR TRIM
COVERS21. INSTALL LUGGAGE COMPARTMENT LIDS22. INSTALL FRONT SCUFF PLATES23. INSPECT WATER LEAKAGE (See page BO–80)24. INSPECT TARPAULIN COVER FOR PROPER TEN-
SION AND ALIGNMENT (See page BO–80)