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


2000 MR2 (RM760U)

BO0ZP–04

–BODY SRS AIRBAGBO–3


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


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


2000 MR2 (RM760U)

REAR BUMPERCOMPONENTS

BO2NB–02

H13943

Headlight

Headlight


Tool Box

Luggage Compartment Trim Box Cover

x18

5.5 (56, 48in.·lbf)

Front Bumper Cover

BO–6–BODY HEADLIGHT


2000 MR2 (RM760U)

HEADLIGHTCOMPONENTS

BO2NC–02

H14003

H14004

–BODY HEADLIGHTBO–7


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


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


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


BO34Y–01

H14150

H14151

H14152

BO–10–BODY ENGINE HOOD


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


� 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


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


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



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



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



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.


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



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.)



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


H14088

SST

H14089

SST

N17571

H14018



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



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



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


2000 MR2 (RM760U)

FRONT WIPER AND WASHERCOMPONENTS

BO2NG–02

H14022

6 Clips

H14050

H14023

H00575

BO–22–BODY FRONT WIPER AND WASHER


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



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


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



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


2000 MR2 (RM760U)

ROOF DRIP SIDE MOULDINGCOMPONENTS

BO2NM–02

H14091

H14092

–BODY ROOF DRIP SIDE MOULDINGBO–27


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


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


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


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


2000 MR2 (RM760U)

WINDSHIELDCOMPONENTS

BO34M–01

H14022

: 6 Clips

H14012

: 2 Clips

H14013

H14014: 2 Clips

–BODY WINDSHIELDBO–31


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



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



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



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



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



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


Hood ReleaseLever

Combination Meter

Column UpperCover

Instrument PanelLower Pad Insert

Instrument Cluster Finish Panel


Column LowerCover

Steering Wheel Pad

RemovableRoof Hook

L

C

C

O

Door Scuff Plate

Cowl SideTrim

Door Scuff Plate

Cowl SideTrim

C


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


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



Stereo Player

F

BO–38–BODY INSTRUMENT PANEL


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



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)



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



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



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



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



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



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



2000 MR2 (RM760U)

REASSEMBLYReassembly is in the reverse order of disassembly (See page BO–45).

BO2O8–02



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


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


2000 MR2 (RM760U)

FRONT SEATCOMPONENTS

BO1F7–03

–BODY FRONT SEATBO–49


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



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



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



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



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.




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



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


BO–56–BODY SEAT BELT


2000 MR2 (RM760U)

SEAT BELTCOMPONENTS

BO1FI–03

BO0632

BO0633

15°

45°

–BODY SEAT BELTBO–57


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


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


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


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



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



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



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



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.


� Do not apply water, etc. to a front seat outer belt withactivated seat belt pretensioner.

AB0158

SST

Battery

H14146

SST

Battery

SST

H14147SST SST



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



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.


� 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



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



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


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


2000 MR2 (RM760U)

H14153

Cloth of Main Body

Spring

Upper Cloth

Side Cloth

Side Cloth End Plate

Spring

Spring



2000 MR2 (RM760U)

BO34T–01

H14104

: 4 Clips

H14105

H14106

: 2 Clips

H14343



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



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



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



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



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



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



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



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



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



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



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



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


H14121

No. 2 Bow

Upper Cloth




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)



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



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



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.



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)

bo–1 - unigeobswildif/cars/docs/mr2_spyder/00 - body.pdf · 2020. 10. 9. · 2000 mr2 (rm760u)...

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