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Hi, we have a 2003 pathfinder too and have all the above you have mentioned. With regards to the pin holes , don't worry when it rains the gaps will swell and seal. We have pin holes in our awning too but have never had a leak despite hard rain. Take some tape with you though just in case as it is always good to have some repair stuff with you.
With regards to the corner we too struggle to pull the canvas over and the stitching is a little undone there too due to this. (Below the cross seam though so ok) Best way to get the canvas over is before you pull out the poles of course just using brute force!!
The zip thing is a common issue for many of us too. Try errecting the camper with the zip shut as this helps with the alinement of the canvas, thus the zip closes sometimes!!!. Sometimes we forget to do this and just end up covering the gap with a tea towel as we can't be bothered sorting but if you do need to then lower the poles and pull the canvas over a bit more on the door side, fasten down the underneath velcro bits and then put the poles back up, all with the door shut. (You need a person inside as well as outside)
Hope this helps
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