2013 Mitsubishi Outlander Body Repair Manual - PDF DOWNLOAD

0-1

GROUP 0

GENERAL CONTENTS VEHICLE IDENTIFICATION . . . . . . .

0-2

MAJOR SPECIFICATIONS . . . . . . . .

0-2

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) .................................

0-3

GENERAL

0-2

VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION M4000001003263

<2000> Model code GF2W

XTSHL6Z

Seating capacity

Engine model

Transmission model

Fuel supply system

5-persons

4B11 (1,998 mL) DOHC MIVEC petrol engine

F1CJA (Front wheel drive 2WD, INVECS-III CVT with sport mode)

MPI

Seating capacity

Engine model

Transmission model

Fuel supply system

5-persons

4B12 (2,360 mL) DOHC MIVEC petrol engine

W1CJA (Electronic control 4WD, INVECS-III CVT with sport mode)

MPI

XTSHZL6Z <2400> Model code GF3W

XTHHZL6Z

W1CJA (Electronic control 4WD, INVECS-III CVT with sport mode)

MAJOR SPECIFICATIONS M4000003002943

Item

GF2W XTSHL6Z

Vehicle dimension mm

Overall length

4,655

Overall width

1,800

Overall height (unladen)

1,680

Wheelbase

2,670

Track

Vehicle Front wheel alignment

Rear

Front

1,540

Rear

1,540

GF3W XTSHZL6Z

Front overhang

955

Rear overhang

1,030

Ground clearance (unladen)

215

Toe-in (at the centre of tyre tread) mm

1±2

Camber

0°20' ± 0°30'*1

Caster

2° 35' ± 0°45'*1

Kingpin inclination angle

12° 45' ± 1° 30'

Toe-in (at the centre of tyre tread) mm

3±2

Camber

−0° 30' ± 0° 45'*1

XTHHZL6Z

GENERAL

0-3

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Item

GF2W

Wheel and tyre

GF3W

XTSHL6Z

XTSHZL6Z

XTHHZL6Z

Tyre size

215/70R16 100H

215/70R16 100H, 225/55R18 98H*2

215/70R16 100H, 225/55R18 98H*2

Wheel size

16 × 6.5JJ

16 × 6.5JJ, 16 × 6.5J*2, 18 16 × 6.5J, 18 ×7J*2 ×7J*2

Offset mm

38

38

38

NOTE: . *1:

Difference between right and left wheels must be less than 0°30'.

*2

: Indicates the optional item.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) M4000004000014

WARNING • Improper service or maintenance of any

component of the SRS and any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering the SRS inoperative).

• The SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, driver's and front passenger's air bag modules, clock spring, side-airbag modules, Curtain air bag modules, front and side impact sensor and seat belt pre-tensioner before drying or baking the vehicle after painting.

• SRS-ECU, air bag modules, clock spring, impact sensor: 93° C or more • Seat belt with pre-tensioner 90°C or more • Service or maintenance of any SRS component and SRS-related component must be performed only at an authorized MITSUBISHI dealer.

• MITSUBISHI dealer personnel must thoroughly review workshop manual, and especially its GROUP 52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the SRS and any

SRS-related component.

1-1

GROUP 1

BODY CONSTRUCTION CONTENTS BODY COMPONENTS. . . . . . . . . . . .

1-2

BODY MAIN CROSS-SECTIONAL VIEWS .................................

1-4

ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-19

UNDER BODY. . . . . . . . . . . . . . . . . . . . . . .

1-21

DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-24

1-6

SILENCER APPLICATION LOCATIONS .................................

1-25

BODY CONSTRUCTION CHARACTERISTICS .................................

1-8

LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL . . . . . . . . . . . . . . .

1-26

MAINTENANCE, SERVICEABILITY .

FRONT BODY. . . . . . . . . . . . . . . . . . . . . . .

1-8

SIDE BODY. . . . . . . . . . . . . . . . . . . . . . . . .

1-15

REAR BODY . . . . . . . . . . . . . . . . . . . . . . . .

1-18

STIFFENER AND DAMP SHEET APPLICATION LOCATIONS . . . . . . .

1-27

BODY CONSTRUCTION

1-2

BODY COMPONENTS

BODY COMPONENTS M4010001002186

49 39

48

36 38

34 37

33

44

103

101* 99*

105

111 51

113 52

114

106

93*

53

97*

95**

54

92*

30 27

29*

19

18 56

28*

26*

17

22

25 24*

58

16 20

23

91* 62

7*

55

21

13

57

90**

14

63

15

85

12

6*

11*

61

5

10

8 4

9

84**

2

66

89

74* 67

76

68*

69*

77**

1

78*

80

NOTE: 87 88 82* 81 : Anti-corrosion steel panels 79 : High-tensile steel panels (*: Indicates 590MPa-high-tensile steel panels.) (**: Indicates 980MPa-ultra-high-tensile steel panels.)

Front bumper reinforcement Headlamp support panel upper

59*

83

86*

3

60* 65

64

75*

1.

2.

110 112

98*

94

109

100*

96**

32 31

104 41

40

50

47

43 108 42* 107

35 102

45

46

3.

4.

70 73*

71

Headlamp support panel lower Headlamp support panel

72* ABC00060 AB

BODY CONSTRUCTION BODY COMPONENTS 5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

63.

Front body frame to side sill brace Front floor sidemember Front sidemember rear bulkhead Front inner sidemember Headlamp support panel lower Front sidemember plate Front sidemember extension Front outer sidemember Fender shield extension Front fender gusset Front fender shield Spring house panel Fender shield frame upper inner Front fender bracket rear Front deck frame front upper Engine mounting gusset Condense tank reinforcement Front end upper bar side Front fender bracket Dash crossmember lower Dash panel crossmember upper Dash crossmember extension Dash panel Dash crossmember side Dash panel reinforcement Cowl top panel Front deck crossmember Hood panel inner Hood panel outer Front door side door beam Front door panel inner Front door panel outer Rear door side door beam Rear door panel inner Rear door panel outer Roof rail front Roof bow A Roof bow centre lower Roof bow centre upper Roof bow B Roof bow C Roof bow D Roof rail rear Roof panel Tailgate panel outer Tailgate panel inner Quarter panel extension outer Quarter panel extension rear lower Side outer panel Fuel filler door panel (Left side) Front deck frame rear upper Rear bumper reinforcement Rear end panel outer Rear end inner centre crossmember Rear bumper reinforcement Rear end inner crossmember side Rear bumper bracket Rear floor Rear seat under floor

64. Rear floor side panel 65. Rear floor rear end crossmember 66. Rear floor crossmember 67. Rear floor crossmember 68. Rear floor under stringer 69. Rear bumper support 70. Rear floor sidemember extension 71. Rear floor sidemember 72 Rear floor side sill inner 73. Rear floor sidemember bulkhead 74. Rear floor extension 75. Rear floor rear seat under crossmember 76. Front floor 77. Front floor side sill inner 78. Front floor sidemember 79. Front floor reinforcement 80. Front floor crossmember rear centre 81. Front floor crossmember front 82. Front floor sidemember 83. Front floor crossmember rear 84. Front floor crossmember front 85. Front floor backbone reinforcement 86. Front floor sidemember 87. Battery tray stay rear (Left side) 88. Battery tray stay front (Left side) 89. Front fender 90. Side sill reinforcement 91. Side sill bulkhead front 92. Front pillar reinforcement lower inner 93. Front pillar reinforcement lower support 94. Front lower inner pillar 95. Front pillar reinforcement upper 96. Front upper inner pillar 97. Centre pillar reinforcement 98. Rear door hinge reinforcement 99. Centre inner pillar 100. Roof side rail reinforcement centre 101. Roof side rail inner 102. Roof rail extension front inner 103. Roof rail extension rear inner <Vehicles without sunroof> 104. Roof side rail reinforcement rear 105. Roof side rail reinforcement rear 106. Rear pillar reinforcement 107. Rear wheel house panel inner 108. Quarter panel upper inner 109. Gate pillar reinforcement 110. Rear inner pillar 111. Quarter panel extension lower inner 112. Quarter panel lower inner 113. Quarter panel extension inner 114. Rear pillar reinforcement lower

1-3

BODY CONSTRUCTION

1-4

BODY MAIN CROSS-SECTIONAL VIEWS

BODY MAIN CROSS-SECTIONAL VIEWS M4010002001346

A

B

C D

E F ABB00858AB

A

Cowl top panel upper

D

Cowl top stay centre Roof panel

Cowl top panel lower

Weight assembly

Cowl top panel inner

Roof rail front Map lamp bracket

ABB00783AB

ABB00786AB

E

B

Front inner pillar lower

Front pillar reinforcement lower

Roof side rail reinforcement centre

Roof side rail inner

Side outer panel ABB00784AB

pillar seat belt C Centre reinforcement upper Centre pillar reinforcement

Centre pillar inner upper Side outer panel

Side outer panel

F

ABB00787AB

Front floor side sill inner

Side sill reinforcement outer rear

ABB00785 AB

Side outer panel

ABB00788 AB

BODY CONSTRUCTION

1-5

BODY MAIN CROSS-SECTIONAL VIEWS

H

G

I

J

K L

ABB00758AB

G Side outer panel

Front pillar reinforcement upper

Front upper inner pillar ABB00789AB

H

Quarter outer panel extension upper Quarter inner Gate inner upper panel pillar upper Gate pillar upper reinforcement

J

Side outer panel

K

Gas spring reinforcement

Rear pillar reinforcement lower

ABB00792 AB

Quarter inner front extension

Side outer panel

Roof panel

Roof rail rear outer Roof rail rear inner

I

Rear pillar reinforcement upper

ABB00790AB

Quarter inner upper panel

ABB00793 AB

Tailgate striker reinforcement Rear end inner centre crossmember

L

Rear end panel outer

Side outer panel

ABB00791AB

Spare tyre bracket

ABB00794AB

BODY CONSTRUCTION

1-6

MAINTENANCE, SERVICEABILITY

MAINTENANCE, SERVICEABILITY M4010003001156

FENDER SHIELD To facilitate the panel replacement, the dash panel and the front sidemember brace upper have a projection and recess for alignment.

ABB00904AB

SIDE STRUCTURE A panel positioning notch has been added on the door opening to improve assembling workability when replacing the panel.

BODY CONSTRUCTION MAINTENANCE, SERVICEABILITY

Panel positioning notch

1-7

ABC00082AB

ABB00754AB

SIDE OUTER PANEL The extra parts are supplied in 4 different cut forms as a result of employing the integrated side-frame side outer panel.

BODY CONSTRUCTION

1-8

BODY CONSTRUCTION CHARACTERISTICS

Centre outer pillar

Quarter panel outer Front outer pillar

Front floor side sill outer ABC00085AB

BODY CONSTRUCTION CHARACTERISTICS FRONT BODY M4010010001664

HEADLAMP SUPPORT • The crush box structure, which has an octagonal cross-section at the front end of the front sidemember, has been adopted. This structure can effectively absorb energy upon frontal impact and reduces the vehicle repair cost caused by a light collision.

• The bolt-on headlamp support panel upper is used to improve maintainability.

BODY CONSTRUCTION

1-9

BODY CONSTRUCTION CHARACTERISTICS 12 ± 2 N·m

ABB00717

12 ± 2 N·m

3

2 4

20 ± 5 N·m

1 A ABC00054AC

1.

2.

3.

4.

NOTE:

Front bumper reinforcement Headlamp support panel upper Front end crossmember upper Front end crossmember lower

8

Front bumper reinforcement

2

A

3

Crush box

7

1 5 6 4

ABC00083AB

Tighten the front bumper reinforcement bolts in the numerical order to 20 ± 5 N⋅m.

ABB00715AB

A crash box has been established in order to efficiently absorb energy upon impact.

2 3

4 Headlamp support panel upper

5

1 6

ABC00084AB

Tighten the headlamp support panel upper bolts in the numerical order to 12 ± 2 N⋅m.

FENDER SHIELD • The front frame structure is supported in three directions by the dash crossmember centre, dash crossmember lower and front sidemember rear in order to improve the frontal collision characteristics, and increase the vehicle body rigidity.

• The padding structure of the front fender bracket and the front fender bracket rear has been adopted to have a crushable structure in order to efficiently absorb energy upon impact, improving the pedestrian protection capability.

BODY CONSTRUCTION

1-10 (Right side)

BODY CONSTRUCTION CHARACTERISTICS

11

13

12

14 15

16

10

17

18

9 8 19

6

20

7

5 4

3

21 22

2

23

1

ABB00718 AB

(Left side)

11

13 12 16

15 9

17 18

10 8

26 25 27

21 24

7

4 3 23

1

2

ABB00719AB

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Fender gusset Fender shield extension Fender bracket lower Front fender shield Condense tank reinforcement Engine mounting gusset Front end upper bar side Front fender bracket Front upper inner frame Upper frame centre bulkhead Front deck frame front upper

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

Upper frame rear bulkhead Front fender bracket rear Horn bracket Spring house bracket reinforcement Spring house corner gusset Spring house bracket front Spring house panel rear Suction hose bracket Spring house harness bracket Spring house panel Engine mounting bracket upper

BODY CONSTRUCTION

1-11

BODY CONSTRUCTION CHARACTERISTICS 23.

24.

25.

26.

27.

FRONT SIDEMEMBER REINFORCEMENT

Front sidemember Engine-ECU bracket Relay box bracket Relay box bracket rear Transmission mounting gusset

(Right side)

4

3

2

The 590-MPa class high tensile strength steel panels have been adopted for the front sidemember extension, front sidemember rear reinforcement lower, front sidemember rear bulkhead, front sidemember rear, backbone sidemember extension and front sidemember inner reinforcement to improve the frontal collision characteristics.

26

28

27

5*

1*

29* 32

23

30 6* 7*

25 31

24

8

22 14

9

13

10*

21

15

20

16

19

12

11

17 18

NOTE: *: Indicates 590MPa-high-tensile steel panels.

ABB00720 AB

27 23

24 25

26

28

6

A

14

B

5

7

13 ABB00721AB

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Front sidemember extension Sidemember front outer reinforcement Brake hose bracket Front sidemember outer Front sidemember rear reinforcement lower Front sidemember rear bulkhead Front sidemember rear Height sensor bracket Dash crossmember lower bulkhead Backbone sidemember extension

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

Dash crossmember extension lower Front body frame to side sill brace Front suspension crossmember bracket front Front sidemember inner Subframe support panel inner Radiator bracket lower Front end crossmember extension lower Front sidemember plate front lower Towing hook Subframe support panel outer

BODY CONSTRUCTION

1-12 21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

BODY CONSTRUCTION CHARACTERISTICS

Subframe bulkhead support Front sidemember plate Front sidemember inner reinforcement front Front sidemember bulkhead front Engine mounting bulkhead Front suspension crossmember bulkhead Engine mounting bracket Front sidemember brace upper Front sidemember inner reinforcement Engine mounting reinforcement Headlamp support panel Front end upper bar bracket

A

30 27 4 25 14 2 B

ABB00722 AB

28 26 4 14 13

(Left side)

8 24

10*

25 6*

27

22

28

31 30 29

23* 24 ± 4 N·m

4

9

26

7*

5*

ABB00723AB

21 11

20

19

3* 24 ± 4 N·m

2

13

1 18 17

NOTE: *: Indicates 590MPa-high-tensile steel panels.

12 14 15 16 ABB00724 AB

BODY CONSTRUCTION

1-13

BODY CONSTRUCTION CHARACTERISTICS

25 24

5

7

28

27

26

6 21

B

A

22 ABB00725AB

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

Front body frame to side sill brace Dash crossmember extension lower Backbone sidemember extension Dash crossmember lower bulkhead Front sidemember rear Front sidemember rear bulkhead Front sidemember rear reinforcement lower Front outer sidemember Brake hose bracket Front sidemember extension Front sidemember plate Subframe bulkhead support Subframe support panel inner Subframe support panel outer Towing hook Front sidemember plate front lower Front end crossmember extension lower Radiator bracket lower Battery tray stay front Battery tray stay rear Front suspension crossmember bracket front Front sidemember inner Front sidemember inner reinforcement Front sidemember brace upper Transmission mounting reinforcement Front suspension crossmember bulkhead Transmission mounting bulkhead Front sidemember inner reinforcement front Horn bracket

30. Headlamp support panel 31. Front end upper bar bracket

24

A

25 27 22 8

21

ABB00726AB

B

24 8 22 26 21

ABB00727AB

BODY CONSTRUCTION

1-14

BODY CONSTRUCTION CHARACTERISTICS

FRONT DECK 4

6

5 15 3

7 2

8 13 12

5 3

14 9

1 2

11

4

10 11

1.

2.

3.

4.

5.

6.

7.

8.

ABB00728 AB

9.

10.

11.

12.

13.

14.

15.

Cowl top panel lower Cowl top stay side Wiper side bracket Upper frame extension inner Fender bracket Cowl top panel upper Deck crossmember bracket Brake pedal support bracket

Brake pedal reinforcement upper Wiper front bracket Harness bracket Wiper bracket centre Harness bracket Cowl top panel inner Cowl top stay centre

DASH PANEL • The front frame structure is supported in three directions by the dash crossmember centre, dash crossmember lower and front sidemember rear in order to improve the frontal collision characteristics, and increase the vehicle body rigidity.

• The 590-MPa class high tensile strength steel panels have been adopted for the dash crossmember centre, dash crossmember side and dash panel reinforcement to improve the frontal collision characteristics.

7 8

6

5

18*

16 10

4

17

3*

Brake tube bracket Harness bracket Dash crossmember centre

12*

1

NOTE: *: Indicates 590MPa-high-tensile steel panels.

1.

2.

3.

11

15 14*

2

9

13*

ABB00729AB

4.

5.

6.

Dash heat protector bracket Dash panel Backbone reinforcement front

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS 7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

Dash panel lower Front floor sidemember reinforcement upper EPS ECU A bracket EPS ECU B bracket EPS ECU C bracket Dash crossmember side Dash crossmember lower Dash crossmember extension Canister bracket Accelerator pedal bracket Steering shaft bracket Dash panel reinforcement

1-15

SIDE BODY M4010011001623

SIDE STRUCTURE • The 590 MPa-high-tensile steel panel has been adopted for the centre pillar and the roof side rail, and the 980 MPa-ultra-high-tensile steel panel has been adopted for the front pillar and the side sill to improve the collision characteristics.

• The front pillar, centre pillar and rear pillar have been connected to the roof, and the closed section structure has been adopted to the tailgate opening to improve body rigidity, steering stability, and riding comfort.

BODY CONSTRUCTION

1-16

BODY CONSTRUCTION CHARACTERISTICS

33

32

34

24

27

23 16

75

22

25

28

5 21 8

15

9*

19

14

30

13

32

13

10* 6**

29

16

1 7

26 20

12

18 35

17 71

31

11

39 72

65*

4

64**

73

37

42 44

70*

66

45

67 68*

63 62*

41

43

2

1

40

36 74

3

38

47 57* 69

55

61 63 60

47

53 51** 52 59

48

46

58 56*

54**

50

NOTE: *: Indicates 590MPa-high-tensile steel panels. **: Indicates 980MPa-ultra-high-tensile steel panels.

1.

2.

3.

4.

Front inner pillar lower Hood opener bracket (Left side) Cowl side trim bracket Harness bracket

49 5.

6.

7.

Deck crossmember bracket (Right side) Front upper inner pillar Roof rail extension front inner

ABC00041AB

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS 8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

63.

64.

Roof rail extension rear inner <Vehicles without sunroof> Roof side rail inner Centre pillar inner upper Centre pillar inner lower Side sill end plate Harness bracket Cargo hook bracket Rear wheel house reinforcement Rear wheel house inner panel Filler pipe mounting bracket (Left side) Rear wheel house reinforcement rear (Left side) Harness bracket (Right side) Gate inner pillar extension lower Gate inner pillar extension centre Gate inner pillar extension upper Gate inner pillar upper Gate pillar inner reinforcement (Left side) <Vehicles with electric tailgate> Gate inner pillar lower Gate pillar lower bulkhead Gate pillar upper reinforcement Gate pillar lower reinforcement Quarter inner upper panel Harness bracket Second seat belt reinforcement lower Quarter inner lower panel Jack support (Right side) Jack bracket (Right side) Rear pillar reinforcement lower Quarter inner front extension Quarter inner front extension lower Quarter outer panel extension upper Gas spring reinforcement Tailgate damper reinforcement side Rear lamp housing Rear lamp housing extension Quarter outer panel extension rear Quarter panel extension lower inner Fuel filler neck bracket (Left side) Side outer panel Nut plate Front fender bracket Fender bracket Front deck frame rear upper Side sill reinforcement outer rear Side sill bulkhead A Side sill reinforcement support front Side sill reinforcement outer front Side sill inner support front Side sill bulkhead front Front pillar reinforcement lower Front door hinge reinforcement lower Front pillar reinforcement bulkhead centre Front door checker reinforcement Front door hinge reinforcement upper Front pillar reinforcement lower support Deck support pipe (Left side) Front pillar reinforcement upper

65.

66.

67.

68.

69.

70.

71.

72.

73.

74.

75.

Roof side rail reinforcement centre Centre pillar seat belt reinforcement upper Centre pillar seat belt reinforcement lower Rear door hinge reinforcement Rear door hinge reinforcement lower Centre pillar reinforcement Roof side rail reinforcement rear Roof side rail reinforcement rear Second seat belt reinforcement upper Rear pillar reinforcement upper Harness bracket (Right side)

1-17

BODY CONSTRUCTION

1-18

BODY CONSTRUCTION CHARACTERISTICS

SIDE STRUCTURE REINFORCEMENT The ring structure of the side structure reinforcement has been adopted to improve the side collision characteristics and the rigidity of the whole vehicle.

Roof side rail reinforcement rear

Gate pillar upper reinforcement

Roof side rail reinforcement centre

Front pillar reinforcement upper

Gate pillar lower reinforcement

Rear pillar reinforcement upper Front pillar reinforcement lower

Rear pillar reinforcement lower Centre pillar reinforcement Side sill reinforcement outer rear Side sill reinforcement outer front

REAR BODY M4010012001002

REAR END CROSSMEMBER The 590-MPa class high tensile strength steel panels have been adopted for the rear end inner crossmember side to improve the frontal collision characteristics.

ABB00770 AB

BODY CONSTRUCTION

1-19

BODY CONSTRUCTION CHARACTERISTICS

6 5

8 7

4* 9 3

1 4* 2

NOTE: *: Indicates 590MPa-high-tensile steel panels.

1.

2.

3.

4.

5.

6.

7.

8.

9.

Rear end inner centre crossmember Spare tyre bracket Rear bumper bracket Rear end inner crossmember side Spare tyre reinforcement rear end Rear bumper reinforcement Rear end panel outer Nut plate Tailgate striker reinforcement

3

ABB00771AB

ROOF M4010013001782

The 590-MPa class high tensile strength steel panels has been adopted for the roof bow centre lower to improve the side collision characteristics.

BODY CONSTRUCTION

1-20

BODY CONSTRUCTION CHARACTERISTICS

<Vehicles without Sunroof>

5 19

5.5 ± 1.5 N·m

21 20

6

7

8

5.5 ± 1.5 N·m

20

19 5.5 ± 1.5 N·m

6

11

13

12

14 18

9

10

13 15 17

3

16*

4

9

2

21 ± 8 N·m

NOTE: 1 *: Indicates 590MPa-high-tensile steel panels.

2

3

ABB00772 AB

<Vehicles with Sunroof>

5 19

5.5 ± 1.5 N·m

6

7

8

21 20 5.5 ± 1.5 N·m

19 20

13

5.5 ± 1.5 N·m

1.

2.

3.

Map lamp bracket Holder bracket Sunvisor bracket

13

26

23

4 2

12

14

18

3

1

6

11 10

9

22

22

25 24 9 21 ± 8 N·m

2

3

ABB00773 AB

4.

5.

6.

Roof rail front Roof panel Tailgate hinge reinforcement

BODY CONSTRUCTION

1-21

BODY CONSTRUCTION CHARACTERISTICS 7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Roof rail rear outer Second seat belt bracket centre Roof rail bracket <Vehicles with roof rail> Roof rail rear inner Roof bow D Roof bow C Head lining bracket Roof bow B Roof bow centre upper Roof bow centre lower Roof bow A Weight assembly Roof rail bracket <Vehicles with roof rail> Roof carrier bracket <Vehicles without roof rail> Roof rail bracket <Vehicles with roof rail>

8

22.

23.

24.

25.

26.

Set bracket rear Sunroof bracket Set bracket front Set bracket front Roof reinforcement

UNDER BODY M4010014001633

FRONT FLOOR The 590-MPa class high tensile strength steel panels have been adopted for the front floor sidemember and front floor sidemember front, and the 980-MPa class ultra high tensile strength steel panels for the front floor crossmember front and front floor side sill inner to improve the body rigidity.

9

6

10 5 18 ± 7 N·m

7

4** 3 3 11 2* 19

1

12**

15 18 17

13 NOTE : *: Indicates 590MPa-high-tensile steel panels. **: Indicates 980MPa-ultra-high-tensile steel panels.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Front floor Front floor sidemember Nut plate Front floor crossmember front Parking brake lever reinforcement Backbone reinforcement Parking brake cable reinforcement Seat centre bracket rear Seat side bracket rear Front floor crossmember rear Seat belt reinforcement

16*

14* ABB00774 AB

12.

13.

14.

15.

16.

17.

18.

19.

Front floor side sill inner Front floor reinforcement Front floor sidemember front Front floor sidemember plate Front floor sidemember Backbone crossmember front Muffler hanger hook Front floor crossmember rear centre

BODY CONSTRUCTION

1-22

BODY CONSTRUCTION CHARACTERISTICS

REAR FLOOR The 590-MPa class high tensile strength steel panels have been adopted for the rear floor extension, second seat rear reinforcement centre and rear seat crossmember to improve the side collision characteristics.

4 3

2 5 6 7 9 1* 14*

15

8 13* 10

17

11 12

16

18

15 16 NOTE : *: Indicates 590MPa-high-tensile steel panels.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Rear floor extension Second seat front bracket centre Rear seat under floor Rear floor Rear floor side panel Rear floor crossmember rear end Rear floor crossmember centre Third seat bracket centre front Rear floor crossmember front Fuel tank rear bracket Nut plate Front stringer Second seat rear reinforcement centre Rear seat crossmember

ABC00047AB

15.

16.

17.

18.

Rear seat crossmember bulkhead side Sidemember front floor extension Rear seat crossmember bulkhead inner Rear floor sidemember

REAR FLOOR SIDEMEMBER REINFORCEMENT The 590-MPa class high tensile strength steel panels have been adopted for the rear bumper support, rear floor side sill inner and rear floor sidemember bulkhead to improve the rear collision characteristics.

BODY CONSTRUCTION

1-23

BODY CONSTRUCTION CHARACTERISTICS

4

3 27 25

2

6 7*

5

24

23 22

21

26

20

28 11

19*

1

8

3

18

17 16

12 10

9

15 NOTE : *: Indicates 590MPa-high-tensile steel panels.

14 13*

ABB00776AB

28

1 16

27

B

6

A

13 19

12

17

18 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

25 20

21

Rear floor sidemember reinforcement Third seat bracket side front Rear floor sidemember extension Muffler hanger rear (Right side) Rear floor crossmember extension rear Third seat anchor reinforcement Rear bumper support Shipping pipe Rear spring house panel Rear spring house bracket Rear spring house reinforcement Rear suspension bracket front Rear floor side sill inner Rear brake hose bracket Rear parking brake cable rear bracket Rear floor sidemember lower

26

3

ABB00777AB

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

Rear floor sidemember extension front Rear tie down plate Rear floor sidemember bulkhead Rear floor sidemember reinforcement rear Trailing arm bracket Rear floor crossmember extension front Rear floor crossmember extension centre Rear floor crossmember extension centre lower Rear floor sidemember bulkhead rear Rear floor sidemember reinforcement rear Rear suspension bracket rear Pipe nut

BODY CONSTRUCTION

1-24

BODY CONSTRUCTION CHARACTERISTICS

A

B

1 1 16

16

21

13

20

12 ABB00779AB

ABB00778AB

DOOR M4010015001120

An uneven thickness steel sheet* has been used for the front door panel inners to make the forward part of the vehicle thicker for reduction in vehicle weight and higher rigidity.

NOTE: *: A steel sheet of varying thickness that is welded into one steel sheet.

(Front door)

1

2 3 13 4 11 8 12 9 10 7 6

5 Welded area ABB00780AB

BODY CONSTRUCTION

1-25

SILENCER APPLICATION LOCATIONS (Rear door)

15

14

16 21 17

24

25

22

23

20 18 19 ABB00781AB

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Front door panel outer Front door window upper sash Front door window rear sash Front door latch reinforcement Front door panel inner Nut plate Front door side door beam Front door outer stiffener rear Front door outer stiffener front Front door mirror reinforcement Front door window front sash Front door beltline outer reinforcement Front door beltline inner reinforcement

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

Rear door panel outer Rear door window upper sash Rear door window rear sash Rear door latch reinforcement Rear door panel inner Nut plate Rear door side door beam Rear door outer stiffener rear Rear door outer stiffener front Rear door hinge reinforcement Rear door window front sash Rear door beltline outer reinforcement

SILENCER APPLICATION LOCATIONS M4010000100128

A silencer (spray-type anti-vibration agent) have been adhered on the top part of the floor and the inside of the cowl top panel inner to improve anti-vibration performance and to shut out exhaust gas heat.

1-26

BODY CONSTRUCTION LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL

NOTE: : 2.5 mm film thick spray-type anti-vibration agent. (Place two 1.6 mm melting sheet one on top of another.) : 4.0 mm film thick spray-type anti-vibration agent. (Place three 1.6 mm melting sheet one on top of another.) ( ) indicates the number of 1.6 mm thick melting sheets that are used for repair.

ABC00051AB

LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL M4010018000405

CAUTION The sound dampening foam material may burn when heated. Always observe the following instructions: • Never use a gas burner to burn the areas where sound dampening foam material are used.

• When cutting the parts which are provided with sound dampening foam material, ensure to use tools (air saw, etc.) that do not generate fire.

• If there are residual sound dampening foam material remaining on the cut section (body side), remove the sound dampening foam material from periphery of the welding area

before welding work.

1. The sound dampening foam material has been adopted to the upper and lower sections of the front pillar, roof side rail section, centre pillar lower section, wheel house arch, and rear end inside to shield from external noise.

2. Urethane foam has been inserted into the centre pillar lower section to shield from external noise.

BODY CONSTRUCTION STIFFENER AND DAMP SHEET APPLICATION LOCATIONS

1-27

1

1

1

2 1 ABB00855AB

STIFFENER AND DAMP SHEET APPLICATION LOCATIONS M4010001400490

To enhance the surface stiffness, a stiffener is adhered to the inside of the side outer panel, and a damping sheet is adhered to the inside of the dash panel.

1-28

BODY CONSTRUCTION STIFFENER AND DAMP SHEET APPLICATION LOCATIONS

NOTE: .

• The main contents of a stiffener are epoxy resin.

It comes in a sheet form and contains a mixture of glass fibre and filler, and cures (stiffens) when heated.

• No spare part of the stiffener for repair is available in the field. If the stiffener is damaged, replace it together with the panel.

Stiffener

Stiffener

ABB00856AB

Damp sheet

ABB00857AB

2-1

GROUP 2

BODY DIMENSIONS CONTENTS BODY DIMENSIONS AND MEASUREMENT METHODS . . . . . . . . . . . . . . . . . . . . .

2-2

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS). . . . . . . . . . . . . . . . . . .

2-7

UNDER BODY. . . . . . . . . . . . . . . . . . . . . . .

2-7 2-9

TYPE A (PROJECTED DIMENSIONS) .................................

2-3

SUSPENSION INSTALLATION DIMENSIONS ......................................

UNDER BODY . . . . . . . . . . . . . . . . . . . . . .

2-3

FRONT BODY . . . . . . . . . . . . . . . . . . . . . . .

2-11

SIDE BODY . . . . . . . . . . . . . . . . . . . . . . . . .

2-14

REAR BODY . . . . . . . . . . . . . . . . . . . . . . . .

2-17

INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . .

2-18

SUSPENSION INSTALLATION DIMENSIONS ......................................

2-5

BODY DIMENSIONS

2-2

BODY DIMENSIONS AND MEASUREMENT METHODS

BODY DIMENSIONS AND MEASUREMENT METHODS M4020001000448 •

•

Projected dimension Centre of hole Height Probe

AB302138AE

Type A (projected dimensions) is the dimension when a measurement location is projected onto the plane.

NOTE: The height indicates a distance from the assumed standard line established 100 mm below the lowest measurement point.

Insert the tracking gauge probes securely into the measurement holes.

• When the standard dimensions in the illustration are enclosed by rectangle, this indicates that the symmetrical left and right positions have the same dimensions.

•

•

A

AB302140AF

Ac dim tual en -me sio as n ure

d

A'

AB302139AE

Type B (actual-measurement dimensions) is the actual distance between the measurement points. Measure using a tracking gauge or a measuring tape, etc.

NOTE: .

• Make the lengths of the tracking gauge probes the same (A=A’).

• Do not bend or twist the measuring tape.

AB302141AD

When using a notch for dimension measurement, set the measuring point at the centre of the outer panel notch.

• The body centre points are shown for the purpose of checking the position of the left and right symmetry location.

BODY DIMENSIONS

2-3

TYPE A (PROJECTED DIMENSIONS)

TYPE A (PROJECTED DIMENSIONS) UNDER BODY M4020005002598

Unit: mm 833

711 171 540

701

510 462

624 976

6

910

962

752

894

1262

877

197 960

875

894

5 564

2 1

1022

1056

375

4

350

3

7

8

393

374

440

10

11

582

12

9

1050 Centre line of the vehicle

ABB00759AB

Unit: mm

1218

6

1394

1079

763

983

1272 1216

1180

1028

5 544

2

3

4

1342 1125

960

686

1

1416

1025

1138 641

1126

7

8

10

11 12

9 Centre line of the vehicle

ABB00760AB

No. Standard measurement point

Hole shape

Size mm

1*

Centre of front end side panel mounting hole

Round

16

2*

Centre of front sidemember inner positioning hole

Round

25

3*

Centre of front axle crossmember mounting hole

Round

15.5

4*

Centre of front sidemember rear water draining hole

Round

16

5

Centre of propeller shaft assembly mounting hole (left side)

Round

11

6

Centre of propeller shaft assembly mounting hole (right side)

Round

11

7*

Centre of front floor sidemember front positioning hole

Round

16

8*

Centre of front floor sidemember front positioning hole

Round

16

9*

Centre of rear floor sidemember lower positioning hole

Oblong

33.9×18

10*

Centre of rear suspension bracket front water draining hole

Round

16

BODY DIMENSIONS

2-4

TYPE A (PROJECTED DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm

11*

Centre of rear floor sidemember lower positioning hole

Round

25

12*

Centre of trailer hitch mounting hole

Round

11

NOTE: The * mark indicates the mounting position for the frame centring gauge.

Unit: mm

486

2

3

1 4 187

347 294

5 259

100

510

11

10

6

12

9

8 7

157 105

105

154

286

354

358

716 350

1049

326 750

1220

1136 1712

NOTE: The assumed standard line is established 100 mm below the measurement point No.4.

3

1, 2

ABB00756AB

4

2

1

ABB00743AB

ABB00745AB

7

5, 6

6

ABB00943AB

8, 9

5

8 9

ABB00747AB

ABB00748AB

ABB00749AB

BODY DIMENSIONS

2-5

TYPE A (PROJECTED DIMENSIONS)

10, 11

12

10

11 ABB00940AB

ABB00752AB

SUSPENSION INSTALLATION DIMENSIONS M4020013002463

Unit: mm 822 510

694 289

603

1129

886 910

3

1288 875

293

1092 894

217

13

1000

8

16

15

579

4

903

254

98

19

1093

17

441 714

18

14

Centre line of the vehicle

ABB00761AB

Unit: mm

1231

1212

1145

945

1047

1253

907

1294

1171

1028

1075

3

13

4

8

15

16

17

14 Centre line of the vehicle

ABB00762AB

No. Standard measurement point

Hole shape

Size mm

3

Centre of front axle crossmember mounting hole

Round

15.5

4

Centre of front sidemember rear water draining hole

Round

16

BODY DIMENSIONS

2-6

TYPE A (PROJECTED DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm

8

Centre of front floor sidemember front positioning hole

Round

16

13

Centre of front axle crossmember mounting hole

Round

15.5

14

Centre of trailing arm assembly mounting hole

Round

14

15

Centre of trailing arm assembly mounting hole

Round

14

16

Centre of rear suspension crossmember mounting hole

Round

15

17

Centre of rear suspension crossmember mounting hole

Round

15

18

Centre of rear shock absorber assembly mounting hole

Round

64

19

Centre of front strut assembly mounting hole

Round

92.6

A

B

Vehicle centre

Unit: mm

Vehicle centre 6˚30´

6˚54´

539 A

3˚06´

1122

19 B

3 13

782 294

162

100

17 222

105

18

16

8

4

284

354

462

570

1066

217 Standard line

0˚

15 14

820

510

1258 NOTE: The assumed standard line is established 100 mm below the measurement point No.4.

3

4, 13

ABB00764AB

8

13

4 ABB00745AB

ABB00746AB

ABB00942AB

BODY DIMENSIONS

2-7

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

16, 17, 18

14, 15

19

18

16 15

14

17

ABB00750AB

ABB00744 AB

ABB00751AB

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) UNDER BODY M4020005002606

Unit: mm 856

719 235 542

702

546

6 487

644 976

910

960

875

222

894

4

1262

1022

350

3

1

894

877

1056

5 378

567

2

965

774

7

399

8 377

460

10

11

582

12

9

1079

ABB00765AB

Unit: mm

1273

996

1225

1138

765

1185

6

1418

1027

643

1415

1230

1356

1046

5

1081

1

2

3

1125 565

960

704

4

1127

7

8

10

11

12

9 ABB00766AB

BODY DIMENSIONS

2-8

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm

1

Centre of front end side panel mounting hole

Round

16

2

Centre of front sidemember inner positioning hole

Round

25

3

Centre of front axle crossmember mounting hole

Round

15.5

4

Centre of front sidemember rear water draining hole

Round

16

5

Centre of propeller shaft assembly mounting hole (left side)

Round

11

6

Centre of propeller shaft assembly mounting hole (right side)

Round

11

7

Centre of front floor sidemember front positioning hole

Round

16

8

Centre of front floor sidemember front positioning hole

Round

16

9

Centre of rear floor sidemember lower positioning hole

Oblong

33.9×18

10

Centre of rear suspension bracket front water draining hole

Round

16

11

Centre of rear floor sidemember lower positioning hole

Round

25

12

Centre of trailer hitch mounting hole

Round

11

3

1, 2

4

2

1

ABB00743AB

ABB00745AB

7

5, 6

6

ABB00943AB

8, 9

5

8 9

ABB00747AB

10, 11

ABB00748AB

12

10

11 ABB00940AB

ABB00752AB

ABB00749AB

BODY DIMENSIONS

2-9

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

SUSPENSION INSTALLATION DIMENSIONS M4020013002474

Unit: mm 841 546

707 295

614

910

886 875

322

3

1288 894

226

1092 1000

4

13

8

16

15

590

262

98

903

446

17

727

14 ABB00767AB

Unit: mm

1236 1219

1151

954

1050

1265 909

1300

1173

1046

1077

3

13

4

8

15

16

17

14 ABB00768AB

No. Standard measurement point

Hole shape

Size mm

3

Centre of front axle crossmember mounting hole

Round

15.5

4

Centre of front sidemember rear water draining hole

Round

16

8

Centre of front floor sidemember front positioning hole

Round

16

13

Centre of front axle crossmember mounting hole

Round

15.5

14

Centre of trailing arm assembly mounting hole

Round

14

15

Centre of trailing arm assembly mounting hole

Round

14

16

Centre of rear suspension crossmember mounting hole

Round

15

17

Centre of rear suspension crossmember mounting hole

Round

15

BODY DIMENSIONS

2-10

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

3

4, 13

8

13

4 ABB00745AB

14, 15

ABB00746AB

16, 17

16

14

17

15 ABB00750AB

ABB00941AB

ABB00942AB

BODY DIMENSIONS

2-11

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

FRONT BODY M4020006001651

Unit: mm

38 Body centre point 1184

39

966 1644

1137

1494 1446

568

36

1010

35

412

28

34 280

1518

1430

32 30

916

1509

415

27

450

24 928

29

23 1052

450

22

ABB00687AB

BODY DIMENSIONS

2-12

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) Unit: mm

33 Body centre point

36 786

724

936

34 796

1568

1500 1497

28

793

32 27

937

629 1078 628 1082 1016

1020 894

22

21 ABB00677AB

Unit: mm

33 Body centre point 1450

353

37 1490 1496

344

396

36

518 1473

34 35

786

872

1392 814

276

26

30

820

32

31

1005 869

24

1026

258 163

29 969

296

23 167

250

700

20 Body centre point

25

289

22

21 ABB00678AB

BODY DIMENSIONS

2-13

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm

20

Body centre point of front end crossmember upper (Body centre point)

Round

6

21

Centre of intercooler mounting hole

Round

12

22

Centre of front bumper reinforcement mounting hole

Round

9

23

Centre of front bumper reinforcement mounting hole (left side)

Round

12

24

Centre of front bumper reinforcement mounting hole (right side)

Round

12

25

Centre of fender gusset positioning hole (left side)

Round

15

26

Centre of fender gusset positioning hole (right side)

Round

15

27

Centre of headlamp support panel upper mounting hole (left side)

Round

11

28

Centre of headlamp support panel upper mounting hole (right side)

Round

11

29

Centre of front sidemember inner positioning notch (left side)

−

−

30

Centre of front sidemember inner positioning notch (right side)

−

−

31

Centre of fender mounting hole

Round

6.6

32

Centre of front end upper bar side positioning hole

Oblong

8×12

33

Cowl top panel lower positioning notch (Body centre point)

−

−

34

Centre of fender mounting hole

Round

6.6

35

Centre of front strut assembly mounting hole

Round

11.5

36

Centre of hood hinge mounting hole

Round

9

37

Centre of fender mounting hole

Round

6.6

38

Centre of pin mounting hole (Body centre point)

Rectangle

8×10

39

Corner of roof panel

−

−

20, 21

22, 23, 25

20

24, 26 25

26 24

23 21 22

ABB00689AB

ABB00688AB

27, 31, 32

32

28

ABB00690AB

29

27 31

ABB00691AB

ABB00694AB

ABB00692AB

BODY DIMENSIONS

2-14

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

33

30

34, 35 35

ABB00693AB

36, 37

ABB00695AB

38

37

34

ABB00696AB

39

36

ABB00697AB

ABB00698AB

ABB00699AB

SIDE BODY M4020007001397

Unit: mm

46

42 44

40

713

867

48 1163

770

677 1232

746

878 986

41

869 1115

43

758

45

1126

49

47 ABB00680AB

BODY DIMENSIONS

2-15

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

Unit: mm

46

42

716

951

52 897

1117

50 1122

378

988

410 1197

51

1067

54

53

ABB00681AB

No. Standard measurement point

Hole shape

Size mm

40

Front pillar positioning notch

−

−

41

Front pillar positioning notch

−

−

42

Roof side rail positioning notch

−

−

43

Side sill positioning notch

−

−

44

Centre pillar positioning notch

−

−

45

Centre pillar positioning notch

−

−

46

Roof side rail positioning notch

−

−

47

Side sill positioning notch

−

−

48

Quarter panel positioning notch

−

−

49

Quarter panel positioning notch

−

−

50

Centre of front door upper hinge mounting hole

Round

11

51

Centre of front door lower hinge mounting hole

Round

11

52

Centre of rear door upper hinge mounting hole

Round

11

53

Centre of rear door lower hinge mounting hole

Round

11

54

Centre of rear door switch mounting hole

Round

5

40

41, 51

42

41 51

ABB00703 AB

ABB00704AB

ABB00705AB

BODY DIMENSIONS

2-16

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

43

45, 53

44

45

ABB00706AB

46, 48

ABB00707AB

53

ABB00708AB

49

47

46 48 ABB00709AB

ABB00711AB

52

50

ABB00730AB

ABB00712AB

54

ABB00731AB

ABB00732 AB

BODY DIMENSIONS

2-17

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

REAR BODY M4020008001367

Unit: mm

55

730

1073

56

724

762 1307

1056

1042

1545

58

1314

1120 272

614 1175

59 1417

60

62 1166

1056

61 ABB00733AB

Unit: mm 1166

57

1308 693 111 1115

60 61 ABB00733AB

No. Standard measurement point

Hole shape

Size mm

55

Centre of tailgate hinge mounting hole

Round

12

56

Centre of tailgate gas spring assembly mounting hole

Round

9

57

Centre of rear combination lamp assembly mounting hole

Square

8.5

58

Centre of rear combination lamp assembly mounting hole

Round

8

59

Centre of rear bumper assembly mounting hole

Round

7

BODY DIMENSIONS

2-18

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm

60

Centre of rear bumper reinforcement mounting hole

Round

15

61

Centre of rear bumper reinforcement mounting hole

Round

15

62

Centre of tailgate striker mounting hole

Round

14

55, 56

57, 58

55

59

57

58

56

ABB00735AB

ABB00734AB

ABB00736AB

62

60, 61 60

61 ABB00737AB

ABB00738AB

INTERIOR M4020009001724

Unit: mm 1238

1273 1382 1380

46 1372

42 40

48

44

1432 1439 1430

41

1430

49

45

1430

47 43

ABB00702 AB

BODY DIMENSIONS

2-19

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

Unit: mm

46

42 44

40

1234

1252 1238

48

1195

1202

768

786

1034

49

45 41

725 803

47

43 64 Body centre point 63 Body centre point

ABB00710AB

Unit: mm

64 Body centre point 998 1093 769

65

1116 600

66

ABB00741AB

No. Standard measurement point

Hole shape

Size mm

40

Front pillar positioning notch

−

−

41

Front pillar positioning notch

−

−

42

Roof side rail positioning notch

−

−

43

Side sill positioning notch

−

−

44

Centre pillar positioning notch

−

−

45

Centre pillar positioning notch

−

−

46

Roof side rail positioning notch

−

−

47

Side sill positioning notch

−

−

48

Quarter panel positioning notch

−

−

49

Quarter panel positioning notch

−

−

63

Centre of backbone reinforcement positioning hole (Body centre point)

Round

15

BODY DIMENSIONS

2-20

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm

64

Alignment projection on the rear seat under floor (Body centre point)

−

−

65

Centre of rear shock absorber assembly mounting hole

Round

14

66

Centre of rear end trim mounting hole

Round

8.5

41

40

ABB00703 AB

43

42

ABB00814AB

45

44

ABB00706AB

46, 48

ABB00705AB

ABB00707AB

ABB00815AB

49

47

46 48 ABB00709AB

63

ABB00711AB

64

ABB00713AB

ABB00712AB

65

ABB00714AB

ABB00739AB

BODY DIMENSIONS

2-21

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

66

ABB00851AB

Unit: mm

69

67 1428

1435

1431

106

102

1431

70

68

ABB00676AB

No. Standard measurement point

Hole shape

Size mm

67

Centre of front deck crossmember mounting hole

Round

13

68

Centre of front deck crossmember mounting hole

Round

13

69

Centre of front deck crossmember mounting hole

Round

9

70

Centre of front deck crossmember mounting hole

Round

9

69, 70

67, 68

69

67 68

70

ABB00700AB

ABB00701AB

3-1

GROUP 3

WELDED PANEL REPLACEMENT CONTENTS ULTRA HIGH STRENGTH STEEL PLATE .................................

3-2 FRONT END CROSSMEMBER . . . . .

FENDER SHIELD. . . . . . . . . . . . . . . .

3-23

REAR FLOOR. . . . . . . . . . . . . . . . . . .

3-24

QUARTER INNER. . . . . . . . . . . . . . . .

3-25

QUARTER INNER LOWER . . . . . . . .

3-29

3-2 3-3

FRONT SIDEMEMBER (PARTIAL REPLACEMENT) . . . . . . . . . . . . . . . .

3-8

FRONT PILLAR . . . . . . . . . . . . . . . . .

3-9

CENTRE PILLAR . . . . . . . . . . . . . . . .

3-12

SIDE SILL. . . . . . . . . . . . . . . . . . . . . .

3-15

QUARTER OUTER . . . . . . . . . . . . . .

3-18

ROOF . . . . . . . . . . . . . . . . . . . . . . . . .

REAR END CROSSMEMBER . . . . . .

3-21

FRONT DOOR OUTER PANEL (WELDED TYPE) . . . . . . . . . . . . . . . . . . . . . . . . .

3-32 FRONT DOOR OUTER PANEL (ADHESION TYPE) . . . . . . . . . . . . . . . . . . . . . . . . .

3-33 REAR DOOR OUTER PANEL (WELDED TYPE) .................................

3-35 REAR DOOR OUTER PANEL (ADHESION TYPE) . . . . . . . . . . . . . . . . . . . . . . . . .

3-36

3-2

WELDED PANEL REPLACEMENT ULTRA HIGH STRENGTH STEEL PLATE

ULTRA HIGH STRENGTH STEEL PLATE M4030002800073

ADVANTAGES OF ULTRA HIGH STRENGTH STEEL PLATE The ultra high strength steel plate has the following advantages as compared with conventional high strength steel plate.

• It has tensile strength approximately 1.7 times higher than the conventional high strength steel sheet.

• It has a higher yielding point and yielding ratio (yielding point/tensile strength).

These advantages allow thinner and lighter plates and better fuel efficiency than the high strength steel plate.

PRECAUTION UPON MAINTENANCE OF ULTRA HIGH STRENGTH STEEL PLATE • Use a spot cutter for ultra high strength steel plate to ensure that the spot-welded area is cut off.

• For the part in which the ultra high strength steel plate is used, do not repair it by cutting and bonding to avoid the reduction in strength by heat.

Instead, replace the whole assembly including the part.

• Be careful with rough extending work, because the ultra high strength steel plate has higher tensile strength and a higher yielding point than high strength steel plate and general steel plate. Careless work will cause symptom such as over-pulling and springback. Do not extend it completely at a time. Do it gradually while removing the distortion by sheet metal processing with a hammer.

• Plug welding of φ 8 mm diameter plug for repair ensures the strength equivalent to spot welding for 2 steel sheets. For 3 sheets, weld 2 sheets each time instead of welding from one side to give sufficient welding strength.

FRONT END CROSSMEMBER M4030003100408

Symbol

Operation description Spot welding MIG plug welding

(

: indicates two panels to be welded : indicates three panels to be welded

MIG spot welding MIG arc welding (continuous) Braze welding

ABC00011AB

Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

)

WELDED PANEL REPLACEMENT

3-3

FENDER SHIELD

REPAIR WELDS

A

A ABB00797AB

FENDER SHIELD M4030004001731

Symbol

Operation description Spot welding MIG plug welding

(

: indicates two panels to be welded : indicates three panels to be welded

MIG spot welding MIG arc welding (continuous) Braze welding

ABC00012AB

Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

)

3-4

WELDED PANEL REPLACEMENT FENDER SHIELD

REPAIR WELDS

A

A ABB00843 AB

NOTE: Refer to the Front End Crossmember section on P.3-2 for the welding point with headlamp support panel lower.

WELDED PANEL REPLACEMENT

3-5

FENDER SHIELD

24 ± 4 N·m

B I F

J

H

C

D

B

E

G

C

ABB00844AB

WELDED PANEL REPLACEMENT

3-6

FENDER SHIELD

(With the front deck frame front upper and front deck frame rear upper removed)

E

D

F

G

H

H

(Right side)

(Left side) ABB00845AB

WELDED PANEL REPLACEMENT

3-7

FENDER SHIELD

I

J ABB00846AB

NOTE ON REPAIR WORK REMOVAL

INSTALLATION

Front sidemember inner

Hole position Front body frame to side sill brace

Front sidemember outer

Front sidemember outer Front body frame to side sill brace

ABB00848 AB ABB00847AB

Turn up the front sidemember outer as shown to cut off the welded point between the front sidemember inner and the front body frame to side sill brace.

Before installing a new front sidemember, remove the front floor sidemember from the existing front sidemember. The welding point between the front sidemember inner and the front body frame-to-side sill brace is not visible from the front sidemember outer. Drill a hole into the front sidemember outer at the same point as the welding point which is visible from the front sidemember inner. Then cut the welding point from front body frame-to-side sill brace.

Then weld the front sidemember inner to the front body frame-to-side sill brace and the front sidemember outer.

WELDED PANEL REPLACEMENT

3-8

FRONT SIDEMEMBER (PARTIAL REPLACEMENT)

FRONT SIDEMEMBER (PARTIAL REPLACEMENT) M4030000100937

Symbol

Operation description Spot welding MIG plug welding

(

: indicates two panels to be welded : indicates three panels to be welded

MIG spot welding MIG arc welding (continuous) Braze welding

ABC00013AB

Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

REPAIR WELDS (Right side)

(Left side)

A

50 mm

45 mm

B

A

B ABC00059AB

NOTE: .

• Refer to the Front End Crossmember section on P.3-2 for the welding point with the headlamp support panel lower.

• Refer to the Fender Shield section on P.3-3 for the welding points with the headlamp support panel and headlamp support panel lower.

)

WELDED PANEL REPLACEMENT

3-9

FRONT PILLAR

FRONT PILLAR M4030005002113

CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn.

Symbol

Operation description Spot welding MIG plug welding

(

: indicates two panels to be welded : indicates three panels to be welded

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

ABC99914AB

REPAIR WELDS Sound dampening foam material

A B F

270 mm

A

B

D

C

C

G

E

The same position as the new front outer pillar parts ABB00889 AB

)

WELDED PANEL REPLACEMENT

3-10

FRONT PILLAR

Sound dampening foam material

E

D

F

(With the front deck frame rear upper and side outer panel removed)

G

(With the side outer panel removed) ABB00890AB

NOTE: Refer to the Fender Shield section on P.3-3 for the welding points with the front deck frame rear upper.

NOTE ON REPAIR WORK

WELDED PANEL REPLACEMENT

3-11

FRONT PILLAR

REMOVAL Cutting position

270 mm

3. When installing the new front pillar reinforcement lower inner parts, in order to prevent the dripping of sound dampening foam material to be filled into the front pillar in the next process, install the front pillar silencer lower to the front pillar reinforcement lower inner, and then apply the butyl-tape to close the hole and gap of the front pillar silencer lower.

ABC00045AB

1. Cut the side outer panel as shown to separate the front pillar reinforcement lower from the front pillar upper reinforcement and the side sill reinforcement outer rear.

INSTALLATION 1. Install the new front lower inner pillar parts.

Side sill bulkhead A

Side sill reinforcement outer rear NOTE: : Body sealant AB900563 AB

2. When installing the new side sill reinforcement parts, remove the side sill reinforcement outer rear and the side sill bulkhead A from the side sill reinforcement.

ABB00893AB

4. Prior to assembling the new front outer pillar parts, apply the body sealant to the area shown in the figure.

Front pillar silencer lower A

Front pillar reinforcement lower

ABB00872AB

Front inner A pillar lower NOTE: : Sound dampening foam material ABC00044AB

3-12

WELDED PANEL REPLACEMENT CENTRE PILLAR

5. After installing the front outer pillar, seal the hole and flange with bolt and sheet-metal tape, and then fill the hole with foam materials as shown in the figure.

Sound dampening foam material: 3M ATD Part No.08463

AB100787

6. Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminium tape, then melt the sound dampening foam material with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with sound dampening foam material.

CENTRE PILLAR M4030006001362

CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn.

Symbol

Operation description Spot welding MIG plug welding

(

: indicates two panels to be welded : indicates three panels to be welded

MIG spot welding MIG arc welding (continuous) Braze welding

ABC00015AB

Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

)

WELDED PANEL REPLACEMENT

3-13

CENTRE PILLAR

REPAIR WELDS

A

D Cutting position

90 mm A

E B

F C

B

Sound dampening foam material The same position as the new centre outer pillar part

The same position as the new centre outer pillar part

C ABB00947AB

WELDED PANEL REPLACEMENT

3-14

CENTRE PILLAR Roof rail extension rear inner <Vehicles without sunroof>

Cutting position

D

E

F

(With the side outer panel removed) ABB00948AB

Roof rail extension rear inner <Vehicles without sunroof>

NOTE ON REPAIR WORK REMOVAL

Roof side rail inner

Cutting position Cutting position

Cutting position Centre pillar inner upper

ABB00901AB

1. To cut the welding points between the centre pillar reinforcement and side sill reinforcement outer rear, cut the side outer panel as shown.

Cutting position ABB00902AB ABB00902

2. Remove the roof rail extension rear inner as the centre pillar inner upper remains on the vehicle body and cannot be removed. Slit the roof side rail inner as shown, and pull it towards you to remove it.

WELDED PANEL REPLACEMENT

3-15

SIDE SILL

INSTALLATION 75 mm

50 mm

50 mm 60 mm

60 mm

75 mm

A

Side outer panel

20 mm

Cutting position

450 mm

25 mm

Centre pillar reinforcement

ABB00944AB

1. To guarantee the strength of the centre pillar cut-off area, cut off the side outer panel as shown.

Centre pillar inner upper

A

NOTE: : Body loose panel cushion

Centre pillar inner lower

ABB00900AB

2. When installing the new centre inner pillar parts, remove the centre pillar inner lower from the centre inner pillar.

Side outer panel ABB00903AB

3. When installing the new centre outer pillar part, because the sound dampening foam material cannot be filled into the centre pillar, machine the body loose panel cushion (MR565301 or MR435765) as a substitute according to the method shown in the figure, and then attach it to the body.

SIDE SILL M4030007001677

CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn.

Symbol

Operation description Spot welding MIG plug welding

(

: indicates two panels to be welded : indicates three panels to be welded

MIG spot welding MIG arc welding (continuous) Braze welding

ABC00016AB

Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

)

WELDED PANEL REPLACEMENT

3-16

SIDE SILL

REPAIR WELDS

Sound dampening foam material

50 mm

25 mm 40 mm

A

B

D

C

Sound dampening foam material

E Sound dampening foam material

(With the side outer panel removed)

A

B

C ABB00916 AB

WELDED PANEL REPLACEMENT

3-17

SIDE SILL

D

E ABB00917AB

NOTE ON REPAIR WORK REMOVAL

INSTALLATION Centre pillar inner upper

80 mm

Centre pillar inner lower

ABB00900AB

Quarter inner front extension lower

1. When installing the new centre inner pillar parts, remove the centre pillar inner upper from the centre inner pillar.

Side sill reinforcement outer rear

Side sill end plate ABC00018 AB

When removing the side sill reinforcement outer rear, cut the centre pillar reinforcement 80 mm downward from the installation hole of the rear door hinge because the centre pillar reinforcement interferes with it. Remove the side sill end plate and the quarter inner front extension lower as the side sill reinforcement outer rear interferes with them.

Side sill bulkhead A AB501219 AD

2. When installing the new side sill reinforcement parts, use only the side sill reinforcement outer rear and the side sill bulkhead A. 3. After installing the side sill reinforcement, install the side sill end plate and the quarter panel extension front.

WELDED PANEL REPLACEMENT

3-18

QUARTER OUTER

4. When assembling the new front floor side sill outer parts, carry out the following procedure.

75 mm

50 mm

50 mm 60 mm

(1) Machine the body loose panel cushion (MR565301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the centre pillar.

75 mm

60 mm

A

20 mm

25 mm

450 mm

Centre pillar reinforcement

NOTE: : Body sealant

ABC00046AB

(2) Apply body sealant in the area shown in the figure of the front floor side sill outer.

A

NOTE: : Body loose panel cushion

Side outer panel ABB00903AB

QUARTER OUTER M4030008001391

CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn.

Symbol

Operation description Spot welding MIG plug welding

(

: indicates two panels to be welded : indicates three panels to be welded

MIG spot welding MIG arc welding (continuous) Braze welding

ABB00859 AB

Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

)

WELDED PANEL REPLACEMENT

3-19

QUARTER OUTER

REPAIR WELDS

C 240 mm

D

B 20 mm Centre of clip mounting hole

E

Sound dampening foam material The same position as the new quarter panel outer parts.

A

Right side 4 points on left side

A

B

C

ABB00865 AB

WELDED PANEL REPLACEMENT

3-20

QUARTER OUTER

100 mm

Centre of tailgate gas spring assembly mounting hole

D

E ABB00866AB

NOTE:

1. When installing the new quarter panel extension rear lower parts, apply the body sealant to the areas as shown in advance.

2. When assembling the new quarter panel outer parts, carry out the following procedure.

A NOTE:

: Cuttable range

15 mm

190 mm

ABB00867AB

Partial replacement is possible depending on the range of damage.

40 mm

NOTE ON REPAIR WORK INSTALLATION

Rear pillar reinforcement lower

Side outer panel

NOTE: : Body sealant

ABB00877 AB

A NOTE: : Body loose panel cushion

Quarter inner front extension

ABB00870AB

WELDED PANEL REPLACEMENT

3-21

ROOF

(1) Machine the body loose panel cushion (MR565301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the wheel arch.

Left side

NOTE:

: Body sealant

ABC00062AB

(2) Apply the body sealant in advance to the areas as shown.

ROOF M4030011001744

Symbol

Operation description Spot welding MIG plug welding

(

: indicates two panels to be welded : indicates three panels to be welded

MIG spot welding MIG arc welding (continuous) Braze welding

ABB00938AB

Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

)

WELDED PANEL REPLACEMENT

3-22

ROOF

REPAIR WELDS <Vehicles without sunroof>

A

A

A

<Vehicles without sunroof>

5.5 ± 1.5 N·m

A ABB00939AB

Adhesive: Urethane body sealer Brand: 3M ATD Part No.08684, 08782 or equivalent

INSTALLATION

NOTE ON REPAIR WORK

Roof rack seal

AB900631AB

When installing the new roof carrier bracket and roof rail bracket, install the roof rack seal to avoid water ingress.

WELDED PANEL REPLACEMENT

3-23

REAR END CROSSMEMBER

REAR END CROSSMEMBER M4030015000743

Symbol

Operation description Spot welding MIG plug welding

(

: indicates two panels to be welded : indicates three panels to be welded

)

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

ABB00816AB

REPAIR WELDS

A

A ABB00821AB

WELDED PANEL REPLACEMENT

3-24

REAR FLOOR

REAR FLOOR M4030010001309

Symbol

Operation description Spot welding MIG plug welding

(

: indicates two panels to be welded : indicates three panels to be welded

)

MIG spot welding MIG arc welding (continuous) Braze welding

ABB00828AB

Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

REPAIR WELDS

A ABB00827AB

B

A

B ABB00826AB AB

NOTE: Refer to the Rear End Crossmember section on P.3-23 for the welding points with the rear end panel.

WELDED PANEL REPLACEMENT

3-25

QUARTER INNER

QUARTER INNER M4030012001446

CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn.

Symbol

Operation description Spot welding MIG plug welding

(

: indicates two panels to be welded : indicates three panels to be welded

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

ABB00860AB

REPAIR WELDS

E 70 mm Left side Right side Right side C B

Sound dampening foam material

A D

F

G

H

(With the side outer panel removed)

A (With the rear pillar reinforcement and rear pillar reinforcement lower removed)

ABB00925AB

)

WELDED PANEL REPLACEMENT

3-26

QUARTER INNER

Right side

Sound dampening foam material

Left side B

C (Left side)

D

C (Right side)

AB ABB00926AB

WELDED PANEL REPLACEMENT

3-27

QUARTER INNER

10.0 ± 4.0 N·m

Sound dampening foam material

E

F

Left side

G

Left side

H (Right side)

NOTE: Refer to the Quarter Outer section on P.3-18 for the welding points with the quarter outer.

ABB00927AB

WELDED PANEL REPLACEMENT

3-28

QUARTER INNER

NOTE ON REPAIR WORK INSTALLATION 80 mm 40 mm

2. When installing the new rear pillar reinforcement lower part, machine the body loose panel cushion (MR565301 or MR435765) for replacement as shown and apply it to the rear pillar reinforcement lower part because the sound dampening foam material cannot be filled into the rear pillar reinforcement lower.

Rear end silencer side

Gate pillar lower bulkhead

A 40 mm

Roof side rail reinforcement rear ABB00891AB

Quarter inner upper panel

Side outer panel

A NOTE: : Body loose panel cushion

ABC00079AB

1. When installing the new quarter panel upper inner parts, machine the body loose panel cushion (MR565301 or MR435765) for replacement as shown and apply it to the quarter panel upper inner parts because the sound dampening foam material cannot be filled into the quarter panel upper inner.

3. When installing the new gate pillar reinforcement parts, in order to prevent the dripping of sound dampening foam material to be filled into the gate pillar in the next process, install the rear end silencer side to the gate pillar lower bulkhead, and then apply the butyl-tape to close the gap of the rear end silencer side.

B

40 mm 35 mm

A Gate inner pillar extension lower

85 mm

Gate pillar lower reinforcement

B NOTE: : Sound dampening foam material ABB00871AB

Rear pillar reinforcement lower

Quarter inner front extension

A NOTE: : Body loose panel cushion

ABB00880AB

4. After installing the quarter panel extension rear lower, seal the hole and flange with sheet-metal tape, and then fill the hole with the sound dampening foam material as shown in the figure of the instructions.

WELDED PANEL REPLACEMENT

3-29

QUARTER INNER LOWER

Sound dampening foam material: 3M ATD Part No.08463

5. Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminium tape, then melt the sound dampening foam material with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with sound dampening foam material.

AB100787

QUARTER INNER LOWER M4030001100338

CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn.

Symbol

Operation description Spot welding MIG plug welding

(

: indicates two panels to be welded : indicates three panels to be welded

MIG spot welding MIG arc welding (continuous) Braze welding

ABB00861 AB

Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

)

WELDED PANEL REPLACEMENT

3-30

QUARTER INNER LOWER

REPAIR WELDS 70 mm Left side Right side Right side C

Sound dampening foam material

A

B (With the side outer panel removed)

A (With the rear pillar reinforcement and rear pillar reinforcement lower removed)

B ABB00933AB

WELDED PANEL REPLACEMENT QUARTER INNER LOWER

3-31

C (Left side)

C (Right side) ABB00934AB

NOTE: Refer to the Quarter Outer section on P.3-18 for the welding points with the quarter outer.

WELDED PANEL REPLACEMENT

3-32

FRONT DOOR OUTER PANEL (WELDED TYPE)

NOTE ON REPAIR WORK INSTALLATION

When installing the new rear pillar reinforcement lower part, machine the body loose panel cushion (MR565301 or MR435765) for replacement as shown and apply it to the rear pillar reinforcement lower part because the sound dampening foam material cannot be filled into the rear pillar reinforcement lower.

40 mm

35 mm

A 85 mm

Rear pillar reinforcement lower

Quarter inner front extension

A NOTE: : Body loose panel cushion

ABB00880AB

FRONT DOOR OUTER PANEL (WELDED TYPE) M4030001501061

Symbol

Operation description Spot welding MIG plug welding

(

: indicates two panels to be welded : indicates three panels to be welded

MIG spot welding MIG arc welding (continuous) Braze welding

ABB00817AB

Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

)

WELDED PANEL REPLACEMENT

3-33

FRONT DOOR OUTER PANEL (ADHESION TYPE)

REPAIR WELDS

A

50 mm

A

NOTE: : Adhesive

ABB00805 AB

Adhesive: Urethane body sealer

Brand: 3M ATD Part No.08684, 08782 or equivalent NOTE: After hemming the new front door panel outer part, MIG spot weld the flange overlap section at a pitch of 50 mm.

FRONT DOOR OUTER PANEL (ADHESION TYPE) M4030001701139

Symbol

Operation description Spot welding MIG plug welding

(

: indicates two panels to be welded : indicates three panels to be welded

MIG spot welding MIG arc welding (continuous) Braze welding

ABB00818AB

Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

)

WELDED PANEL REPLACEMENT

3-34

FRONT DOOR OUTER PANEL (ADHESION TYPE)

REPAIR WELDS

A

NOTE: : Adhesive 1 : Adhesive 2

• Adhesive 1: Urethane body sealer Brand: 3M ATD Part No.08684, 08782 or equivalent • Adhesive 2: Epoxyayresin adhesive Brand: 3M ATD Part No.8115 or equivalent

A ABB00806AB

NOTE ON REPAIR WORK INSTALLATION 1. When installing the new front door panel outer part, grind the bonding surface and remove the paint to improve adhesion. Then, degrease the front door panel outer.

2. Install the front door panel outer and hem it. Then, wipe off the adhesive that squeezed out.

WELDED PANEL REPLACEMENT REAR DOOR OUTER PANEL (WELDED TYPE)

3-35

REAR DOOR OUTER PANEL (WELDED TYPE) M4030001600797

Symbol

Operation description Spot welding MIG plug welding

(

: indicates two panels to be welded : indicates three panels to be welded

)

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

ABB00819AB

REPAIR WELDS

A

50 mm

NOTE: : Adhesive

Adhesive: Urethane body sealer

A ABB00807 AB

Brand: 3M ATD Part No.08684, 08782 or equivalent NOTE: After hemming the new front door panel outer part, MIG spot weld the flange overlap section at a pitch of 50 mm.

WELDED PANEL REPLACEMENT

3-36

REAR DOOR OUTER PANEL (ADHESION TYPE)

REAR DOOR OUTER PANEL (ADHESION TYPE) M4030001800779

Symbol

Operation description Spot welding MIG plug welding

(

: indicates two panels to be welded : indicates three panels to be welded

)

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

ABB00820AB

REPAIR WELDS

A

NOTE: : Adhesive 1 : Adhesive 2

• Adhesive 1: Urethane body sealer Brand: 3M ATD Part No.08684, 08782 or equivalent • Adhesive 2: Epoxyayresin adhesive Brand: 3M ATD Part No.8115 or equivalent

A

ABB00808 AB

NOTE ON REPAIR WORK INSTALLATION 1. When installing the new rear door panel outer part, grind the bonding surface and remove the paint to improve adhesion. Then, degrease the rear door panel outer.

2. Install the rear door panel outer and hem it. Then, wipe off the adhesive that squeezed out.

4-1

GROUP 4

CORROSION PROTECTION CONTENTS BODY SEALING LOCATIONS . . . . .

4-2

UNDERCOAT APPLICATION LOCATIONS .................................

4-6

CORROSION PROTECTION

4-2

BODY SEALING LOCATIONS

BODY SEALING LOCATIONS M4040001002480

If the sealant application is directly visible on the outer plate and requires appearance quality of the application in areas such as the drip rail, pillar, clinch and so on, then apply the sealant so that it is flat, or wipe off any excess mounding after the application.

Be careful not to obstruct the water draining hole.

NOTE: The bold dotted line indicates the application area on the underside.

FLOOR

3 2

4

1

ABB00755AB

UPPER BODY

5

6 8

7

9 ABB00753AB

CORROSION PROTECTION

4-3

BODY SEALING LOCATIONS

SIDE BODY

Left side only

13 10 11

14

12

16

15 17 ABC00078 AB

1

3

Driver's side only

ABC00032 AB

ABC00023AB

4

2

ABC00022 AB

ABC00024 AB

CORROSION PROTECTION

4-4

BODY SEALING LOCATIONS

9

5

ABC00033AB

ABC00019AB

10

6

Driver's side only

ABC00034AB

7

ABC00036AB

11

ABC00025AB

ABC00035 AB

8

12

ABC00065AB

ABC00026AB

CORROSION PROTECTION

4-5

BODY SEALING LOCATIONS

13

17

ABC00027AB

ABC00030AB

Hood

14

ABC00028AB

15

Left side only

ABB00684AB

Front door

ABC00031AB

16

ABB00682AB

Rear door

ABC00029AB

ABB00683AB

4-6

CORROSION PROTECTION UNDERCOAT APPLICATION LOCATIONS

Tail gate

ABB00685 AB

UNDERCOAT APPLICATION LOCATIONS • The under parts of the body is undercoated for anti-corrosive, anti-rust, anti-chipping, and anti-vibration performance.

• After correcting the body, restore as shown in the instructions of the figure, if necessary.

NOTE: : Undercoat (film thickness is at least 0.8 mm)

M4040003001610

• To avoid splashing of undercoat material during the coating, protect component installation holes with masking tape.

ABB00757AB

5-1

GROUP 5

SYNTHETIC-RESIN PARTS CONTENTS LOCATION OF SYNTHETIC-RESIN PARTS

.................................

5-2

SYNTHETIC-RESIN PARTS

5-2

LOCATION OF SYNTHETIC-RESIN PARTS

LOCATION OF SYNTHETIC-RESIN PARTS M4050001002102

The location and material of each of the principal synthetic-resin parts are shown below.

8 7

10 40

2

35 1, 4

3

27

26 28 6

25

29 23

24

5 ABC00037 AB

16

17 31 34

17

38

32

13 37 14

12 36

15

33

30

19 22

21

20

11

9

18

39 ABC00038AB

SYNTHETIC-RESIN PARTS

5-3

LOCATION OF SYNTHETIC-RESIN PARTS

No.

Part Name

Name Of Resin

Abbreviat Heat-resis ion tant Temp [°C ]

1

Door mirror outer cover (colour)

Acrylonitrile butadiene styrene

ABS

80

2

Tailgate garnish

3

Radiator grille

Acrylonitrile styrene acrylate

ASA

80

4

Door mirror outer cover (black)

5

Headlamp

Polycarbonate

PC

120

6

Door outside handle

Polycarbonate+Polyethylene terephthalate

PC+PET

120

7

Front roof rail cover

8

Rear roof rail cover

9

Rear splash shield

Polyethylene terephthalate+Allyl chloride

PET+AC

80

10

Rear wiper arm assembly

Glass fibre reinforced polyethylene PET-GF45 80 terephthalate (45%)

11

Shift lever panel assembly

Polyoxymethylene

POM

80

12

Front door sash trim

Polypropylene

PP

80

13

Inside rear view mirror

14

Quarter trim lower

15

Rear end trim

16

Tailgate upper trim

17

Tailgate opening side trim

18

Rear splash shield

19

Rear scuff plate

20

Front scuff plate

21

Cowl side trim

22

Front splash shield

23

Front bumper lamp hole cover

Rubber modified polypropylene

PP+E/P

80

24

Front fog lamp bezel

25

Front bumper face

26

Radiator grille

27

Rear bumper face

28

Rear mud guard

29

Side air dam

30

Front door trim

Talc filled polypropylene (10%)

PP-TD10

110 − 120

31

Centre pillar trim lower

32

Rear door trim

33

Tailgate trim

34

Front pillar trim

Talc filled rubber modified polypropylene (15%)

PP+E/P-T 80 D15

SYNTHETIC-RESIN PARTS

5-4

LOCATION OF SYNTHETIC-RESIN PARTS

No.

Part Name

Name Of Resin

Abbreviat Heat-resis ion tant Temp [°C ]

35

Front deck garnish

Talc filled polypropylene (20%)

PP-TD20

120 − 130

36

Instrument panel

37

Centre pillar trim upper

38

Quarter trim upper

39

Rear console

40

Roof drip moulding assembly

Thermoplastic elastomer

TPO

80 − 100

NOTE: .

• A slash (/) in the material symbol indicates that two different materials make two-layer construction. A plus sign (+) indicates that the two different materials mix each other.

• The indicated heat-resistant temperature for parts which are composed of two or more types of material is the value for the material with the lowest heat-resistant temperature.

• The material symbols for synthetic-resin parts are embossed on the parts in hidden places.

6-1

GROUP 6

BODY COLOUR CONTENTS BODY COLOUR CODE . . . . . . . . . . .

6-2

BODY COLOUR CHARTS. . . . . . . . .

6-2

BODY COLOURING . . . . . . . . . . . . .

6-3

FRONT END . . . . . . . . . . . . . . . . . . . . . . . .

6-3

WHEELHOUSE . . . . . . . . . . . . . . . . . . . . . .

6-3

FRONT BUMPER . . . . . . . . . . . . . . . . . . . .

6-4

REAR BUMPER . . . . . . . . . . . . . . . . . . . . .

6-4

BODY COLOUR

6-2

BODY COLOUR CODE

BODY COLOUR CODE M4060001001382

Body colour code is stamped on the vehicle information code plate, which is attached on the hood.

Body colour code

AC905413

ABA00001AB

BODY COLOUR CHARTS M4060002004049

Check the vehicle’s body colour code, and then use this body colour chart to determine the refinishing paint supplier from which the colour can be purchased.

Colour Colour Colour Colour name code number

Coating film Composition of film structure

SILVER

A31

CMA10031 Cool Silver Metallic

2M

Metallic

REDDISH BROWN

C07

CMC10007 Copper Metallic

2M

Metallic

DARK BLUE

D14

CMD10014 Cosmic Blue Mica

2P

Interferenced Pearl

GREY

U17

CMU10017 Titanium Grey Metallic

2M

Metallic

BLUISH SILVER

U21

CMU10021 Technical Silver Metallic 2M

Metallic

WHITE

W13

CMW10013 White Pearl

3P

Pearl

WHITE

W37

CMW10037 White Solid

2S

Solid

BLACK

X42

AC11342

2P

Interferenced Pearl

Black Mica

NOTE: .

• The coating film structure indicates top coating only (2S: 2 coat solid, 2M: 2 coat metallic, 2P: 2 coat pearl, 3P: 3 coat pearl).

• For painting, inner panel colours should be similar to the outer panel colours.

• The roof rail is coated in Black (AC10657).

BODY COLOUR BODY COLOURING

6-3

BODY COLOURING FRONT END M4060015000757

NOTE:

: Black (AC10657)

ABC00017AB

WHEELHOUSE M4060012000974

(EXCEPT COLOUR CODE D14, X42) <Front>

<Rear>

NOTE: : Black (AC10657) : Black (AC10657) <Except vehicle with rear splash shield>

ABC00008AB

BODY COLOUR

6-4

BODY COLOURING

FRONT BUMPER M4060000500392

1 A

1

1

2 1 Body Colour 2 Material colour

2

A

ABC00009AB

REAR BUMPER M4060000300257

1

1

A

2

1 Body Colour 2 Material colour

2

A ABC00010 AB