DOWNLOAD PDF Mitsubishi Colt CAR BODY REPAIR MANUAL

COLT* РУКОВОДСТВО ПО КУЗОВНОМУ РЕМОНТУ (пилотная версия)

GENERAL …………………………….……………

BODY CONSTRUCTION …………………………

BODY DIMENSIONS …………………………..…

WELDED PANEL REPLACEMENT ……………

CORROSION PROTECTION ……………………

SYNTHETIC-RESIN PARTS ….…………………

BODY COLOUR …..………………………………

REFERENCE MATERIAL ……………………....

0 1 2 3 4 5 6 8

0-1

GROUP 0

GENERAL CONTENTS VEHICLE IDENTIFICATION . . . . . . .

0-2

MAJOR SPECIFICATIONS . . . . . . . .

0-2

0-2

GENERAL VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION M4000001000286

MODELS Model code

Engine model

Z32A

134910-DOHC MIVEC (1,124 mL) F5MGA <2WD, 5M/T>

XNLHL6

Transmission model

Fuel supply system MPI

XNLHR6 Z34A

XNLHL6

135930-DOHC MIVEC (1,332 mL)

XNLHR6 XJLHL6

Z36A

XJLHR6

F6SGA <2WD, 6-speed automated manual transmission>

XNLHL6

135950-DOHC MIVEC (1,499 mL) F5MGA <2WD, 5M/T>

XNLHR6 XJLHL6

F6SGA <2WD, 6-speed automated manual transmission>

XJLHR6

MAJOR SPECIFICATIONS M4000003000185

Items

Vehicle dimension mm

Z32A

Z34A

Z36A

XNLHL6/R6

XNLHL6/R6 XJLHL6/R6

XNLHL6/R6 XJLHL6/R6

Overall length

3,870

Overall width

1,695

Overall height (unladen)

1,550/1,565*2

Wheelbase

2,500

Track

Front

1450

Rear

1445

Front overhang

780

Rear overhang

590

Ground clearance (unladen)

154/169*2

0-3

GENERAL MAJOR SPECIFICATIONS

Items

Vehicle Front wheel alignment

Steering angle Rear

Wheels and tyres

Z32A

Z34A

Z36A

XNLHL6/R6

XNLHL6/R6 XJLHL6/R6

XNLHL6/R6 XJLHL6/R6

Toe-in (at the centre 0 ± 2 of tyre tread) mm Toe angle (per wheel)

0°00' ± 06'

Toe-out angle on turns (inner wheel outer wheel at 20°)

21°21'

Camber

-0°30' ± 30'*1/-0°15' ± 30'*1*2

Caster

2°40' ± 30'*1/2°30' ± 30'*1*2

Kingpin inclination angle

13°20' ± 30'/13°00' ± 30'*2

Inner wheels

36°40' ± 1°30'

Outer wheels (reference)

32°50'

Toe-in (at the centre 3 ± 3.5/2.5 ± 3.5*2 of tyre tread) mm Camber

-1°00' ± 45' 30'*1

Tyre size

175/65R14 82T, 195/50R15 82H*3

175/65R14 82T, 195/50R15 82H, *3 195/50R15 82H, 205/45R16 83H*3 205/45R16 83H*3

Wheel size

14 × 5.5J, 15 × 6JJ*3

14 × 5.5J, 15 × 15 × 6J, 16 × *3 *3 6JJ , 16 × 6.5JJ 6.5JJ*3

Offset mm

46

NOTE: . *1: Difference between right and left wheels must be less than 30'. *2

: Vehicles with high ground suspensions.

*3

: Vehicles with aluminium wheels.

1-1

GROUP 1

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

1-2

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

1-4 MAINTENANCE, SERVICEABILITY .

1-6

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

1-8

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

1-8

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

1-12

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

1-14

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

1-15

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

1-16

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

1-19

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

1-20

1-2

BODY CONSTRUCTION BODY COMPONENTS

BODY COMPONENTS M4010001000232

21

31

20 30

22 24

23 19

18

17

25

61

16

13

15 14

26

28

27

32

29 62 33

59 60 58 63

56

57

66 34

55 64

54 12

11 8 9

38 10

36

65

53

37

41

52

7

42 43

39

46 45

6 5 4

3

2

47

44

40

1 51

: Anti-corrosion steel panels : High-tensile steel panels

1.

2.

3.

4.

5.

6.

7.

8.

35

Front floor sidemember Front sidemember reinforcement rear Front inner sidemember Front sidemember bulkhead front Front outer sidemember Fender shield gusset Fender shield upper frame bulkhead front Spring house panel

50 49 9.

10.

11.

12.

13.

14.

15.

16.

17.

48 Dash panel extension Front pillar extension inner Front fender Hood inner panel Hood outer panel Dash panel crossmember Dash panel Cowl top panel Front deck crossmember

AB301751AC

BODY CONSTRUCTION BODY COMPONENTS 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.

65.

66.

Front door panel inner Front door side door beam Front door panel outer Rear door panel outer Rear door side door beam Rear door panel inner Roof panel Roof rail front Roof centre bow Roof rear bow front Roof rear bow rear Roof rail rear Tailgate inner panel Tailgate outer panel Quarter panel extension upper outer Rear combination lamp housing panel Quarter panel extension lower inner Rear end Rear bumper centre bracket Rear bumper side bracket Spare tyre bracket Rear floor sidemember extension Rear floor sidemember Rear floor reinforcement rear Rear floor crossmember Rear floor reinforcement front Rear floor rear seat under crossmember Rear floor Front seat side bracket Backbone crossmember centre Front floor side sill inner Backbone crossmember Front floor crossmember front Front floor Backbone reinforcement Front pillar reinforcement lower Front deck frame upper outer Front deck frame upper inner Front inner pillar Front pillar reinforcement upper Centre inner pillar Roof side rail inner Rear wheel house panel inner Quarter panel upper inner Quarter panel lower inner Fuel filler neck bracket Side outer panel Side sill reinforcement Centre pillar reinforcement

1-3

1-4

BODY CONSTRUCTION BODY MAIN CROSS-SECTIONAL VIEWS

BODY MAIN CROSS-SECTIONAL VIEWS M4010002000257

A B

C

D

F

E

AB301823AB

A

D Cowl top inner panel

Roof panel

Roof rail front AB301761AB

Cowl top outer panel

E

B

Front pillar extension inner

Cowl top lower panel AB301759AB

Front pillar lower bulkhead

Front pillar reinforcement upper

Side outer panel Front pillar inner upper

C Centre inner pillar

AB301756AB AB301756

Centre pillar seat belt reinforcement

Front pillar reinforcement lower

F Front floor side sill inner

Side outer panel AB301758AB

Side sill outer reinforcement

Centre pillar reinforcement

Side outer panel Side outer panel

AB301762AB

Side sill bulkhead A

AB301760AB

1-5

BODY CONSTRUCTION BODY MAIN CROSS-SECTIONAL VIEWS H

I

G

J

L K

AB301824AB

G

J

Quarter inner panel upper Seat belt plate rear

Rear pillar reinforcement lower

Side outer panel Roof side rail inner

Rear combination lamp housing panel

AB301767AB

AB301763AB

Front pillar reinforcement upper

Side outer panel

Roof panel

K

H Roof rail rear outer

Side outer panel

Roof panel

Roof antenna reinforcement Roof rail seat belt reinforcement

Quarter inner panel lower

Roof rear rail inner

I

AB301766AB

AB301764AB

Quarter inner panel upper

L

Rear end inner panel Side outer panel

Rear end outer panel AB301757AB

AB301765AB

1-6

BODY CONSTRUCTION MAINTENANCE, SERVICEABILITY

MAINTENANCE, SERVICEABILITY M4010003000249

FENDER SHIELD Positioning holes, marks, and notches have been provided at the following overlapped areas to improve operation performance when replacing panels.

AB301857

AB301823

AB301856 AB302121AB

1-7

BODY CONSTRUCTION MAINTENANCE, SERVICEABILITY

SIDE STRUCTURE Panel positioning notches have been provided at the door opening section to improve operation performance when replacing panels.

Panel positioning notch

AB200202 AC

AB301771AB

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.

Centre outer pillar

Front outer pillar Quarter panel outer

Front floor side sill outer AB302122 AB

1-8

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

BODY CONSTRUCTION CHARACTERISTICS FRONT BODY

M4010010000274

FENDER SHIELD • Due to the adoption of straightened front sidemember and the rear floor sidemember, the structure can effectively absorb energy from the impact at the time of collision.

• An uneven thickness steel sheet* was employed for the front sidemember outer and the front sidemember rear. The steel sheet for the front sidemember outer is thicker on the rear side of the vehicle, and that for the front side member rear is thicker on the front side of the vehicle to ensure safety upon impact, body rigidity and lightweightness.

NOTE: *: Steel plates with different thickness welded together to make one steel plate.

Right side

4

5

3

6 2

7 4

1

8

C

9

Left side

5

B

3 A

2 8 AB302095AB

1.

2.

3.

4.

5.

6.

7.

8.

9.

Engine mount reinforcement Gusset Fender shield upper frame bulkhead front Spring house bracket Spring house panel Hot bottle bracket upper Hot bottle bracket lower Front sidemember Hose bracket

A

Front sidemember outer

Front sidemember inner AB301788 AB301788AB

1-9

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS Front sidemember outer

B

Cowl top inner panel

C

Cowl top outer panel

Front sidemember inner

Spring house bracket

Spring house panel

AB301789AB

• The octagonal cross section for the front of the front sidemember and 8-shaped cross section for the rear of the front sidemember have been adopted for enlargement so that the applied structures can effectively absorb energy from the impact at the time of collision.

Cowl top lower panel

AB301833AB

• The cowl top lower panel and the spring house panel are directly joined to increase rigidity at the front suspension mounting area, thus improving the drivability.

FRONT SIDEMEMBER REINFORCEMENT

Right side

12

11

13

10 8

9

6

14

7 15

5

4

3

20 21 22 23

2 1 A

B

18 19

16 17

AB301723AB

7

13 6 18 14 1.

2.

3.

4.

5.

6.

7.

Fem carrier B bracket Fem carrier A bracket Front sidemember inner Front sidemember bulkhead front Front sidemember bulkhead front reinforcement Engine mount reinforcement inner front Engine mount reinforcement inner rear

8.

9.

10.

11.

12.

13.

14.

15.

Front sidemember outer Sidemember to side sill brace Dash side extension Front pillar extension inner Dash brace side A Front sidemember reinforcement rear Front sidemember bulkhead rear lower Front sidemember rear

AB301780AB

1-10 16.

17.

18.

19.

20.

21.

22.

23.

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

Suspension crossmember rear reinforcement Suspension crossmember rear bracket Front sidemember bulkhead rear Dash crossmember extension Front suspension crossmember bracket upper Pipe nut Suspension crossmember reinforcement front Suspension crossmember bracket front

B

8

A

3 7

AB301776 AB

8

3 6

AB301777AB

Left side

11 10 9

12 13 14

8

7 6

15 5 4

3

2

1 15

B

16

21 22 23 24

17

18 20

19

AB301725AB

A

9 8 7 1.

2.

3.

4.

5.

6.

Battery bracket front Battery bracket rear Dash crossmember extension Suspension crossmember rear bracket Suspension crossmember rear reinforcement Front sidemember rear

7.

8.

9.

10.

11.

12.

AB301779 AB

Front sidemember bulkhead rear lower Front sidemember bulkhead rear Front sidemember reinforcement rear Dash brace side A Front pillar extension inner Dash side extension

1-11

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS 13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

Sidemember to side sill brace Front sidemember outer Transmission mount reinforcement Front sidemember bulkhead front reinforcement Front sidemember bulkhead front Front sidemember inner Fem carrier A bracket Fem carrier B bracket Front suspension crossmember bracket upper Pipe nut Suspension crossmember reinforcement front Suspension crossmember bracket front

B

12

9 13 7 AB302159AB

6

FRONT DECK

A

15

14

18

AB301775AB

6

5 4

3 2 9 8

7

1 1.

2.

3.

4.

5.

Carrier bracket rear Wiper bracket centre Cowl top outer panel Cowl top lower panel Dash upper extension

AB301721AB

6.

7.

8.

9.

Cowl top inner panel Front deck frame upper outer Front upper frame inner Dash side extension upper

1-12

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

DASH PANEL 3

2

4

5 1

AB301720AB

1.

2.

3.

4.

5.

SIDE BODY

Dash panel crossmember Dash panel Backbone reinforcement front Dash extension centre Steering bracket

M4010011000244

SIDE STRUCTURE 13

12 11

14

17

18

15 16

10

19

35

39

36

34

37 38

9

40

8 7

33

32 31

28

30

6

41 42

29 4

23

27

5

21

26

3 2

24 1 22 25

20 AB301724AB

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS 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.

Front pillar reinforcement lower Front door hinge reinforcement lower Front pillar lower bulkhead Front door hinge reinforcement upper Front pillar inner lower Deck crossmember bracket front Deck crossmember bracket rear Front pillar inner upper Front pillar reinforcement upper Roof side rail inner Stiffener lower (Right side) Seat belt reinforcement upper (Right side) Quarter inner panel upper Rear pillar reinforcement upper Seat belt plate rear Stiffener Rear pillar reinforcement lower Quarter panel extension upper outer Rear combination lamp housing panel Side outer panel Striker reinforcement Fender bracket Side sill end plate Side sill outer reinforcement Side sill outer reinforcement front Side sill bulkhead A

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

1-13

Centre pillar bracket Side sill bulkhead Centre pillar reinforcement Rear door hinge reinforcement lower Rear door hinge reinforcement upper Hinge plate upper Centre inner pillar Centre pillar seat belt reinforcement Absorber bracket Absorber reinforcement Rear wheel house inner panel Seat belt reinforcement lower Cargo hook bracket Quarter panel extension lower inner Fuel filler neck bracket (Left side) Quarter inner panel lower

SIDE STRUCTURE REINFORCEMENT • An uneven-thickness steel sheet* for the centre pillar reinforcement, which is thinner at the side sill, is used to improve collision safety and reduce weight.

NOTE: *: Steel plates with different thickness welded together to make one steel plate.

Centre pillar reinforcement

AB301722 AB

1-14 REAR BODY

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS M4010012000214

REAR END PANEL

3 2

4 1

5 AB301728AB

1.

2.

3.

Rear end inner panel Tailgate striker reinforcement Rear end outer panel

4.

5.

Rear bumper centre bracket Rear bumper side bracket

1-15

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

ROOF

M4010013000228

Standard roof

2 3 4 1

6 5 7 9

8

10

11 Sunroof

2 3 4 1

6 5 8

7 12

13

11

AB302074 AB

1.

2.

3.

4.

5.

6.

7.

Roof panel Roof rail rear outer Roof rail seat belt reinforcement Tailgate hinge reinforcement Roof rear rail inner Roof antenna reinforcement Roof rear bow rear

8.

9.

10.

11.

12.

13.

Roof rear bow front Roof bow reinforcement Roof centre bow Roof rail front Sunroof bracket Roof panel reinforcement

1-16

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

UNDER BODY

M4010014000276

FRONT FLOOR The front floor pan has been curved to suppress vibration and noise.

5

6

7

4

3 8 2 1 1.

2.

3.

4.

5.

6.

Backbone crossmember Backbone crossmember centre Front floor Front floor crossmember front Backbone reinforcement Seat bracket

AB301718AB

7.

8.

Front seat side bracket Front floor side sill inner

1-17

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

REAR FLOOR 4

6

5

7

3

8

2

9 10 1

AB301717AB

1.

2.

3.

4.

5.

6.

7.

Rear floor reinforcement front Rear floor rear seat under crossmember Rear floor pan Spare tyre bracket Rear floor reinforcement rear Muffler hanger hook Rear seat bracket rear centre

8. Rear seat bracket rear side 9. Rear floor crossmember 10. Rear floor sidemember

1-18

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

REAR FLOOR SIDEMEMBER REINFORCEMENT 5

6

4 3

7 8 9 10 11

2

11 12

1 13

15

14 A

9

B

AB301731AB

1

3

6

13

15

7

14 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

2

Rear floor sidemember Rear floor sidemember reinforcement front Rear seat belt bracket Rear floor crossmember extension Muffler hanger (Right side) Rear floor sidemember extension Brake hose bracket Spring sheet Rear floor brace plate Rear floor side sill inner extension Pipe nut Rear floor sidemember brace rear Rear floor sidemember bulkhead B

12 11

10 AB301778 AB

14. Rear floor sidemember brace front 15. Rear floor side sill inner

A

3 1

10 13 2

12

15 AB301773 AB

1-19

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

B

DOOR

3

M4010015000224

For better appearance and wind noise reduction, a one-piece top-bottom structure was employed for the door outer panel and the door inner panel.

1 AB301772AB

Front Door

6 5

7 2

3

4

10 8 1

9

Rear Door

14

13

15

12 16 17

11

AB302133AB

1.

2.

3.

4.

Front door hinge reinforcement Front door mirror reinforcement Front door window sash Front door panel outer

5.

6.

7.

8.

Front door belt line outer reinforcement Front door latch reinforcement Front door belt line inner reinforcement Front door side door beam

1-20 9.

10.

11.

12.

13.

14.

15.

16.

17.

BODY CONSTRUCTION LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL

Front door panel inner Front door inside handle bracket Rear door hinge reinforcement Rear door window sash Rear door panel outer Rear door belt line outer reinforcement Rear door latch reinforcement Rear door side door beam Rear door panel inner

LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL • By filling of the front pillar, bottom of the front pillar, centre pillar, side roof rail and inside the wheel house arch with acoustic foam material, penetration of noise is prevented.

• Introduction of noise was prevented by inserting urethane foam inside the centre pillar and front fender.

M4010007000199

CAUTION The foam materials may burn when heated.

Always observe the following instructions.

• Never use a gas burner or burn the areas using foam materials.

• When cutting the parts using foam materials, ensure to use tools (air saw, etc.) that do not generate fire.

• If there is residual foam material at body side then weld after removing the foam materials from periphery of the welding area.

F

A

E

C B

D AB301864

Urethane foam AB302192 AB

1-21

BODY CONSTRUCTION LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL

D

A Acoustic foam

Front pillar reinforcement upper Front pillar inner upper

Acoustic foam

Side outer panel

Side outer panel Urethane foam Acoustic foam

Side sill reinforcement

AB301794AB

B

Acoustic foam

Front pillar reinforcement lower

Centre pillar reinforcement AB301795AB

E Acoustic foam Quarter inner panel lower

Front pillar extension inner Front pillar lower bulkhead Side sill reinforcement

Side outer panel AB301796AB

C

Acoustic foam

Side outer panel

F

AB301797AB

Side outer panel

Centre pillar reinforcement

Acoustic foam

Side outer panel AB301798AB

Quarter inner panel upper

AB301793AB

2-1

GROUP 2

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

2-2

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

2-6

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

2-6

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

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

2-8

2-3

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

2-10

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

2-3

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

2-12

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

2-13

2-2

BODY DIMENSIONS BODY DIMENSIONS AND MEASUREMENT METHODS

BODY DIMENSIONS AND MEASUREMENT METHODS M4020001000255

Projected dimension Centre of hole Height Probe

AB100780AD

AB100778 AB

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

The difference in height of the measurement points should be taken into consideration when measuring.

3. Insert the tracking gauge probes securely into the measurement holes.

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

Ac

tua

l-m

ea

su

red

A

dim

en

sio

n

A'

AB100781AB AB100779AB

2. Type B (actual-measurement dimensions) Indicates the actual distance between the measurement points.

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

Bolt

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.

Measurement point AB100782AB

6. When measuring the suspension mounting arm, or link mounting position, use the suspension mounting bolt, etc. (Type B only) 7. The body centre points are shown for the purpose of checking the position of the left and right symmetry location.

2-3

BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS)

TYPE A (PROJECTED DIMENSIONS) UNDER BODY

M4020005000558

mm 1,131

853

130 458

566

895

960

880

1,067

971

1,271

910 1,030

1,011

940

1,099 358

2 575

288

278

3

1

6

8

5

4

9

11

10

7

387

673 AB302024AB

1,177

1,091 1,205

930 1,524

940

1,254

1

1,499

1,053

1,065

2

3

4

1,068

1,060

6 8

5

9

7

AB302026 AB

No. Standard measurement point

Hole shape

Size mm

1*

Centre of front sidemember inner positioning hole

Round

25

2*

Centre of crossmember mounting hole

Round

15

3*

Centre of crossmember mounting hole

Round

16

4*

Centre of front sidemember rear positioning hole

Round

25

5*

Centre of rear floor sidemember water draining hole

Oblong

37.5 × 21.6

6*

Centre of torsion axle arm mounting hole

Round

12.5

7

Centre of torsion axle arm mounting hole

Round

12.5

8*

Centre of spring sheet positioning hole

Round

12

9*

Centre of towing hook mounting hole

Round

13

10

Centre of front strut mounting hole

Round

86.6

11

Centre of rear shock absorber mounting hole

Round

22

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

2-4

BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS) mm A

0˚40´

B

8˚10´

Vehicle centre

Vehicle centre

579

AB201349

783

3˚10´

0˚

10

11

A B

1

9

8

2 752

3

4

6 7

5

682 336

279

121

288 566 1140

100

100

1175

279

150

313

315 672 1130 AB302057AB

2-5

BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS)

2

1

3, 4

3 4 AB301974 AB

5, 6, 7

AB301975AB

8, 9

AB301976AB

10

8

5 7 6 AB301977AB

11

AB301973AB

9 AB301978AB

AB301981AB

2-6

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) UNDER BODY

M4020005000569

mm 1,151

880

130 460

594

960

895

1,271

910

880

1,030

940

971

1,011

380

2 578

289

320

3

1

6

8

5

4

9 7

408

696 AB302025 AB

1,184

1,092 1,219

943 1,524

941

1,272

1

1,514

1,061

1,080

2

3

4

1,069

1,060

6 8

5

9

7

AB302026AC

No. Standard measurement point

Hole shape

Size mm

1

Centre of front sidemember inner positioning hole

Round

25

2

Centre of crossmember mounting hole

Round

15

3

Centre of crossmember mounting hole

Round

16

4

Centre of front sidemember rear positioning hole

Round

25

5

Centre of rear floor sidemember water draining hole

Oblong

37.5 × 21.6

6

Centre of torsion axle arm mounting hole

Round

12.5

7

Centre of torsion axle arm mounting hole

Round

12.5

8

Centre of spring sheet positioning hole

Round

12

9

Centre of towing hook mounting hole

Round

13

2-7

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

2

1

3, 4

3 4 AB301974 AB

5, 6, 7

AB301975AB

8, 9

8

5 7 6 AB301977AB

9 AB301978AB

AB301976AB

2-8

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

FRONT BODY

M4020006000272

mm 1,100

19 1,026 1,603

1,380 400

196

1,404

17

1,427 1,422

16

18

943

14

15

879 1,288

1,387

144 701

820

13

833 820

12

22 Body centre point 673 276

274

913

16

913

521

15 861

1,277

924

515

17 14

725 540 604

185 942 898 895

12

21

20 AB301950AB

2-9

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm

12

Centre of headlamp support assembly mounting hole

Round

10.5

13

Centre of headlamp support assembly mounting hole

Round

10.5

14

Centre of headlamp support assembly mounting hole

Round

11.5

15

Centre of hood hinge mounting hole

Round

11.5

16

Centre of front fender mounting hole

Round

8

17

Centre of front strut mounting hole

Round

11.5

18

Centre of cowl top panel mounting hole

Oblong

9 × 11

19

Corner of roof panel

−

−

20

Centre of front sidemember bulkhead front positioning hole

Round

15

21

Centre of front sidemember inner positioning hole

Round

10

22

Notch on cowl top outer panel (Body centre point)

−

−

15,17

17

12,13

14,18

18

13

15

12

14

AB302006AB

AB301879AB

19

16, 22

AB301880AB

20, 21 21

22

16

20 AB301877AB

AB301878AB

AB302005AB

2-10

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

SIDE BODY

M4020007000275

mm

29

25 27

23 1,183

899

879 741

687

683

31

730

748

1,117 1,051

1,111 850

24

687

32

28 30

26

AB301919 AB

29

25

807 723

35 1,045

33

355

368

34

786

1,114

1,092 1,039

37

810

36

AB301920AB

No. Standard measurement point

Hole shape

Size mm

23

Front pillar positioning notch (upper)

−

−

24

Front pillar positioning notch (lower)

−

−

25

Roof side rail positioning notch (front)

−

−

26

Side sill positioning notch (front)

−

−

27

Centre pillar positioning notch (upper)

−

−

28

Centre pillar positioning notch (lower)

−

−

29

Roof side rail positioning notch (rear)

−

−

30

Side sill positioning notch (rear)

−

−

31

Quarter panel positioning notch (upper)

−

−

32

Quarter panel positioning notch (lower)

−

−

33

Centre of front door upper hinge mounting hole

Round

11.5

34

Centre of front door lower hinge mounting hole

Round

11.5

2-11

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm

35

Centre of rear door upper hinge mounting hole

Round

11.5

36

Centre of rear door lower hinge mounting hole

Round

11.5

37

Centre of rear door switch mounting hole

Round

5

24, 26, 34

23, 25

27

24 25

26 34

23 AB301980AB

AB301871AB

29, 31

28, 30

AB301870AB

32, 37 37

29 28

30

32 31

AB301873AB

AB301874AB

33

35, 36 35 36

AB301979AB

AB302104AB

AB301872AB

2-12

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

REAR BODY

M4020008000289

mm

38 600 937 1,207 924

715

1,165

914 1,410

1,260

39

42 351 314 366

41

40

1,038

AB301847AB

No. Standard measurement point

Hole shape

Size mm

38

Centre of tailgate hinge mounting hole

Round

12

39

Centre of rear combination lamp mounting hole

Square

8 × 13

40

Centre of rear bumper side bracket mounting hole

Round

8

41

Centre of rear bumper side bracket mounting hole

Round

8

42

Centre of tailgate striker mounting hole

Round

13

38

39, 40

41, 42 42 39

41

40 AB301849AB

AB301850AB

AB301851AB

2-13

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

INTERIOR

M4020009000293

mm

29

1,112

25

1,193

1,224

31

1,306

1,343

27 23 1,340 1,349

1,343

32

1,340

1,340

28 30

24 26

AB301865AB

29 25 31

27 1,156

23

1,125

1,154 1,147

1,060

733

43 786

24

590

32

677

716

28 30

26 44 Body centre point AB301866AB

No. Standard measurement point

Hole shape

Size mm

23

Front pillar positioning notch (upper)

−

−

24

Front pillar positioning notch (lower)

−

−

25

Roof side rail positioning notch (front)

−

−

26

Side sill positioning notch (front)

−

−

27

Centre pillar positioning notch (upper)

−

−

28

Centre pillar positioning notch (lower)

−

−

29

Roof side rail positioning notch (rear)

−

−

30

Side sill positioning notch (rear)

−

−

31

Quarter panel positioning notch (upper)

−

−

32

Quarter panel positioning notch (lower)

−

−

2-14

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm

43

Centre of floor console bracket mounting hole

Round

8

44

Body centre point of rear floor

−

−

24, 26

23, 25

27

24 25

26

23 AB302105AB

AB301871AB

29, 31

28, 30

AB301870AB

32

29 28

30

31

AB301873AB

AB301874AB

43

44

AB301867AB

AB301868AB

AB302106AB

2-15

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

mm

44 Body centre point

1,099 463

11

935

1,171

600

45

AB301848AB

46 Body centre point

47

1,375

803

780 1,378

48

1,371

AB301860AB

No. Standard measurement point

Hole shape

Size mm

11

Centre of rear shock absorber mounting hole

Round

22

44

Body centre point of rear floor (Body centre point)

−

−

45

Centre of rear end trim mounting hole

Round

8.5

46

Tip of instrument panel bracket centre (Body centre point)

−

−

47

Centre of front deck crossmember mounting hole (upper)

Round

10.5

48

Centre of front deck crossmember mounting hole (lower)

Round

10.5

2-16

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

44

11

45

AB301852AB

AB301853AB

47, 48

46

47

48

AB301861AB

AB301862AB

AB301854AB

3-1

GROUP 3

WELDED PANEL REPLACEMENT CONTENTS FENDER SHIELD. . . . . . . . . . . . . . . .

3-2

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

3-5

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

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

3-17

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

3-19

REAR END PANEL. . . . . . . . . . . . . . .

3-22

QUARTER, INNER . . . . . . . . . . . . . . .

3-22

QUARTER INNER LOWER . . . . . . . .

3-25

FRONT DOOR OUTER PANEL . . . . .

3-26

REAR DOOR OUTER PANEL . . . . . .

3-27

3-6

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

3-9

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

3-12

QUARTER, OUTER . . . . . . . . . . . . . .

3-14

3-2

WELDED PANEL REPLACEMENT FENDER SHIELD

FENDER SHIELD M4030004000288

Symbol

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates 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.)

AB302078AB

REPAIR WELDS

A

AB301887

A

AB301886 AB302101AB

3-3

WELDED PANEL REPLACEMENT FENDER SHIELD

AB301883

B

D E F

B

C

G

C

AB301889

AB301888

AB302102 AB

3-4

WELDED PANEL REPLACEMENT FENDER SHIELD

AB302091 AB301884

D

E

(With the Front deck frame upper outer removed)

4 Points on right side

AB301890

AB301885

F

G

AB302103 AB

3-5

WELDED PANEL REPLACEMENT FRONT SIDEMEMBER (PARTIAL REPLACEMENT)

FRONT SIDEMEMBER (PARTIAL REPLACEMENT) M4030000100186

Symbol

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates 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.)

AB302079 AB

REPAIR WELDS

AB302039 AB302038

50 mm

25 mm A

B

100 mm AB302037

A

110 mm AB302036

B

AB302131AB

3-6

WELDED PANEL REPLACEMENT FRONT PILLAR

FRONT PILLAR M4030005000452

Symbol

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates 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.)

AB302080 AB

REPAIR WELDS

C

A

250 mm Acoustic foam

AB302064

B

AB301927

A

D

160 ± 10 mm

Acoustic foam E

F

(With the Front deck frame upper outer removed) B

AB302132

AB302111AB

3-7

WELDED PANEL REPLACEMENT FRONT PILLAR

CAUTION When repairing the area using foam materials do not use firing tools since the foaming materials may burn.

AB301930

AB301931

C D

AB302059

(With the side sill reinforcement removed)

(With the side outer panel removed) AB302069

E

F AB302155 AB

NOTE ON REPAIR WORK INSTALLATION

Front pillar reinforcement upper

50 mm

Side outer panel 50 mm 100 mm AB302062 AB

1. To reinforce the strength of the front pillar cut area, cut the side outer panel 100 mm above the cut-out area and front pillar reinforcement upper 50 mm above the cut-out area.

Side sill reinforcement

Side outer panel AB302061AB

2. To reinforce the strength of the side sill cut area, cut the side outer panel 50 mm back from the cut-out area of side sill

Urethane foam

AB302153AB

3-8

WELDED PANEL REPLACEMENT FRONT PILLAR

3. After assembling the front inner pillar, attach the urethane foam to the area shown in the figure in order to prevent foam materials from flowing out.

Urethane foam

Urethane foam

AB302154 AB

4. Before assembling the new front pillar reinforcement outer part, attach urethane foam to the area shown in the figure as an alternative to the foam material.

Urethane foam

AB302063 AB

Front pillar reinforcement outer

7. Before assembling the new front out pillar part, attach urethane foam to the area shown in the figure as an alternative to the foam material.

Front deck upper outer frame

Front outer pillar

AB302126AB

5. Remove the front deck frame upper outer from the new front pillar reinforcement part.

Front pillar reinforcement outer

: Body sealant

AB302065AB

6. Apply in advance the body sealant in the areas shown in the figure when assembling the front pillar reinforcement outer.

: Body sealant

AB302060AB

8. Apply in advance the body sealant in the area shown in the figure when assembling the front outer pillar.

3-9

WELDED PANEL REPLACEMENT CENTRE PILLAR

9. Assemble the front outer pillar, seal the hole and flange with the bolt and plated tape, and fill the hole with foam materials as shown in the figure.

FOAM: 3M ATD ULTRAPRO Panel foam-Yellow

AB100787

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

AB302100AB

CENTRE PILLAR M4030006000262

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding AB302081AB

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

3-10

WELDED PANEL REPLACEMENT CENTRE PILLAR

REPAIR WELDS

D

160 mm

AB301933

A A

AB301934

E

F

B

190 ± 60 mm

B

80 mm

AB301932

C

Acoustic foam

AB302066

C

(With the side outer panel removed) AB302112 AB

3-11

WELDED PANEL REPLACEMENT CENTRE PILLAR

CAUTION When repairing the area using foam materials do not use firing tools since the foaming materials may burn.

AB301938

AB301936

AB301937

D

F

E

AB302156 AB

NOTE ON REPAIR WORK REMOVAL

INSTALLATION 40 mm

40 mm

105 mm Side outer panel

Centre pillar reinforcement AB302093AB

1. After cutting the centre pillar, cut the side outer panel 105 mm downwards from the position shown. Then, cut the welding point inside.

Side sill reinforcement

Side outer panel AB302067AB

1. To reinforce the strength of the side sill cut area, cut the side outer panel in 2 locations of 40 mm forward and 40 mm back, both from the cut-out area of side sill.

CAUTION Centre pillar seat belt reinforcement Centre pillar reinforcement

Centre inner pillar

AB302068AB

2. Cut the welding point shown and turn over the roof side rail inner. Then, remove the centre pillar seat belt reinforcement and remove the remaining centre inner pillar.

AB302094AB

Weld and repair the centre pillar seat belt reinforcement if it is damaged.

2. Assemble the centre inner pillar and the side sill reinforcement. Cut the centre pillar reinforcement, aligned with the body-side, of the new centre pillar reinforcement parts so the centre pillar seat belt reinforcement is not damaged.

3-12

WELDED PANEL REPLACEMENT SIDE SILL

3. After assembling the centre pillar reinforcement, adhere in advance urethane foam to the area shown in the figure as an alternative to the foam material.

Urethane foam

AB302097AB

SIDE SILL M4030007000287

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding AB302082 AB

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

3-13

WELDED PANEL REPLACEMENT SIDE SILL

REPAIR WELDS 340 ± 20 mm

Cut the body side outer panel in alignment with new front floor side sill outer.

35 mm A

C

B

D Acoustic foam Acoustic foam AB301968 Acoustic foam

AB302137 AB301971

B

A

AB301967

AB301970

C D AB302134AB

CAUTION When repairing the area using foam materials do not use firing tools since the foaming materials may burn.

Cut the side sill reinforcement within the range shown in the figure, and replace it.

: Cuttable range

(With the side outer panel removed)

AB302092AB

3-14

WELDED PANEL REPLACEMENT QUARTER, OUTER

NOTE ON REPAIR WORK INSTALLATION

1. When assembling the front floor side sill outer, apply body sealant in the area shown in the figure of the front pillar. Attach in advance urethane foam to the front pillar and the centre pillar as shown in the figure as an alternative to the foam material.

NOTE: Partial replacement of side sill reinforcement is possible depending on the range of damage. Cut the side sill reinforcement so that it displaces 50 mm from the butt welding area with the side outer panel.

Front pillar Urethane foam AB302069

Centre pillar

Urethane foam AB302070

: Body sealant

AB302127AB

QUARTER, OUTER M4030008000257

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding

AB302086 AB

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

3-15

WELDED PANEL REPLACEMENT QUARTER, OUTER

REPAIR WELDS

220 mm C

160 ± 120 mm

A

B

E D

AB302010

20 ± 20 mm

A

Acoustic AB302011 foam F

AB302015 AB302013

B

AB302014

C

D AB302119AB

3-16

WELDED PANEL REPLACEMENT QUARTER, OUTER

AB302009

E

F AB302120 AB

NOTE ON REPAIR WORK INSTALLATION

Left side

Urethane foam

Right side

AB302072AB

1. Before assembling the quarter outer panel, attach urethane foam in the area shown to prevent the foam materials from flowing out.

: Body sealant

AB302136

2. When assembling the quarter outer panel, apply in advance body sealant to the areas shown in the figure.

3-17

WELDED PANEL REPLACEMENT ROOF

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

NOTE:

AB302151AB

3. After assembling the quarter outer panel, seal the hole and flange with bolt and sheet-metal tape, and then fill the hole with foam materials as shown in the figure.

FOAM: 3M ATD ULTRAPRO Panel foam-Yellow

: Cuttable range

AB302012AB

Partial replacement is possible depending on the range of damage.

AB100787

ROOF M4030011000246

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding

AB302083AB

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

3-18

WELDED PANEL REPLACEMENT ROOF

REPAIR WELDS

A

B

C

D

AB301960

C

A

D

AB301961

: Adhesive

Adhesive: Urethane body sealer

AB302146 AB

Brand: 3M ATD Part No.8542 or equivalent

3-19

WELDED PANEL REPLACEMENT REAR FLOOR

AB301966 AB301964

A

B

AB301963

C AB301959

D AB302147AB

REAR FLOOR M4030010000265

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding AB302084AB

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

3-20

WELDED PANEL REPLACEMENT REAR FLOOR

REPAIR WELDS D

A

AB302077

E B

C

AB302000

A

AB301999

B AB302128 AB

NOTE: Refer to the Rear End Panel Section on P.3-22 for the welding points with the rear end panel.

3-21

WELDED PANEL REPLACEMENT REAR FLOOR

AB301004

AB301003

C

D

AB301002

E

NOTE ON REPAIR WORK INSTALLATION

AB302152 AB

1. When cutting the rear floor, cut it 65 mm behind the floor carpet assembling hole as shown.

65 mm

AB302001AB

3-22

WELDED PANEL REPLACEMENT REAR END PANEL

REAR END PANEL M4030009000142

Symbol

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates 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.)

AB302087AB

REPAIR WELDS

A

AB301910

A AB301909 AB302107 AB

QUARTER, INNER M4030012000250

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding

AB302085 AB

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

3-23

WELDED PANEL REPLACEMENT QUARTER, INNER

REPAIR WELDS

6 points on left side

C

A

B

D

E AB302040

(With the quarter outer panel removed)

AB302042

AB302044

A

B

(With the fuel filler neck bracket removed) AB302129 AB

NOTE: Refer to the quarter outer Section on P.3-14 for the welding point with quarter outer panel and rear combination lamp housing panel.

3-24

WELDED PANEL REPLACEMENT QUARTER, INNER

AB302045

C

AB302047

AB302046

E

D

AB302130AB

NOTE ON REPAIR WORK REMOVAL

INSTALLATION

Quarter panel extension lower inner

: Body sealant AB302043AB

1. When removing the quarter panel extension lower inner, cut the welding points shown in the figure so that it is pulled out easily.

AB302041AB

1. When assembling the new fuel filler neck bracket, apply in advance body sealant to the areas shown in the figure.

3-25

WELDED PANEL REPLACEMENT QUARTER INNER LOWER

QUARTER INNER LOWER M4030001100026

Symbol

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates 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.)

AB302118 AB

REPAIR WELDS

A

AB302115

(With the quarter outer panel and fuel filler neck bracket removed)

AB302114

A AB302145 AB

NOTE: .

• Refer to the quarter outer Section on P.3-14 for the welding point with quarter outer panel and rear combination lamp housing panel.

• Refer to the quarter inner Section on P.3-22 for the welding point with Fuel filler neck bracket.

3-26

WELDED PANEL REPLACEMENT FRONT DOOR OUTER PANEL

FRONT DOOR OUTER PANEL M4030013000231

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding AB302088 AB

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

REPAIR WELDS AB302075

50 mm

A AB301902

A

B

B

AB301904

AB301903

D C AB301901

C

: Adhesive

• Adhesive : Urethane body sealer Brand: 3M ATD Part No.8542 or equivalent NOTE: After hemming the front door outer panel, MIG spot weld the flange overlap section at a pitch of 50 mm.

D AB302108 AB

NOTE ON REPAIR WORK REMOVAL Cut the door outer panel from the bottom of the window sash, and replace it.

3-27

WELDED PANEL REPLACEMENT REAR DOOR OUTER PANEL

REAR DOOR OUTER PANEL M4030014000223

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding AB302089 AB

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

REPAIR WELDS AB302076

50 mm

A

A

B

AB301906

AB301907

C B

C

AB301905 AB302109 AB

: Adhesive

• Adhesive : Urethane body sealer Brand: 3M ATD Part No.8542 or equivalent NOTE: After hemming the rear door outer panel, MIG spot weld the flange overlap section at a pitch of 50 mm.

NOTE ON REPAIR WORK REMOVAL Cut the door outer panel from the bottom of the window sash, and replace it.

4-1

GROUP 4

CORROSION PROTECTION CONTENTS BODY SEALING LOCATIONS . . . . .

4-2

WAX INJECTION LOCATIONS . . . . .

4-5

ANTICORROSION PRIMER LOCATIONS .................................

4-9

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

4-9 UNDERBODY ANTICORROSION AGENT LOCATIONS . . . . . . . . . . . . . . . . . . . .

4-10

4-2

CORROSION PROTECTION BODY SEALING LOCATIONS

BODY SEALING LOCATIONS M4040001000291

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

2 3

1

AB301956AB

UPPER BODY

4 5

7 6 AB302027AB

4-3

CORROSION PROTECTION BODY SEALING LOCATIONS

SIDE BODY

10 8

9

1

AB301953AB

3

AB301893 AB

AB301891AB

2

4

AB301892AB

AB301986AB

4-4

CORROSION PROTECTION BODY SEALING LOCATIONS

9

5

AB301987AB

6

AB301992AB

10

AB301989AB

7

AB301991AB

Hood

AB301990AB

8

AB301836AB

Front door

AB301988AB

AB301838AB

CORROSION PROTECTION WAX INJECTION LOCATIONS

Rear door

4-5

Tailgate

AB301839 AB

AB301837AB

WAX INJECTION LOCATIONS M4040008000117

In order to provide greater corrosion resistance, wax injection has been performed for the lower areas of the vehicle, such as the frame, the side sill, and other panels which are a hollow-construction. If any of these panels are replaced, wax injection must be performed for the new parts.

Recommended wax: • Tectyl 506, 506T or ML • Waxoyl • Dinitrol 3122 or 3654-1 • Mercasol 831-ML • Terotex • HV200PLUS or HV300

NOTES REGARDING WAX INJECTION WORK

• Be careful that the wax does not get onto other parts. Especially if wax is to be injected into the lower part of the centre pillar and into the side sill, first remove the seat belt retractor and the door switch.

• For wax injection locations which have a rubber plug, do not forget to reinstall the rubber plug after the wax injection is completed.

4-6

CORROSION PROTECTION WAX INJECTION LOCATIONS

7 H

G

8 5

7 G

F

E

6 2 B

3

C

D

4

A

1

AB302113AB

NOTE: For the numbers shown in the figure, refer to detailed illustrations with the same numbers on later pages.

4-7

CORROSION PROTECTION WAX INJECTION LOCATIONS

Application surfaces

: Nozzle insertion openings

A

1

AB301952AB

2

AB301948AB

B

AB301843AB

3

AB301947AB

C

AB301943AB

AB301954AB

D

4

AB301955AB

AB301949AB

4-8

CORROSION PROTECTION WAX INJECTION LOCATIONS

Application surfaces

: Nozzle insertion openings

E

5

AB301842 AB

AB301944AB

F

6

AB301840 AB

7 Front door

Rear door

AB301946AB

G

AB302051AB

AB302090AB

8

H

AB301841AB

AB301945AB

4-9

CORROSION PROTECTION ANTICORROSION PRIMER LOCATIONS

ANTICORROSION PRIMER LOCATIONS M4040002000227

To prevent rusting from chipping (flying rock), an anticorrosion primer has been applied to the areas indicated in the figure.

The primer is applied between the under and middle coat. It improves anti-corrosive performance by preventing flying rock to damage the body panel with the primer application, according to the thickness and elasticity of the primer. Apply the primer before the middle coat when replacing the panel complete with the primer application.

• Primer 1: Stone chipping resistant primer Brand: Glasurit FX89-8101 (Polyester basis) or FX92-7102 (Water basis) or equivalent Coating thickness: 0.015 mm • Primer 2: Rocker panel primer Recommended primer: Glasurit FX89-7300 (Polyester basis) or FX90-7103 (Water basis) or equivalent Coating thickness: 0.5 mm or more

A

120 mm

30 mm

A : Primer 1 : Primer 2

AB302048AB

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

M4040003000242

4-10

CORROSION PROTECTION UNDERBODY ANTICORROSION AGENT LOCATIONS

: Undercoat (film thickness is at least 0.8 mm)

AB301951AB

UNDERBODY ANTICORROSION AGENT LOCATIONS After undercoating the fuel and brake pipe, the underbody anticorrosion agent was applied to improve anti-corrosive performance.

Recommend wax: • Tectyl 506T, 506 or S • Waxoyl

M4040009000143

Fuel and brake pipe

: Underbody anticorrosion agent

AB301921AB

5-1

GROUP 5

SYNTHETIC-RESIN PARTS CONTENTS LOCATION OF SYNTHETIC-RESIN PARTS

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

5-2

5-2

SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS

LOCATION OF SYNTHETIC-RESIN PARTS M4050001000270

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

35 3 5 33 2

12 1 11 4

13

6

14 19 27

26

16

34

28 29

9 15

30

8 25 36 24

10 31 32

20 7

23 22

18 21

17 AB302017AB

5-3

SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS

No.

Part name

Material

Abbreviation of material

Heat−resistant temperature (°C)

1

Radiator grille

Acrylonitrile styrene acrylate

ASA

80

2

Fuel filler lid panel

66polyamide and polymer of 6I/6T PA66+PA6I/6T polyamide

80

3

Rear wiper arm

Polybutylene terephthalate (30%) PBT-GF30

80

4

Headlamp

Polycarbonate

PC

120

5

Tailgate outside handle

PC+PET

120

6

Door outside handle

Polycarbonate+Polyethylene terephthalate

7

Splash shield

Polypropylene

PP

80

8

Delta cover

9

Inside rear view mirror

10

Splash shield rear

11

Front bumper

Rubber denatured polypropylene

PP+E/P

80

12

Rear bumper

13

Rear door moulding

PP+E/P-M30

80

14

Front door moulding

Mineral filled modified polypropylene (30%)

15

Front door trim

PP+E/P-TD20

90

16

Rear door trim

Talc filled rubber modified polypropylene (20%)

17

Cargo floor box

Polypropylene foam

PP-FOAM

80

18

Inside spare wheel box

19

Door mirror

Glass reinforced polypropylene (25%)

PP-GF25

80

20

Headlamp support assembly Glass reinforced polypropylene (40%)

PP-GF40

90

21

Floor console

PP+P/E-TD10

90

22

Console side cover

Talc filled rubber modified polypropylene (10%)

23

Cowl side trim

Talc filled polypropylene (10%)

PP-TD10

90

24

Instrument panel

25

Front pillar trim

26

Centre pillar trim upper

27

Centre pillar trim lower

28

Quarter trim lower

29

Rear end trim

30

Tailgate trim

31

Rear scuff plate

32

Front scuff plate

5-4

SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS

No.

Part name

Material

Abbreviation of material

Heat−resistant temperature (°C)

33

Front deck garnish

Talc filled polypropylene (20%)

PP-TD20

120-130

34

Quarter trim upper

35

Roof drip moulding

Poly vinyl chloride

PVC

80

36

Instrument panel pad

Woodfiber polyolefinic thermoplastic elastomer

TEO/WF

90

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

6-2

BODY COLOUR BODY COLOUR CODE

BODY COLOUR CODE M4060001000259

Body colour code is printed in the vehicle information code label, which is attached on the bottom of the centre pillar.

Body colour code Vehicle information code label AB302035AB

BODY COLOUR CHARTS M4060002000337

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 code Colour number Colour name

Composition of film

PURE SILVER

A50

AC11150

Haag Silver

Metallic

DARK GREY

U63

AC11363

Steel Grey

Metallic

BLUE

T42

CNT10042

Aqua Grey

Pearl

BLUE

T43

CNT10043

Old China

Pearl

GREEN

G94

CNG10094

Light Green

Metallic

GREEN

G96

CNG10096

Agave

Metallic

BLACK

X19

CNX10019

Deep Black

Solid

WHITE

W16

CNW10016

New White

Solid

RED

P04

CNP10004

Amazon Red

Solid

RED

P14

CNP10014

Dark Red

Pearl

PURPLE

V04

CNV10004

Cassis

Pearl

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

8-1

GROUP 8

REFERENCE MATERIAL CONTENTS BOLTED PANEL FIT AND ADJUSTMENT .................................

8-2

ADJUSTMENT OF OTHER PARTS . .

8-6

FRONT WHEEL ALIGNMENT . . . . . . . . . .

8-6

HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2

REAR WHEEL ALIGNMENT . . . . . . . . . . . .

8-7

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

8-3

HEADLAMP AIMING . . . . . . . . . . . . . . . . . .

8-8

TAILGATE. . . . . . . . . . . . . . . . . . . . . . . . . .

8-4

FRONT FOG LAMP AIMING . . . . . . . . . . . .

8-10

INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS. . . . . . . .

8-5

MOULDING. . . . . . . . . . . . . . . . . . . . . . . . .

8-5

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - AIR BAG . . . . . . . . . . . . . . . . . . . . . .

8-11

8-2

REFERENCE MATERIAL BOLTED PANEL FIT AND ADJUSTMENT

BOLTED PANEL FIT AND ADJUSTMENT HOOD

M4080005000242

HOOD FIT ADJUSTMENT

A

B

A B

AC312307

1. If the clearance between the hood and body is uneven, loosen the hood hinge mounting nut and hood hinge mounting bolt, move the hood to and fro, and left and right to adjust the hood so the clearance around the hood is even.

Hood hinge mounting nut tightening torque: 20 ± 2 N⋅m Hood hinge mounting bolt tightening torque: 20 ± 2 N⋅m

Section A – A

16 mm

Damper Section B – B

15 mm

Damper AC312524AB

2. Rotate the hood damper by using the arrow mark on the hood damper as a guide to adjust the hood height. If the hood damper is rotated just one turn, the hood height changes by approximately 3 mm.

AC312258AB

3. If the hood level, floating, unlock, lock is heavy check the cord of the release cable, loosen the hood latch mounting bolts, lift the hood latch and adjust the bite with the hood striker.

Hood latch mounting bolts tightening torque: 7.6 ± 0.6 N⋅m

8-3

REFERENCE MATERIAL BOLTED PANEL FIT AND ADJUSTMENT

DOOR

M4080006000290

DOOR FIT ADJUSTMENT CAUTION Attach protection tape to the fender and door edges where the hinge is installed.

1. When the clearance between the door and the body is uneven (1) Remove the front pillar pad <Front door>.

Door hinge mounting bolts tightening torque: 26 ± 2 N⋅m 2. When the door is not flush with the vehicle body surface.

(1) Remove the front pillar pad <Front door>.

(2) Loosen the door-side hinge mounting bolts.

(3) Move the door to adjust until the door is flush with the vehicle body.

Door hinge mounting bolts tightening torque: 26 ± 2 N⋅m 3. When the door is stiff to lock and unlock:

Tool

MB990939

AC312513 AB

(2) Loosen the body-side door hinge mounting bolts.

NOTE: <Front door>

Door hinges

Temporary bolts

Striker AC006109AF

(1) Adjustment by using the striker (toward the inside of the vehicle and vertical direction) Install a temporary bolts instead of the striker mounting bolts, and use special tool brass bar (MB990939) and a hammer to tap the bolt to the desired direction.

MB990211 AC312511

MB990243

<Rear door>

Door hinges

Striker AC006110 AB

AC312512 AC313261AB

Install the tool to the bolts as shown.

(3) Move the door to adjust until the clearance around the door is even.

(2) Adjustment by using the striker (toward the outside of the vehicle) Use special tools sliding hammer (MB990211) and body puller (MB990243) to pull the striker toward the outside of the vehicle.

Door striker mounting bolts tightening torque: 24 ± 2 N⋅m

8-4

REFERENCE MATERIAL BOLTED PANEL FIT AND ADJUSTMENT

ADJUSTMENT OF FRONT DOOR HEIGHT

Tailgate striker mounting screw tightening torque: 24 ± 3 N⋅m

A

A Section A – A

AC201556

14.5 mm

2. If the clearance between the tailgate and the body is uneven, loosen the tailgate-side tailgate hinge mounting bolts to adjust it.

Tailgate hinge mounting bolts tightening torque: 7.4 ± 1.4 N⋅m

ADJUSTMENT OF TAILGATE HEIGHT

Damper

A

AC207673AB

Rotate the damper by using arrow mark on the damper as a guide to adjust the front door height.

The damper height is altered by roughly 3 mm when the damper is rotated once.

NOTE: If a rattling noise is heard due to the vibration of the door when the vehicle is being driven, adjust the damper height until the damper is seated on the vehicle body.

TAILGATE

A

Section A – A 18 mm

M4080007000248

TAILGATE FIT ADJUSTMENT AC105284

MB990939 Temporary bolts Bumper AC207663 AB

Striker AC312709 AB

1. If the striker is not engaged with the tailgate latch properly, remove the rear end trim. Replace the striker mounting screw with a temporary bolts, and use the special tool (brass bar, MB990939) and a hammer to tap the bolt head to adjust the striker.

Turn the tailgate damper using the arrow of the tailgate damper as a guideline to adjust the height of the tailgate. The dumper height is altered by approximately 3 mm by turning the tailgate damper one rotation.

NOTE: If a rattling noise is heard due to the vibration of the tailgate when the vehicle is being driven, adjust the damper height until the damper is seated on the vehicle body.

8-5

REFERENCE MATERIAL INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS

INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS MOULDING

M4080014000046

Rear door moulding

Front door moulding

Double-sided tape affixed location Rear door moulding

Front door moulding Double-sided tape

Double-sided tape Adhesive tape: double-sided tape [ 8 mm width and 1.2 mm thickness ] AB302135 AB

REMOVAL SERVICE POINT

FRONT DOOR MOULDING AND REAR DOOR MOULDING REMOVAL Gently lift and remove the door moulding. If there is any double-sided tape remaining on the door moulding, remove according to the following instructions. <Remove double-sided tape remaining on the body surface>

8-6

REFERENCE MATERIAL ADJUSTMENT OF OTHER PARTS

Protection tape

Double-sided tape

AC000420 AB

1. Attach protection tape all the way along the edges of the double-sided tape which is still adhering to the body.

Double-sided tape

AC313343

1. Scrape off the double-sided tape on the door moulding with a resin spatula as possible.

2. Wipe the door moulding surface and clean it with a rag moistened with isopropyl alcohol.

3. Remove only a small portion of the residual adhesive.

4. Adhere the double-sided tape as specified on the door moulding.

INSTALLATION SERVICE POINT AC000421 AB

2. Use a resin spatula to scrape off the double-sided tape.

3. Peel off the protection tape.

4. Wipe the body surface and clean it with a rag moistened with isopropyl alcohol. <Remove double-sided tape remaining on door moulding and adhere double-sided tape (when re-using door moulding)>

Adhesive tape

Backing paper AC313344 AB

1. Tear off the double-sided tape backing paper.

NOTE: If attach the adhesive tape to the edge of the backing paper, it will be easy to tear off.

2. Install the door moulding.

NOTE: If the double-sided tape is difficult to affix in cold temperature, etc., warm the bonding surfaces of the body and door moulding to about 40− 60°C before affixing the tape.

3. Firmly press in the door moulding.

ADJUSTMENT OF OTHER PARTS FRONT WHEEL ALIGNMENT

TOE-IN M4080009000244

Measure wheel alignment with alignment equipment on a level surface. The front suspension, steering system, wheels, and tyres should be serviced to normal condition before measuring wheel alignment.

Standard value: at the centre of tyre tread: 0 ± 2 mm Toe angle (per wheel): 0°00' ± 06'

8-7

REFERENCE MATERIAL ADJUSTMENT OF OTHER PARTS Clip

Jam nut

AC312518AB

1. Adjust the toe-in by undoing the clip and jam nut, and turning the left and right tie rod turnbuckles by the same amount (in opposite directions).

NOTE: The toe will move out as the left turnbuckle is turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle.

2. Install the clip and tighten the jam nut to the specified torque.

Tightening torque: 43 ± 7 N⋅m 3. Confirm that the toe-in is at the standard value.

4. Use a turning radius gauge to check that the steering angle is at the standard value.

STEERING ANGLE Standard value:

Item

Standard suspension

High-ground suspension

Camber

-0°30' ± 30'*

-0°15' ± 30'*

Caster

2°40' ± 30'*

2°30' ± 30'*

Kingpin inclination

13°20'±°30'

13°00'±°30'

NOTE: *: difference between right and left wheels must be less than 30' NOTE: Camber and caster are preset at the factory and cannot be adjusted.

CAUTION Never subject the wheel bearings to the vehicle load when the driveshaft nuts are loosened.

NOTE: MB991004

AC001079 AB

Outer wheels (reference) 32°50'

For vehicles with aluminium wheels, attach the camber/caster/kingpin gauge to the driveshaft by using special tool wheel alignment gauge attachment (MB991004). Tighten the special tool to the same torque 245 ± 29 N⋅m as the driveshaft nut.

TOE-OUT ANGLE ON TURNS

REAR WHEEL ALIGNMENT

Item

Specification

Inner wheels

36°40' ± 1°30'

To check the steering linkage, especially after the vehicle has been involved in an accident or if an accident is presumed, it is advisable to check the toe-out angle on turns in addition to the wheel alignment.

Conduct this test on the left turn as well as on the right turn.

Standard value: Item

Specification

Toe-out angle on turns 21°21' (inner wheel when outer wheel at 20°)

M4080010000248

Measure wheel alignment with an alignment equipment on level earth.

The rear suspension, wheels, and tyres should be serviced to the normal condition prior to wheel alignment measurement.

TOE-IN STANDARD VALUE: Item Standard suspension At the centre of 3 ± 3.5 mm tyre tread

High-ground suspension 2.5 ± 3.5 mm

CAMBER CAMBER, CASTER AND KINGPIN INCLINATION Standard value:

Standard value: -1°00' ± 45' (Left/right deviation within 30')

8-8

REFERENCE MATERIAL ADJUSTMENT OF OTHER PARTS

<USING A SCREEN> (LOW -BEAM)

NOTE:

Screen

Headlamp centre line

Compensator

Vehicle centre line

5m AC102503AD

.

• For vehicles with aluminium wheel, we

recommend that a compensator be used to measure the camber and caster.

• The camber is pre-adjusted at factory and is not adjustable.

HEADLAMP AIMING

Bulb centre

M4080011000252

<USING A BEAM SETTING EQUIPMENT> AC313203 AB

AC102583

1. The headlamps should be aimed with the proper beam setting equipment, and in accordance with the equipment manufacture’s instructions.

2. Alternately turn the adjusting screw to adjust the headlamp aiming.

1. Inflate the tyres to the specified pressures and there should be no other load in the vehicles other than driver or substituted weight of approximately 75 kg placed in driver’s position.

2. Put the headlamp levelling switch in "0" position.

3. Set the distance between the screen and the centre marks of the headlamps as shown in the illumination.

(V) Distance of vertical direction (H)

Lamp centre

15

High intensity zone AC312781AB

4. Check if the beam shining onto the screen is at the standard value.

Standard value: (Vertical direction) 60 mm below horizontal (H) (Horizontal direction) 15° sloping section intersects the vertical line (V) NOTE: The illustration shows LH drive vehicles.

For RH drive vehicles, it is symmetrical.

8-9

REFERENCE MATERIAL ADJUSTMENT OF OTHER PARTS

CAUTION Be sure to adjust the aiming adjustment screw in the tightening direction.

Horizontal direction adjustment

Vertical direction adjustment

Vertical direction adjustment Horizontal direction adjustment

1. Inflate the tyres to the specified pressures and there should be no other load in the vehicles other than driver or substituted weight of approximately 75 kg placed in driver’s position.

2. Put the headlamp levelling switch in "0" position.

3. Set the distance between the screen and the centre marks of the headlamps as shown in the illumination.

4. Check if the beam shining onto the screen is at the standard value.

Standard value: (Vertical direction) Within 0.40°below horizontal (H)

CAUTION Be sure to adjust the aiming adjustment screw in the tightening direction.

Vertical direction

AC312301AB

5. Alternately turn the adjusting screw to adjust the headlamp aiming.

<USING A SCREEN> (HIGH-BEAM) Vertical direction Screen

Headlamp centre line

Vehicle centre line

5m AC312302 AB

5. Alternately turn the adjusting screw to adjust the headlamp aiming.

Bulb centre

AC313206 AB

8-10

REFERENCE MATERIAL ADJUSTMENT OF OTHER PARTS

FRONT FOG LAMP AIMING

Vertical direction

M4080013000214

Lamp centre

Lamp centre Screen

Fog lamp centre line

Cut off line

Vertical direction

Vehicle centre line

High intensity zone 5m AC312352 AB AC312351AB

1. Measure the centre of the front fog lamps, as shown in the illustration.

2. Set the distance between the screen and the centre of the front fog lamps as shown in the illustration.

3. Inflate the types to the specified pressures and there should be no other load in the vehicles other than driver or substituted weight of approximately 75 kg placed in the driver’s position.

4. With the engine running at 2,000 r/min, aim the front fog lamp.

5. Check if the beam shining onto the screen is at the standard value.

Standard value: (Vertical direction) 100 mm below horizontal (H) (Horizontal direction) Parallel to direction of vehicle travel

CAUTION When marking the aiming adjustment, be sure to mask those lamps which are not being adjusted.

NOTE: The horizontal direction is non-adjustable. If the deviation of the light beam axis exceeds the standard value, check to be sure that the mounting location or some other point is not defective.

REFERENCE MATERIAL SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - AIR BAG

8-11

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - AIR BAG M4080016000183

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, and seat belt pre-tensioner before drying or baking the vehicle after painting.

• SRS-ECU, air bag modules, clock spring: 93°C or more • Seat belt 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.