BODY REPAIR SECTION BRM CONTENTS BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY BRM-1 VEHICLE INFORMATION... 2 PRECAUTION... 3 PREPARATION...

Transcription

1 Y XTRR, RS, R & V SURTY ST R Y RR TTS V RT... 2 Y XTRR T R... 2 ody xterior aint olor...2 RUT... 3 RUTS... 3 igh Voltage recautions...3 RR STRT ST... 5 igh Strength Steel (SS)...5 andling of Ultra igh Strength Steel late arts...7 T T... 8 riteria for attery Removal When rying ainting...8 RTT V... 9 rotection of Vehicle...9 RRT...10 RR TR...10 oam Repair...10 Y T RTS...12 Underbody omponent arts...12 ody omponent arts...15 S ST...18 RR WRK W...18 Repair udgment low...18 RV STT...20 RRS RTT...20 escription...20 Undercoating...20 Stone uard oat...21 ody Sealing...22 Y STRUT...26 ody onstruction...26 Rear ender emming rocess...27 RT RTS...29 escription...29 Radiator ore Support...31 oodledge...32 oodledge (artial Replacement)...33 ront Side ember...34 ront Side ember (artial Replacement)...37 ront illar...39 enter illar...42 uter Sill (artial Replacement)...45 uter Sill...46 Rear ender...49 Rear ender xtension...53 Rear anel...54 Rear loor Rear...55 Rear Side ember xtension...56 SRV T STS (SS)...58 Y T...58 ody enter arks...58 escription...59 otor Room...59 Underbody...62 assenger ompartment...64 Rear ody...67 T ST RTS...69 recautions for lastics...69 ocation of lastic arts...70 R R-1

2 < V RT > V RT Y XTRR T R ody xterior aint olor Y XTRR T R : SK2267ZZ olor code K3 K23 QX1 RT escription lack Silver Red White lue omponent aint type ote 2S 3 3 ard clear coat 1 utside mirror cover ody color K3 K23 QX1 RT 2 harge port lid ody color K3 K23 QX1 RT 3 umper fascia ody color K3 K23 QX1 RT 4 Rear spoiler ody color K3 K23 QX1 RT 5 ack door handle ody color K3 K23 QX1 RT 6 oor outside handle hromium plate r r r r r T: S: Solid 2S: Solid + lear S: olor clear solid : etallic : 2-oat pearl 3: 3-oat pearl 3: 3-oat pearl metallic : ron oxide pearl R: ulti flex color T: icro titanium metallic : earl metallic R-2

3 < RUT > RUT RUTS igh Voltage recautions RUTS : R: Since hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly. e sure to follow the correct work procedures when performing inspection and maintenance. WR: e sure to remove the service plug in order to disconnect the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts. The removed service plug must always be carried in a pocket of the responsible worker or placed in the tool box during the procedure to prevent the plug from being connected by mistake. e sure to wear insulated protective equipment before beginning work on the high voltage system. ever allow workers other than the responsible person to touch the vehicle containing high voltage parts. To keep others from touching the high voltage parts, these parts must be covered with an insulating sheet except when using them. UT: ever bring the vehicle into the RY status with the service plug removed unless otherwise instructed in the Service anual. malfunction may occur if this is not observed. VT RSS QUT TT ll the high voltage harnesses and connectors are orange. The i-ion battery and other high voltage devices include an orange high voltage label. ever touch these harnesses and high voltage parts. VT RSS TRS mmediately insulate disconnected high voltage connectors and terminals with insulating tape. RUTS WRKRS WT TRS WR: The vehicle contains parts that contain powerful magnets. f a person who is wearing a heart pacemaker or other medical device is close to these parts, the medical device may be affected by the magnets. Such persons must not perform work on the vehicle. RT TS T RRY UR T WRK ybrid vehicles and electric vehicles contain parts with high voltage and intense magnetic force. ever carry metal products and magnetic recording media (e.g. cash card, prepaid card) to repair/inspect high voltage parts. f this is not observed, the metal products may create a risk of short circuit and the magnetic recording media may lose their magnetic recording. ST S R! VT R. K UT R R-3

4 < RUT > RUTS ndicate " VT. T TU" on the vehicle under repair/inspection to call attention to other workers. S1600 R-4

5 < RUT > RR STRT ST RR STRT ST igh Strength Steel (SS) : igh strength steel is used for body panels in order to reduce vehicle weight. ccordingly, precautions in repairing automotive bodies made of high strength steel are described below: Tensile strength a 980 a ajor applicable parts Rear side member closing plate Trans control reinforcement (enter front floor component part) Rear side member front extension (ront floor component part) ront floor front (ront floor component part) 2nd crossmember (ront floor component part) 3rd crossmember (ront floor component part) nner sill reinforcement (nner sill component part) Side dash ront suspension spring support (ront strut housing component part) ront side member front assembly ront side member assembly ront side member closing plate assembly Rear seat crossmember Rear crossmember center assembly Rear side member Rear side member extension reinforcement assembly Rear side member extension nner side roof rail Upper inner front pillar ront pillar brace ower center pillar brace uter sill reinforcement nner rear pillar reinforcement ower rear panel reinforcement (Upper rear panel component part) ront roof rail (ower) (ront roof rail component part) Roof member reinforcement (enter roof reinforcement component part) ront side member center extension (ront floor component part) ront side member rear extension (ront floor component part) nner sill nner front sill reinforcement (Upper & ower) (nner sill component part) ower dash crossmember (Upper R & ) (ower dash component part) ower dash crossmember (ower) enter pillar seat belt anchor (nner center pillar assembly component part) nner center pillar assembly (Upper side) uter side roof rail reinforcement enter pillar reinforcement (ower center pillar brace component part) ront roof rail reinforcement (ront roof rail component part) R Read the following precautions when repairing SS: R-5

6 < RUT > RR STRT ST 1. dditional points to consider The repair of reinforcements (such as side members) by heating is not recommended, because it may weaken the component. When heating is unavoidable, never heat SS parts above 550 (1,022 ). Verify heating temperature with a thermometer. (rayon-type and other similar type thermometer are appropriate.) 0115 When straightening body panels, use caution in pulling any SS panel. ecause SS is very strong, pulling may cause deformation in adjacent sections of the body. n this case, increase the number of measuring points, and carefully pull the SS panel When cutting SS panels, avoid gas (torch) cutting if possible. nstead, use a saw to avoid weakening surrounding areas due to heat. f gas (torch) cutting is unavoidable, allow a minimum margin of 50 mm (1.97in) When welding SS panels, use spot welding whenever possible in order to minimize weakening surrounding areas due to heat. f spot welding is impossible, use. welding. o not use gas (torch) for welding because it is inferior in welding strength. SK0082 R-6

7 < RUT > RR STRT ST Spot welding on SS panels is harder than that of an ordinary steel panel. Therefore, when cutting spot welds on a SS panel, use a low speed high torque drill (1,000 to 1,200 rpm) to increase drill bit durability and facilitate the operation. 2. recautions in spot welding SS This work should be performed under standard working conditions. lways note the following when spot welding SS: The electrode tip diameter must be sized properly according to the metal thickness The panel surfaces must fit flush to each other, leaving no gaps R ollow the specifications for the proper welding pitch. Unit: mm (in) Thickness (T) inimum pitch () 0.6 (0.024) 0.8 (0.031) 1.0 (0.039) 1.2 (0.047) 1.6 (0.063) 1.8 (0.071) 10 (0.39) or more 12 (0.47) or more 18 (0.71) or more 20 (0.79) or more 27 (1.06) or more 31 (1.22) or more andling of Ultra igh Strength Steel late arts SK0781ZZ : RT UT T ever cut and oint the stiffener front side member (front floor inside frame parts) because its material is high strength steel plate (ultra high strength steel plate). The front floor assembly must be replaced if this part is damaged. R-7

8 < RUT > T T T T riteria for attery Removal When rying ainting : To use painting booth, maintain outer sill () temperature at 60 (140 ) or less to prevent deterioration in liion battery. T: easure the temperature with a noncontact thermometer. f a sill cover (resin) is included, remove the sill cover to measure the temperature. f outer sill () temperature is more than 60 (140 ), remove li-ion battery beforehand and place in the painting booth. SK2340ZZ. uter sill temperature measurement part R-8

9 < RUT > RTT V rotection of Vehicle RTT V : The seats, glass, and carpet must be removed or covered with appropriate material (spatter cover), according to the type of work to be done, to prevent contamination and welding spatter. n addition, when cutting the vehicle in an area close to high voltage parts or performing a welding operation, the high voltage parts must be covered with a heat-resistant insulating cover (spatter cover). R R-9

10 < RRT > RRT RR TR oam Repair RR TR : uring factory body assembly, foam insulators are installed in certain body panels and locations around the vehicle. Use the following procedure(s) to replace any factory-installed foam insulators. URT TS Use commercially available Urethane foam for sealant (foam material) repair of material used on vehicle. <Urethane foam for foaming agent> Read instructions on product for fill procedures. 3 utomix lexible oam or equivalent xample of foaming agent filling operation procedure 1. ill procedures after installation of service part. a. liminate foam material remaining on vehicle side. b. lean area after eliminating form insulator and foam material. c. nstall service part. d. nsert nozzle into hole near fill area and fill foam material or fill enough to close gap with the service part. SK Urethane foam. ozzle insert hole : Vehicle front 2. ill procedures before installation of service part. a. liminate foam material remaining on vehicle side. b. lean area after eliminating foam insulator and foam material. c. ill foam material on wheelhouse outer side. R-10

11 < RRT > RR TR 1. Urethane foam. ill while avoiding flange area : Vehicle front T: ill enough to close gap with service part while avoiding flange area. d. nstall service part. T: Refer to label for information on working times. SK0130 R R-11

12 < RRT > Y T RTS Underbody omponent arts Y T RTS : SK2268ZZ R-12

13 < RRT > Y T RTS : oth sided anti-corrosive precoated steel sections : igh strength steel (SS) sections : oth sided anti-corrosive steel and SS sections *: luminum portion o. arts name Tensile strength (a) oth sided anti-corrosive precoated steel sections 1. Rear floor rear Under Rear floor rear side (R & ) 590 luminum portion 3. Upper seat crossmember assembly Under Rear floor front Rear side member closing plate (R & ) Rear floor front extension Under enter front floor ront floor (R & ) a. T=1.8 mm (0.071 in) 980 caution b. T=1.8 mm (0.071 in) 980 caution 9. nner sill (R & ) c. d. e. T=1.4 mm (0.055 in) T=2.0 mm (0.079 in) T=1.6 mm (0.063 in) 980 caution 980 caution 980 caution 10. owl top Under Upper dash Under ower dash f. 13. ower dash crossmember T=1.4 mm (0.055 in) T=2.0 mm (0.079 in) 980 caution 980 caution 14. Side dash (R & ) ront strut housing (R & ) ower front hoodledge (R & ) Under Upper hoodledge (R & ) Under oodledge reinforcement (R & ) Under oodledge connector (R & ) Under Side radiator core support (R & ) Under nner center front bumper reinforcement 22. ront side member front assembly (R & ) ront side member assembly (R & ) ront suspension mounting bracket (R & ront) ront side member closing plate assembly (R & ) uter add on frame bracket (R & ) Under ront suspension mounting bracket (R & Rear) Under Rear seat crossmember Rear crossmember center assembly th crossmember Under 440 R R-13

14 < RRT > Y T RTS o. arts name Tensile strength (a) oth sided anti-corrosive precoated steel sections 31. Rear side member (R & ) Rear side member extension reinforcement assembly (R & ) Rear side member extension (R & ) 590 T: or the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with. Tensile strength column shows the largest strength value of a part in the component part. UT: f the high strength steel (ultra high strength steel) of this is broken, replace by assembly for the supply part. luminum portion R-14

15 < RRT > ody omponent arts Y T RTS : R SK2269ZZ : oth sided anti-corrosive precoated steel sections : igh strength steel (SS) sections : oth sided anti-corrosive steel and SS sections *: luminum portion R-15

16 < RRT > Y T RTS o. arts name Tensile strength (a) oth sided anti-corrosive precoated steel sections 1. ood 2. ront fender (R & ) Under 440 luminum portion 3. nner side roof rail (R & ) Upper inner front pillar (R & ) nner center pillar assembly (R & ) a. b. T=1.6 mm (0.063 in) T=1.4 mm (0.055 in) 980 caution 980 caution 6. Side body assembly (R & ) Refer to o uter side roof rail reinforcement (R & ) T=1.4 mm (0.055 in) 980 caution 8. ront pillar brace (R & ) ower center pillar brace (R & ) c. T=1.2 mm (0.047 in) 980 caution 10. uter front side body (R & ) Under ront fender bracket assembly (R & ) Under uter sill reinforcement (R & ) uter sill (R & ) Under ront door (R & ) 15. uter front door panel (R & ) 16. Rear door (R & ) 17. uter rear door panel (R & ) 18. nner rear pillar (R & ) nner rear pillar reinforcement (R & ) nner rear wheelhouse (R & ) uter rear wheelhouse (R & ) Under uter rear wheelhouse extension (R & ) Under Roof Under ront roof rail d. T=1.0 mm (0.039 in) 980 caution 25. Roof bow o.1 Under enter roof reinforcement Roof bow o.3 Under Roof bow o.4 Under Rear roof rail Under Rear fender (R & ) Under Rear fender extension (R & ) Under Rear fender corner (R & ) Under ack door Under Upper rear panel Upper rear bumper retainer Under Rear side bumper bracket Under 440 R-16

17 < RRT > Y T RTS o. arts name Tensile strength (a) oth sided anti-corrosive precoated steel sections 37. Rear bumper stay (R & ) Under nner center rear bumper reinforcement T: or the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with. Tensile strength column shows the largest strength value of a part in the component part. UT: f the high strength steel (ultra high strength steel) of this is broken, replace by assembly for the supply part. luminum portion R R-17

18 < S ST > S ST RR WRK W Repair udgment low RR WRK W : WR: ecause hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly. e sure to follow the correct work procedures when performing inspection and maintenance. e sure to remove the service plug in order to disconnect the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts. To prevent the removed service plug from being connected by mistake during the procedure, always carry it in your pocket or put it in the tool box. e sure to wear insulating protective equipment consisting of glove, shoes, face shield and glasses before beginning work on the high voltage system. learly identify the persons responsible for high voltage work and ensure that other persons do not touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or similar item to prevent other persons from contacting them. Refer to -33, "igh Voltage recautions". UT: There is the possibility of a malfunction occurring if the vehicle is changed to RY status while the service plug is removed. Therefore do not change the vehicle to RY status unless instructed to do so in the Service anual. VR SQU SK2341 T W 1.K T STR WR heck that the master warning lamp is. R-18

19 < S ST > RR WRK W s master warning lamp? YS >> T 2. >> T 3. 2.TT UT RT Y TRU SS, R T T SRV U- onnect SUT to check malfunction information. s there malfunction information in high voltage parts? YS >> T 5. >> T 3. 3.K VT RTS R Visually check high voltage parts for damage. WR: When performing high voltage-related work, always wear insulating protective gear. s there a malfunction in high voltage parts? YS >> T 5. >> T 4. 4.K R T T R T RS VT RTS heck high voltage parts requiring additional removal work. s additional removal work required for high voltage parts? YS >> T 5. >> Start body repair and painting. 5.RT WR: isconnect high voltage. Refer to -31, "ow to isconnect igh Voltage". heck voltage in high voltage circuit. (heck that condenser are discharged.) 1. ift up the vehicle and remove the battery under covers. Refer to V-161, "Removal and nstallation". 2. isconnect high voltage connector from front side of i-ion battery. Refer to V-161, "Removal and nstallation". 3. easure voltage between high voltage harness connector terminals. R: Touching high voltage components without using the appropriate protective equipment will cause electrocution. R Standard : 5 V or less S1362ZZ UT: or voltage measurements, use a tester which can measure to 500V or higher. >> T 6. 6.RV VT RTS S T WRK, R T T SRV U- Remove high voltage parts as an additional work, according to the Service anual. WR: When performing high voltage-related work, always wear insulating protective gear. >> Start body repair and painting. R-19

20 RRS RTT < RV STT > RV STT RRS RTT escription : To provide improved corrosion prevention, the following anti-corrosive measures have been implemented in SS production plants. When repairing or replacing body panels, it is necessary to use the same anti-corrosive measures. T-RRSV RT ST (V ST) To improve repairability and corrosion resistance, a new type of anticorrosive precoated steel sheet has been adopted replacing conventional zinc-coated steel sheet. alvannealed steel is electroplated and heated to form Zinc-iron alloy, which provides excellent and long term corrosion resistance with cationic electrodeposition primer. S2294 issan enuine Service arts are fabricated from galvannealed steel. Therefore, it is recommended that U SS RTS or equivalent be used for panel replacement to maintain the anti-corrosive performance built into the vehicle at the factory. ST T TRTT T TRST RR phosphate coating treatment and a cationic electrodeposition primer, which provide excellent corrosion protection, are employed on all body components. UT: onfine paint removal during welding operations to an absolute minimum issan enuine Service arts are also treated in the same manner. Therefore, it is recommended that U- SS RTS or an equivalent be used for panel replacement to maintain anti-corrosive performance built into the vehicle at the factory. Undercoating : The underside of the floor and wheelhouse are undercoated to prevent rust, vibration, noise and stone chipping. Therefore, when such a panel is replaced or repaired, apply undercoating to that part. Use an undercoating which is rust resistant, soundproof, vibration-proof, shock-resistant, adhesive, and durable. RUTS URT 1. ever apply undercoating to any place unless specified (such as the areas above the muffler and threeway catalyst that are subjected to heat). 2. ever undercoat the exhaust pipe or other parts that become hot. 3. ever undercoat rotating parts. 4. pply bitumen wax after applying undercoating. 5. fter putting seal on the vehicle, put undercoating on it. R-20

21 < RV STT > RRS RTT SK2446ZZ : Undercoated areas : Sealed portions Stone uard oat : To prevent damage caused by stones, the lower outer body panel (fender, door, etc.) have an additional layer of Stone uard oating over the primer coating. When replacing or repairing these panels, apply Stone uard coating to the same portions as before. Use a coating which is rust preventive, durable, shock-resistant and has a long shelf life. R R-21

22 RRS RTT < RV STT > SK2271ZZ : Stone guard coated portions ody Sealing : The following figure shows the areas that are sealed at the factory. Sealant that is applied to these areas should be smooth and free from cuts or gaps. are should be taken not to apply an excess amount of sealant and not to allow other unaffected parts to come into contact with the sealant. R-22

23 < RV STT > RRS RTT R SK2272ZZ : Vehicle front : Sealed portions R-23

24 RRS RTT < RV STT > SK2569ZZ : Vehicle front : Sealed portions R-24

25 < RV STT > RRS RTT R SK2274ZZ : Vehicle front : Sealed portions R-25

26 Y STRUT < RV STT > Y STRUT ody onstruction : SK2275ZZ 1. uter side body 2. uter front pillar reinforcement 3. nner front side roof rail 4. Upper dash 5. oodledge reinforcement 6. Weld nut 7. Side dash 8. Upper hinge plate 9. nner front pillar reinforcement R-26

27 < RV STT > Rear ender emming rocess Y STRUT 10. ower dash 11. ower front pillar hinge brace 12. ower hinge plate 13. nner front sill reinforcement 14. nner sill 15. ront side member extension center 16. ront side member closing plate 17. ront outrigger 18. ront floor front 19. ower front pillar reinforcement 20. uter sill reinforcement 21. uter sill brace 22. ront side member extension rear 23. loor member extension 24. enter sill reinforcement 25. Roof 26. enter roof reinforcement 27. Roof member reinforcement 28. nner center pillar 29. enter pillar seat belt anchor 30. enter pillar reinforcement 31. enter pillar hinge brace 32. uter side roof rail 33. ront floor side 34. Rear side member closing plate 35. Rear side member reinforcement 36. Rear side member 37. nner sill extension 38. nner rear sill reinforcement 39. uter rear wheelhouse extension 40. nner rear wheelhouse 41. uter rear wheelhouse 42. Rear fender extension 43. ack door stay bracket 44. nner rear pillar 45. Rear roof rail brace 46. nner rear pillar reinforcement 47. Rear pillar seat belt anchor : wheel arch is to be installed and hemmed over the left and right outer wheel houses. 2. n order to hem the wheel arch, it is necessary to repair any damaged or defaced parts around outer wheel house. UT: nsure that the area that is to be glued around the outer wheelhouse is undamaged or defaced. RUR T RSS eel off old bonding material on the surface of the outer wheelhouse and clean thoroughly. eel off a primer coat in the specified area where new adhesive is to be applied on rear fender (the replacing part). pply new adhesive to both specified areas of the outer wheelhouse and rear fender. <dhesive> 3 utomix anel onding dhesive or equivalent ttach rear fender to the body of the car, and weld the required part except the hemming part. end the welded part starting from the center of the wheel arch gradually with a hammer and a dolly. (lso hem the end of the flange.) emming with a hammer is conducted to an approximate angle of 80 degrees. SK0136 R S2245 R-27

28 Y STRUT < RV STT > Starting from the center, hem the wheel arch gradually, using slight back and forth motion with a hemming tool. S2246 Seal up the area around the hemmed end of the flange. SK0137 R-28

29 < RV STT > RT RTS escription RT RTS : This section is prepared for technicians who have attained a high level of skill and experience in repairing collision-damaged vehicles and also use modern service tools and equipment. ersons unfamiliar with body repair techniques should not attempt to repair collision-damaged vehicles by using this section. Technicians are also encouraged to read the ody Repair anual (undamentals) in order to ensure that the original functions and quality of the vehicle are maintained. The ody Repair anual (undamentals) contains additional information, including cautions and warnings, that are not including in this manual. Technicians should refer to both manuals to ensure proper repair. lease note that this information is prepared for worldwide usage, and as such, certain procedures might not apply in some regions or countries. The symbols used in this section for welding operations are shown below. Symbol marks escription 2-spot welds SK0049ZZ 3-spot welds SK0053ZZ SK0050ZZ R plug weld or 3 panels plug weld method SK0054ZZ SK0051ZZ SK0055ZZ seam weld / oint weld SK0052ZZ SK0056ZZ R-29

30 RT RTS < RV STT > ront pillar butt joint can be determined anywhere within shaded area as shown in the figure. The best location for the butt joint is at position due to the construction of the vehicle etermine cutting position and record distance from the locating indent. Use this distance when cutting the service part. ut outer front pillar over 60 mm (2.36 in) above the inner front pillar cut position. SK0104 repare a cutting jig to make outer pillar easier to cut. lso, this will permit the service part to be accurately cut at the joint position. SK0105 n example of cutting operation using a cutting jig is as per the following. 1. ark cutting lines. : ut position of outer pillar : ut position of inner pillar 2. lign cutting line with notch on jig. lamp jig to pillar. 3. ut outer pillar along groove of jig (at position ). 4. Remove jig and cut remaining portions. 5. ut inner pillar at position in same manner R-30

31 < RV STT > Radiator ore Support RT RTS : R SK2302ZZ : Vehicle front Replacement parts Side radiator core support () oodledge connector () igh voltage system parts (Removal required depending on damage) Service plug ront side i-ion battery high voltage harness connector harge port R-31

32 RT RTS < RV STT > oodledge : Work after radiator core support is removed. SK2303ZZ : Vehicle front : Weld the parts onto the back of the component part. Replacement parts ront strut housing () oodledge reinforcement () igh voltage system parts (Removal required depending on damage) Service plug ront side i-ion battery high voltage harness connector R-32

33 RT RTS < RV STT > harge port T elements heater Traction motor lectric compressor Traction motor inverter /-/ View : efore installing hoodledge reinforcement oodledge (artial Replacement) Work after radiator core support is removed. : R SK2304 Unit: mm (in) : Vehicle front Replacement parts Upper hoodledge (R) ower front hoodledge (R) oodledge reinforcement (R) R-33

34 RT RTS < RV STT > igh voltage system parts (Removal required depending on damage) Service plug ront side i-ion battery high voltage harness connector harge port T elements heater Traction motor lectric compressor Traction motor inverter /-/ View and : efore installing hoodledge reinforcement ront Side ember : Work after radiator core support and hoodledge are removed. SK2305ZZ R-34

35 < RV STT > RT RTS : Vehicle front : rill φ11 mm (0.43 in) hole for the plug welding hole (ultra high strength steel plate). : rill φ12 mm (0.47 in) hole for the plug welding hole (ultra high strength steel plate). : Weld the parts onto the back of the component part. Replacement parts ront side member assembly () ront side member closing plate assembly () igh voltage system parts (Removal required depending on damage) Service plug ront side i-ion battery high voltage harness connector harge port T elements heater Traction motor lectric compressor Traction motor inverter /-/ ront suspension mounting bracket ( Rear) R R-35

36 RT RTS < RV STT > SK2306ZZ : Vehicle front : rill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel plate). : rill φ11 mm (0.43 in) hole for the plug welding hole (ultra high strength steel plate). View and : efore installing front suspension mounting bracket (Rear) R-36

37 < RV STT > RT RTS R SK2615. olt diameter 12 mm (0.47 in). olt diameter 13 mm (0.51 in) : Vehicle front : m (kg-m, ft-lb) ront Side ember (artial Replacement) Work after radiator core support is removed. : R-37

38 RT RTS < RV STT > SK2308ZZ : Vehicle front : Weld the parts onto the back of the component part. Replacement parts ront suspension mounting bracket uter add on frame bracket (R) (R ront) igh voltage system parts (Removal required depending on damage) Service plug ront side i-ion battery high voltage harness connector harge port View : efore installing outer add on frame bracket R-38

39 < RV STT > ront illar Work after hoodledge reinforcement is removed. RT RTS : R SK ody sealing 2. ront pillar brace 3. Urethane foam Unit: mm (in) : Vehicle front : rill φ9 mm (0.35 in) hole for the plug welding hole (ultra high strength steel plate). : Weld the parts onto the back of the component part. Replacement parts Side body assembly () Side dash () R-39

40 RT RTS < RV STT > SK Urethane foam Unit: mm (in) : Vehicle front : rill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel plate). : rill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel plate). : rill φ9 mm (0.35 in) hole for the plug welding hole (ultra high strength steel plate). : Weld the parts onto the back of the component part. View : efore installing outer front side body R-40

41 < RV STT > RT RTS R SK Urethane foam Unit: mm (in) : Vehicle front : rill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel plate). : Weld the parts onto the back of the component part. View : efore installing side body assembly View : efore installing outer front side body R-41

42 RT RTS < RV STT > enter illar : nstall the inner center pillar assembly to the side body assembly as shown in the figure for repairing the hidden welding point View. SK nner center pillar assembly 2. ower center pillar brace 3. uter sill reinforcement Unit: mm (in) : Vehicle front : rill φ8 mm (0.31 in) hole for the plug welding hole (ultra high strength steel plate). : rill φ9 mm (0.35 in) hole for the plug welding hole (ultra high strength steel plate). : Weld the parts onto the back of the component part. R-42

43 < RV STT > RT RTS Replacement parts Side body assembly () nner center pillar assembly () R SK2313 Unit: mm (in) : Vehicle front : rill φ7 mm (0.28 in) hole for the plug welding hole (ultra high strength steel plate). : rill φ9 mm (0.35 in) hole for the plug welding hole (ultra high strength steel plate). View : efore installing outer front side body View : nner center pillar assembly and side body assembly (replacement parts) R-43

44 RT RTS < RV STT > SK nner center pillar assembly 2. uter sill reinforcement Unit: mm (in) : Vehicle front : rill φ9 mm (0.35 in) hole for the plug welding hole (ultra high strength steel plate). : Weld the parts onto the back of the component part. View : efore installing outer front side body R-44

45 < RV STT > uter Sill (artial Replacement) RT RTS : R Unit: mm (in) Replacement parts uter sill () SK2315 R-45

46 RT RTS < RV STT > uter Sill : SK Urethane foam 2. ront pillar brace 3. nner center pillar assembly 4. ower center pillar brace 5. uter sill reinforcement Unit: mm (in) : Vehicle front Replacement parts uter sill () ront fender bracket assembly () R-46

47 < RV STT > RT RTS R SK emming portion 2. uter sill reinforcement 3. nner center pillar assembly 4. ront pillar brace 5. ower center pillar brace 6. dhesive 7. ody sealing Unit: mm (in) : Vehicle front T R-47

48 RT RTS < RV STT > erform the hemming to the flange of wheelarch after applying the adhesive. pply the sealing to the flange end. Refer to R-27, "Rear ender emming rocess". 1. uter rear wheelhouse 2. Rear fender 3. dhesive 4. Sealant SK0204 R-48

49 < RV STT > Rear ender RT RTS : R 1. Urethane foam 2. dhesive 3. emming portion Unit: mm (in) : Vehicle front Replacement parts Rear fender () SK2322 R-49

50 RT RTS < RV STT > SK ody sealing Unit: mm (in) : Vehicle front : Weld the parts onto the back of the component part. R-50

51 < RV STT > RT RTS R SK Urethane foam Unit: mm (in) : Vehicle front : Weld the parts onto the back of the component part. View K: efore installing rear fender T R-51

52 RT RTS < RV STT > erform the hemming to the flange of wheelarch after applying the adhesive. pply the sealing to the flange end. Refer to R-27, "Rear ender emming rocess". 1. uter rear wheelhouse 2. Rear fender 3. dhesive 4. Sealant SK0204 R-52

53 < RV STT > Rear ender xtension RT RTS : R 1. ody sealing : Vehicle front Replacement parts Rear fender corner () SK2325ZZ R-53

54 RT RTS < RV STT > Rear anel : SK2330 Unit: mm (in) : Vehicle front : Welding method and the number of welding points apply to both side of the vehicle. : Weld the parts onto the back of the component part. Replacement parts Upper rear panel R-54

55 < RV STT > Rear loor Rear Work after rear panel is removed. RT RTS : R SK2331ZZ 1. side 2. R side : Vehicle front : Welding method and the number of welding points apply to both side of the vehicle. Replacement parts Rear floor rear Rear floor rear side () igh voltage system parts (Removal required depending on damage) R-55

56 RT RTS < RV STT > Service plug ront side i-ion battery high voltage harness connector n board charger Rear Side ember xtension : Work after rear panel is removed. SK2332ZZ : Vehicle front Replacement parts Rear side member extension () Rear side member extension reinforcement assembly () R-56

57 < RV STT > RT RTS View : efore installing replacement parts (Weld the rear side member extension and rear side member extension reinforcement assembly) R R-57

58 Y T < SRV T STS (SS) SRV T STS (SS) Y T ody enter arks : mark is placed on each part of the body to indicate the vehicle center. When repairing the vehicle frame (members, pillars, etc.) damaged by an accident which it enables more accurate and effective repair by using these marks together with body alignment specifications. SK2276ZZ : Vehicle front oints ortion arks ront roof mbossment owl top mbossment Trans control reinforcement ole φ31 (1.22) Unit: mm (in) R-58

59 < SRV T STS (SS) Y T oints ortion arks enter front floor ole φ11 (0.43) Rear roof mbossment escription : ll dimensions indicated in the figures are actual. When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and gauge itself to make sure there is no free play. When a measuring tape is used, check to be sure there is no elongation, twisting or bending. easurements should be taken at the center of the mounting holes. n asterisk (*) following the value at the measuring point indicates that the measuring point on the other side is symmetrically the same value. The coordinates of the measurement points are the distances measured from the standard line of X, Y and Z. Z : maginary base line [200 mm (7.87 in) below datum line ( 0Z at design plan)] SK Vehicle center 2. ront axle center 3. maginary base line otor Room : R SURT imensions marked with * indicate symmetrically identical dimensions on both the right and left hand of the vehicle. R-59

60 Y T < SRV T STS (SS) SK2277 Unit: mm (in) «The others» Unit: mm (in) oint imension emo oint imension emo oint imension emo oint imension emo (12.56) - j 790 (31.10) - d 1447 (56.97) - j 843 (33.19) - c 738 (29.06) - K 659 (25.94) - e 1447 (56.97) h (33.07) (22.24) - k 914 (35.98) (14.09) - k 923 (36.34) - d 968 (38.11) (10.55)* f - g 363 (14.29) h - K 937 (36.89) (23.15) - c 1272 (50.08)* - g 1086 (42.76) - j 822 (32.36) - e 982 (38.66) - f 1563 (61.54)* f (42.99) - k 878 (34.57) (21.65) - c 1037 (40.83) - h 782 (30.79) j - K 893 (35.16) SURT TS R-60

61 < SRV T STS (SS) Y T R SK2278ZZ : Vehicle front Unit: mm (in) oint aterial oint aterial Upper dash hole center φ7 (0.28), g Side radiator core support hole center φ9 (0.35), b ood hinge installing hole center φ11 (0.43), h,, j, c ront strut installing hole center ( ), d,, e ront fender installing hole center φ7 (0.28), m,, n, f oodledge reinforcement hole center φ12 (0.47) Traction motor inverter member mounting hole center, h, : φ18 (0.71) j: ( ) K, k ront side member hole center 12 7 ( ) ront bumper stay installing hole center φ15 (0.59) R-61

62 Y T < SRV T STS (SS) Underbody : SURT imensions marked with * indicate symmetrically identical dimensions on both the right and left hand of the vehicle. The following figure shows a bottom view and a side view of the vehicle. SK2279 R-62

63 < SRV T STS (SS) Y T Unit: mm (in) : Vehicle front : Vehicle left side SURT TS R SK2280ZZ oints a : Vehicle front oordinates oordinates Remarks oints X Y Z X Y Z (18.504) ( ) (18.598) ( ) ( ) ( ) (12.886) (12.886) (12.886) ole φ11 (0.43) ole φ11 (0.43) ole φ20 (0.79), g, h, j ±626.8 (±24.677) ±575.4 (±22.653) ±350.0 (±13.780) (74.976) (81.102) (95.394) (12.520) (8.661) (15.370) Unit: mm (in) Remarks ole φ16 (0.63) ole φ13 (0.51) ole φ16 (0.63) R-63

64 Y T < SRV T STS (SS) oints b c, d, e, f oordinates oordinates Remarks oints X Y Z X Y Z ( ) (18.205) ( ) ±458.8 (±18.063) ±538.0 (±21.181) ±538.0 (±21.181) ( ) ( ) ( ) (22.555) (41.811) (60.630) assenger ompartment (12.886) (19.402) (19.402) (7.449) (8.661) (8.661) ole φ20 (0.79) ole φ16 (0.63) ole φ16 (0.63) ole ( ) ole φ15 (0.59) ole φ15 (0.59) K, k, m, n, o, p ±482.3 (±18.988) ±331.3 (±13.043) ±488.5 (±19.232) ±583.6 (±22.976) ±575.4 (±22.653) ( ) ( ) ( ) 6.6 (0.260) ( ) (13.713) (16.528) (14.779) (34.181) (29.039) Remarks ole φ12 (0.47) : ole φ16 (0.63) m: ole ( ) ole ( ) ole φ98 (3.86) ole φ20 (0.79) : SURT imensions marked with * indicate symmetrically identical dimensions on both the right and left hand of the vehicle. SK2281 Unit: mm (in) «The others» R-64

65 < SRV T STS (SS) Y T Unit: mm (in) oint imension emo oint imension emo oint imension emo oint imension emo - e 1227 (48.31) K - k 1441 (56.73) Q - q 1392 (54.80) T - Q 1169 (46.02)* - g 1582 (62.28)* - m 1267 (49.88) R - r 1441 (56.73) T - R 983 (38.70)* - h 1397 (55.00)* - o 1545 (60.83)* S (42.05)* U - u 1539 (60.59) - k 1599 (62.95)* - p 1385 (54.53)* S (33.66)* U - W 1162 (45.75)* - f 1420 (55.91) - r 1630 (64.17)* S (30.39)* U - X 1133 (44.61)* - j 1663 (65.47)* - n 1420 (55.91) S (51.06)* V - v 1567 (61.69) - g 1425 (56.10) - q 1575 (62.01)* S (42.05)* V - W 1215 (47.83)* - h 1852 (72.91)* - o 1441 (56.73) S - K 925 (36.42)* V - X 1105 (43.50)* - k 1666 (65.59)* - p 1717 (67.60)* T (42.13)* W - w 1559 (61.38) - h 1270 (50.00) - r 1558 (61.34)* T (33.35)* X - x 1590 (62.60) - k 1555 (61.22)* - p 1160 (45.67) T (28.82)* - j 1420 (55.91) - r 1562 (61.50)* T (54.25)* SURT TS R R-65

66 Y T < SRV T STS (SS) SK2282ZZ : Vehicle front oint aterial oint aterial Unit: mm (in) owl top flange end of center positioning mark, p, Q, q, R, r Rear fender indent Roof flange end of center positioning mark S Trans control reinforcement hole center of center positioning mark φ31 (1.22), c,, f uter side body joggle T, d,, e,, g uter side body indent, h,, j, K, k,, m,, n,, o enter pillar indent U, u, V, v, W, w, X, x enter front floor hole center of center positioning mark φ11 (0.43) oor hinge installing hole center U, u, V, v, X, x: φ12 (0.47) W, w: φ9 (0.35) R-66

67 < SRV T STS (SS) Rear ody Y T : SURT imensions marked with * indicate symmetrically identical dimensions on both the right and left hand of the vehicle. SK2283 R Unit: mm (in) SURT TS R-67

68 Y T < SRV T STS (SS) SK2284ZZ : Vehicle front Unit: mm (in) oint aterial oint aterial Roof indent of center positioning mark, c,, d Rear combination lamp base joggle, b Rear fender extension joggle, e ack door striker installing hole center φ15 (0.59) R-68

69 < SRV T STS (SS) T ST RTS recautions for lastics T ST RTS : bbreviation aterial name eat resisting temperature ( ) olyethylene 60 (140) Resistance to gasoline and solvents asoline and most solvents are harmless if applied for a very short time (wipe out quickly). S crylonitrile utadiene Styrene 80 (176) void gasoline and solvents. / thylene ropylene (iene) copolymer 80 (176) asoline and most solvents are harmless if applied for a very short time (wipe out quickly). ther cautions lammable lammable S olystyrene 80 (176) void solvents. lammable V oly Vinyl hloride 80 (176) asoline and most solvents are harmless if applied for a very short time (wipe out quickly). T Thermoplastic lefine 80 (176) lammable S crylonitrile crylic Styrene 85 (185) void gasoline and solvents. oly ethyl ethacrylate 85 (185) V thylene Vinyl cetate 90 (194) olypropylene 90 (194) asoline and most solvents are harmless if applied for a very short time (wipe out quickly). oisonous gas is emitted when burned. lammable, avoid battery acid. UR olyurethane 90 (194) void gasoline and solvents. U Unsaturated olyester 90 (194) lammable S crylonitrile Styrene crylate 100 (212) lammable oly henylene ther 110 (230) TU Thermoplastic Urethane 110 (230) T+ oly utylene Terephthalate + olycarbonate 120 (248) lammable olycarbonate 120 (248) oly xymethylene 120 (248) void battery acid. olyamide 140 (284) T oly utylene Terephthalate 140 (284) R olyarylate 180 (356) T olyethylene terephthalate 180 (356) olyetherimide 200 (392) void immersing in water. UT: When repairing and painting a portion of the body adjacent to plastic parts, consider their characteristics (influence of heat and solvent) and remove them if necessary or take suitable measures to protect them. lastic parts should be repaired and painted using methods suiting the materials, characteristics. R R-69

70 T ST RTS < SRV T STS (SS) ocation of lastic arts : SK2285ZZ omponent aterial omponent aterial Side roof molding V + Stainless 10 oor outside molding V + Stainless 1 ower side molding S ens 11 Rear combination lamp 2 Upper windshield molding T ousing S ens 12 Rear spoiler S 3 ront side marker lamp ousing ens 13 igh mount stop lamp ens ousing S 4 ront combination lamp ousing 14 ack door handle S 5 harge port lid + T ens 15 icense plate lamp 6 umper fascia + ousing 7 ront fender protector ens 16 Reflex reflector ens ousing S 8 Side turn signal lamp + T + ousing + S rip body 17 oor outside handle lass fiber ase + lass fiber rip cover + S 9 oor outside mirror ase T + T + lass fiber over S R-70

71 < SRV T STS (SS) T ST RTS SK2286ZZ omponent aterial omponent aterial 1 ront pillar garnish 5 Rear pillar finisher ens ody 6 enter console ap lamp ousing onsole finisher + S 2 enter cover 7 luster lid + S Sunglass holder ase 8 love box older + S 9 nstrument panel 3 enter pillar garnish luster lid 4 Room lamp ens 10 luster lid finisher ousing eter cover + S R R-71