BODY CONSTRUCTION GROUP CONTENTS BODY COMPONENTS BODY MAIN CROSS-SECTIONAL VIEWS SILENCER APPLICATION LOCATIONS...

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1 - GROUP ODY CONSTRUCTION CONTENTS ODY COMPONENTS ODY MIN CROSS-SECTIONL VIEWS MINTENNCE, SERVICEILITY. -6 CHRCTERISTICS FRONT ODY ROOF SIDE ODY RER ODY UNDER ODY DOOR SILENCER PPLICTION LOCTIONS LOCTIONS USING URETHNE FOM ND FOM MTERIL STIFFENER ND DMP SHEET PPLICTION LOCTIONS THEFT PROTECTION

2 - ODY COMPONENTS ODY COMPONENTS M : nti-corrosion steel panels : High-tensile steel panels 0

3 - ODY COMPONENTS. HEDLMP SUPPORT PNEL. HOOD LOCK STY. FRONT END CROSSMEMER. FRONT END UPPER R. HEDLMP SUPPORT PNEL SIDE 6. FRONT FENDER SHIELD. FRONT UPPER FRME INNER 8. UPPER FRME ULKHED FRONT 9. UPPER FRME ULKHED 0. UPPER FRME ULKHED RER. FRONT SIDEMEMER INNER. ENGINE MOUNT RCKET. FRONT SIDEMEMER RER. FRONT SIDEMEMER OUTER. SPRING HOUSE PNEL 6. DSH PNEL. DSH PNEL SILENCER 8. DSH PNEL 9. UPPER FRME TO FRONT PILLR RCE 0. UPPER FRME EXTENSION OUTER. UPPER FRME EXTENSION INNER. COWL TOP LOWER PNEL. COWL TOP INNER PNEL. COWL TOP UPPER PNEL. FRONT DECK CROSSMENER 6. HOOD INNER PNEL. HOOD OUTER PNEL 8. FRONT ROOF RIL 9. FRONT ROOF OW 0. ROOF PNEL. ROOF OW FRONT. RER ROOF OW. RER ROOF RIL. SET CK PLTE. RER SET CK PNEL 6. RER SHELF PNEL. RER SET CK RCE 8. TRUNK LID OUTER PNEL 9. TRUNK LID INNER PNEL 0. TRUNK LID HINGE. QURTER INNER EXTENSION RER. QURTER CORNER PNEL. RER COMINTION LMP HOUSING. SIDE ROOF RIL INNER. ROOF SIDE RIL CENTER 6. FRONT PILLR INNER UPPER. FRONT PILLR INNER LOWER 8. CENTER PILLR INNER 9. SIDE OUTER PNEL 0. RER WHEEL HOUSE INNER PNEL. QURTER INNER PNEL. RER FLOOR SIDE RCE. QURTER OUTER EXTENSION LOWER. FUEL FILLER DOOR. RER END PNEL OUTER 6. RER END PNEL INNER. RER DOOR OUTER PNEL 8. RER DOOR SIDE DOOR EM LOWER 9. RER DOOR SIDE DOOR EM UPPER 60. RER DOOR INNER PNEL 6. FRONT DOOR OUTER PNEL 6. FRONT DOOR SIDE DOOR EM 6. FRONT DOOR INNER PNEL 6. FENDER PNEL 6. FRONT FLOOR CROSSMEMER RER 66. FRONT FLOOR CROSSMEMER FRONT 6. FRONT FLOOR SIDE SILL INNER 68. FRONT FLOOR SIDEMEMER 69. CKONE 0. INSTRUMENT PNEL CENTER RCKET. FRONT FLOOR PN. FRONT FLOOR EXTENSION PNEL RER. RER FLOOR EXTENSION. RER FLOOR PN. SET CK PLTE EXTENSION 6. JCK RCKET. SPRE TIRE RCKET 8. TOWING HOOK 9. RER FLOOR SIDEMEMER EXTENSION 80. CROSSMEMER CENTER SUPPORT 8. RER FLOOR CROSSMEMER 8. RER FLOOR SIDEMEMER 8. RER SET CK

4 - ODY MIN CROSS-SECTIONL VIEWS ODY MIN CROSS-SECTIONL VIEWS M C E F D 09C ROOF PNEL ROOF PNEL FRONT PILLR UPPER SIDE OUTER PNEL FRONT ROOF RIL MP LMP RCKET 098C SIDE ROOF RIL INNER FRONT PILLR INNER FRONT PILLR REINFORCE- MENT UPPER () 0886 C COWL TOP UPPER PNEL D FRONT END CROSSMEMER REIFORCEMENT COWL TOP LOWER PNEL COWL TOP INNER PNEL 00C FRONT END CROSSMENER OUTER FRONT END CROSS- MENER INNER 006C E FRONT PILLR LOWER FRONT PILLR INNER LOWER F FRONT FLOOR SIDE SILL INNER SIDE SILL OUTER CENTER SIDE OUTER PNEL 098 SIDE SILL SUPPORT SIDE OUTER PNEL 008C

5 - ODY MIN CROSS-SECTIONL VIEWS G H I K J 09 G (STNDRD ROOF) FRONT PILLR INNER UPPER SIDE OUTER PNEL FRONT PILLR UPPER FRONT PILLR INNER UPPER FRONT PILLR REINFORCE- MENT UPPER () FRONT PILLR INNER UPPER 088 G (SUNROOF) FRONT PILLR UPPER SIDE OUTER PNEL FRONT PILLR INNER UPPER 0 H CENTER PILLR INNER CENTER PILLR SETELT I RER PILLR INNER CENTER PILLR SIDE OUTER PNEL 0986 SIDE OUTER PNEL 0988 J K SIDE OUTER PNEL RER WHEEL HOUSE INNER PNEL QURTER INNER PNEL RER END PNEL INNER RER END PNEL OUTER 006C 0989

6 -6 MINTENNCE, SERVICEILITY MINTENNCE, SERVICEILITY FENDER SHIELD positioning hole, marking and cut-out has been added on the front fender shield, front upper frame inner, front side member gusset rear and dash panel to improve assembling workability when replacing the panel. M

7 SIDE STRUCTURE panel positioning cut-out has been added on the door opening to improve assembling workability when replacing the panel. - MINTENNCE, SERVICEILITY PNEL POSITIONING NOTCH SIDE OUTER PNEL The extra parts are supplied in different cut forms as a result of employing the integrated side-frame side outer panel. CENTER PILLR OUTER FRONT PILLR OUTER QURTER OUTER SIDE SILL OUTER 00

8 -8 CHRCTERISTICS CHRCTERISTICS FRONT ODY HEDLMP SUPPORT y adopting a steel sheet with variable thickness* for the front end crossmember outer, the steel sheet thickness on the right side of the vehicle has been increased to improve safety in collision and body rigidity. NOTE: *: Steel sheets with different thickness welded to form one steel sheet. M FRONT END UPPER R. SENSOR RCKET. HEDLMP SUPPORT PNEL. HOOD LOCK STY. FRONT END CROSSMEMER INNER 6. /C CONDENSER RCKET. RDITOR RCKET 8. FRONT END CROSSMEMER INNER 9. FRONT END CROSSMEMER OUTER 0. SHIPPING HOOK 0. FRONT END CROSSMEMER

9 FENDER SHIELD The cross section of the front sidemember has been increased and a steel sheet with variable thickness* has been adopted for the front sidemember inner to increase the thickness of the cabinet side in the aim to improve safety in collision, body rigidity, and realize lightweight. RIGHT SIDE 8-9 CHRCTERISTICS 9 NOTE: *: Steel sheets with different thickness welded to form one steel sheet. 6 0 LEFT SIDE HEDLMP SUPPORT PNEL SIDE. FRONT FENDER SHIELD. ENGINE MOUNT. UPPER FRME ULKHED FRONT. FRONT UPPER FRME INNER 6. UPPER FRME ULKHED. UPPER FRME ULKHED RER 0 8. SPRING HOUSE RCKET 9. SPRING HOUSE RCKET 0. SPRING HOUSE PNEL. FRONT SIDEMEMER. TRNSMISSION MOUNT OUTER COWL TOP LOWER PNEL The spring house panel has been designed to be directly installed with the cowl top lower panel, and the body rigidity of the suspension attachment holder has been increased to improve operational stability and quietness. SPRING HOUSE RCKET SPRING HOUSE PNEL 00C

10 -0 FRONT SIDEMEMER RIGHT SIDE CHRCTERISTICS FRONT SIDEMEMER INNER. FRONT SIDEMEMER ULKHED. FRONT SIDEMEMER OUTER. ENGINE MOUNT RCKET. FRONT SIDEMEMER INNER LOWER 6. FRONT SIDEMEMER GUSSET RER. FRONT SIDEMEMER INNER RER 8. TIE DOWN 9. DSH PNEL EXTENSION 00C 0. PIPE SUPPORT RER. PIPE NUT. FRONT SIDEMEMER RER. DSH CROSSMEMER EXTENSION. SUSPENSION CROSSMEMER SUPPORT RCKET. SUSPENSION CROSSMEMER RCKET INNER 6. PIPE. SQURE HED OLT 8. RETINER 9. PIPE SUPPORT FRONT C

11 - CHRCTERISTICS LEFT SIDE SUSPENSION CROSSMEMER SUPPORT RCKET. DSH CROSSMEMER EXTENSION. FRONT SIDEMEMER RER. PIPE NUT. PIPE SUPPORT RER 6. DSH PNEL EXTENSION. FRONT SIDEMEMER INNER UPPER 8. TIE DOWN 9. FRONT SIDEMEMER INNER 0. FRONT SIDEMEMER GUSSET RER. FRONT SIDEMEMER OUTER. FRONT SIDEMEMER ULKHED RER 00C. FRONT SIDEMEMER INNER. FRONT SIDEMEMER OUTER. FRONT SIDEMEMER ULKHED () 6. FRONT SIDEMEMER INNER. PIPE SUPPORT FRONT 8. RETINER 9. SQURE HED OLT 0. PIPE. SUSPENSION CROSSMEMER RCKET INNER. TRNSMISSION MOUNT. TRNSMISSION MOUNT RCKET. TRNSMISSION MOUNT RER 6 008C 6 008

12 - FRONT DECK Strut house gusset and upper frame to front pillar brace have been added to improve body rigidity. CHRCTERISTICS STRUT TOWER R RCKET. COWL TOP LOWER PNEL. COWL TOP LOWER. COWL TOP UPPER CENTER. COWL TOP INNER PNEL 6. COWL TOP UPPER PNEL. PEDL SUPPORT RCKET CLUTCH PEDL SUPPORT RCKET 9. UPPER FRME EXTENSION INNER 0. UPPER FRME EXTENSION OUTER. UPPER FRME TO FRONT PILLR RCE. STRUT HOUSE GUSSET. COWL TOP LOWER RCKET. COWL TOP UPPER DSH PNEL dash panel crossmember has been added and the thickness of the dash panel lower has been increased to improve collision stability. silencer (steel sheet biding type vibration damping material) has been added between the dash panel and dash panel silencer to control the penetrating sound and vibration from the engine DSH PNEL CROSSMEMER. DSH PNEL. DSH SILENCER CENTER. DSH PNEL SILENCER. CCELERTOR PEDL DSH PNEL. CCELERTOR STOPPER RCKET 8. DSH LOWER 9. DSH PNEL LOWER

13 - CHRCTERISTICS ROOF The cross section of the roof bow has been made large to improve safety in collision. STNDRD ROOF M SUN ROOF ROOF PNEL. RER ROOF RIL. RER ROOF OW. ROOF OW FRONT. FRONT ROOF OW 6. MP LMP RCKET. FRONT ROOF RIL 8. ROOF PNEL

14 - SIDE ODY SIDE STRUCTURE CHRCTERISTICS M FRONT PILLR LOWER EXTENSION. FRONT PILLR INNER LOWER EXTENSION. FRONT PILLR LOWER. FRONT DOOR HINGE LOWER. FRONT DOOR CHECK 6. SIDE SILL TO FLOOR PLTE. FRONT PILLR INNER LOWER 8. FRONT DOOR HINGE UPPER 9. DECK CROSSMEMER RCKET FRONT 0. DECK CROSSMEMER RCKET. FRONT PILLR INNER UPPER. FRONT PILLR INNER UPPER (VEHICLES WITH STNDRD ROOF). SIDE ROOF RIL INNER. RER SET CK RCE. RER SHELF UPPER RCE 6. RER SHELF LOWER RCE. RER PILLR INNER 8. QURTER INNER PNEL 9. OIL TNK RCKET 0. RER PILLR. RER FLOOR SIDE RCE. RER FLOOR RCE. FUEL FILLER NECK RCKET (LH only). QURTER INNER EXTENSION RER. QURTER CORNER PNEL 6. RER COMINTION LMP HOUSING. RER UMPER RCKET 8. QURTER OUTER EXTENSION LOWER 9. STRIKER 0. SIDE OUTER PNEL. SIDE SILL OUTER RER. SIDE SILL OUTER CENTER. SIDE SILL OUTER FRONT. SIDE SILL ULKHED FRONT. SIDE SILL SUPPORT 6. SIDE SILL () ULKHED. SIDE SILL (C) ULKHED 8. SIDE SILL (D) ULKHED 9. SIDE SILL (E) ULKHED 0. CENTER PILLR. CENTER PILLR INNER LOWER. RER DOOR HINGE LOWER

15 . RER DOOR HINGE UPPER. CENTER PILLR SETELT. CENTER PILLR INNER 6. FRONT PILLR UPPER () (VEHICLES WITH STNDRD ROOF). FRONT PILLR INNER (VEHICLES WITH STNDRD ROOF) 8. FRONT PILLR UPPER 9. ROOF SIDE RIL CENTER 0. RER SPRING HOUSE RCE. RER WHEEL HOUSE INNER. RER WHEEL HOUSE INNER PNEL. SPRING HOUSE PNEL. SPRING HOUSE RCKET. SIDE SILL END PLTE 6. RER SETELT WHEEL HOUSE. SPRING HOUSE RCE - CHRCTERISTICS SIDE STRUCTURE. The thickness of the reinforcements of the front pillar and center pillar has been increased to improve collision safety.. The front pillar reinforcement upper, side outer panel, and front roof rail have been joined to improve twisting rigidity.. The side sill has been made thin by employing a variable thickness steel sheet* for the center pillar reinforcement to improve safety in collision and realize lightweight.. The cross section of the side sill outer reinforcement has been made large to improve safety in collision and body rigidity.. rear pillar reinforcement has been added, and the rear shelf and rear wheel house have been joined to improve the twisting rigidity of the suspension attaching portion. NOTE: *: Steel sheets with different thickness welded to form one steel sheet., 000

16 -6 RER ODY CHRCTERISTICS M RER END CROSSMEMER rear shelf extension has been added to form closed structure. Then, the rear shelf and the rear floor have been joined to improve the torsion rigidity of the seat back plate SET CK PLTE. RER SET CK PNEL. RER SHELF EXTENSION. RER SHELF PNEL. RER SHELF CHILD SET ELT 6. RER SHELF. TRUNK LID HINGE 8. SET ELT RER END PNEL 00. RER END PNEL INNER. RER END PNEL OUTER. TRUNK LID LOCK RCKET SUPPORT. TRUNK LID LOCK RCKET

17 UNDER ODY FRONT FLOOR The cross section of the front floor sidemember has been made large to improve safety in collision. - CHRCTERISTICS M INSTRUMENT PNEL CENTER RCKET. FRONT FLOOR CROSSMEMER FRONT. FRONT FLOOR CROSSMEMER RER. FRONT FLOOR EXTENSION PNEL RER. FRONT FLOOR PN 6. FRONT FLOOR SIDE SILL INNER. FRONT FLOOR SIDEMEMER RER 8. FRONT FLOOR SIDEMEMER 9. FRONT FLOOR SIDEMEMER FRONT 0. FRONT FLOOR SIDEMEMER. CKONE CROSSMEMER RER. CKONE CROSSMEMER FRONT. CKONE

18 -8 RER FLOOR CHRCTERISTICS RER FLOOR PN. SET CK PLTE EXTENSION. JCK RCKET. SPRE TIRE RCKET. RER SET CK 6. TOWING HOOK. CROSSMEMER CENTER SUPPORT 8. RER FLOOR CROSSMEMER 9. RER FLOOR SET ELT 0. DIFFERENTIL / FUEL SUPPORT RCKET RER. RER FLOOR SIDEMEMER. DIFFERENTIL / FUEL SUPPORT RCKET FRONT. RER SET CROSSMEMER. SET CROSSMEMER. FUEL TNK FRONT 6. RER FLOOR EXTENSION. FRONT FLOOR SIDEMEMER EXTENSION

19 RER FLOOR SIDEMEMER -9 CHRCTERISTICS TRILING RM OUTER RCKET. RER FLOOR SIDEMEMER SUPPORT. TRILING RM INNER RCKET. RER FLOOR SIDEMEMER. RER FLOOR CROSSMEMER EXTENSION 6. DIFFERENTIL MOUNT ULKHED. DIFFERENTIL MOUNT 8. PIPE 9. SQURE HED OLT 0. RETINER. RER SUSPENSION RCKET. MUFFLER HNGER CENTER 00. RER FLOOR SIDEMEMER FRONT. MUFFLER HNGER RER. RER FLOOR SIDEMEMER RER 6. UMPER STY. RER FLOOR SIDEMEMER EXTENSION 8. RER FLOOR SIDEMEMER 9. UPPER LINK RCKET 0. TOE-CONTROL LINK SIDE. TOE-CONTROL LINK RCKET. RER FLOOR SIDE SILL 00 00

20 -0 DOOR The front and back of side door beam has been made large to cope with the force from the front and sides during collision. RONT DOOR CHRCTERISTICS M ER DOOR FRONT DOOR HINGE PNEL. FRONT DOOR HINGE UPPER. FRONT DOOR SIDE DOOR EM. FRONT DOOR OUTER PNEL. FRONT DOOR OUTSIDE HNDLE 6. FRONT DOOR ELTLINE OUTER. FRONT DOOR WINDOW SSH 8. FRONT DOOR ELTLINE INNER 9. FRONT DOOR LTCH 0. FRONT DOOR INNER PNEL 00. RER DOOR HINGE PNEL. RER DOOR SIDE DOOR EM LOWER. RER DOOR SIDE DOOR EM UPPER. RER DOOR OUTER PNEL. RER DOOR ELT LINE OUTER 6. RER DOOR ELT LINE RCKET. RER DOOR ENERGY SORER 8. RER DOOR WINDOW SSH 9. RER DOOR ELTLINE INNER 0. RER DOOR LTCH RER DOOR INNER PNEL

21 - SILENCER PPLICTION LOCTIONS SILENCER PPLICTION LOCTIONS silencer (MD- and melting sheet) has been adhered on the top part of the floor to improve antivibration performance and to shut-out exhaust gas heat. M NOTE:. MD- is a high performance sheet composed of asphalt applied with mica and thermosetting resin for improving anti-vibration performance :.6 mm (0.06 in) thick melting sheet :. mm (0.6 in) thick melting sheet [Place two.6 mm (0.06 in) melting sheet one on top of another.] :.0 mm (0. in) thick MD- [Place three.6 mm (0.06 in) melting sheet one on top of another.] NOTE: When you use melting sheet(s) in place of MD- during serving, follow the instructions enclosed by [ ].

22 - LOCTIONS USING URETHNE FOM ND FOM MTERIL LOCTIONS USING URETHNE FOM ND FOM MTERIL M Introduction of noise was prevented by inserting urethane foam inside the center pillar. Introduction of noise was prevented by adding foam noise absorbing materials inside each pillar, side roof rail and wheel house arch interior. High rigidity foam materials were added inside the side roof rail and the side sill to heighten panel rigidity. CUTION Precautions upon sheet metal processing the areas using foam materials. The foam materials may burn when heated. lways 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 materials remaining on the cut section (body side) then weld after removing the foam materials from periphery of the welding area. D C 08 FRONT PILLR UPPER () FOM COUSTIC MTERIL 00 FRONT PILLR INNER LOWER FRONT PILLR INNER FOM COUSTIC MTERIL 09 FRONT PILLR LOWER 008 C SIDE SILL OUTER REINFORCE- MENT CENTER HIGH RIGIDITY FOM MTERIL D SIDE OUTER PNEL FOM COUSTIC MTERIL QURTER INNER PNEL SIDE OUTER PNEL

23 - LOCTIONS USING URETHNE FOM ND FOM MTERIL E F H G I 098 E HIGH RIGIDITY FOM MTERIL F FOM COUSTIC MTERIL SIDE OUTER PNEL FRONT PILLR UPPER 09 SIDE OUTER PNEL SIDE ROOF RIL INNER 0980 G RER PILLR INNER H FOM COUSTIC MTERIL CENTER PILLR INNER SIDE OUTER PNEL FOM COUSTIC MTERIL 098 RER DOOR HINGE UPPER SIDE OUTER PNEL 098 I CENTER PILLR REINFORCE- MENT URETHNE FOM SIDE SILL OUTER CENTER 098

24 - STIFFENER ND DMP SHEET PPLICTION LOCTIONS STIFFENER ND DMP SHEET PPLICTION LOCTIONS M Sound insulation was improved with anti-vibration effects and heightening surface rigidity with a stiffener on the inner side of the side outer panel, and roof panel, as well as a damping sheet adhered to the inner side of the front door. NOTE: The main contents of a stiffener are epoxy resin. It comes in a sheet form and contains a mixture of glass fiber and filler, and cures (stiffens) when heated. It is used to improve the rigidity of the outer plate. STIFFENER (VHIECLES WITH SUNROOF) STIFFENER DMP SHEET STIFFENER DMP SHEET

25 THEFT PROTECTION LEL FOR ORIGINL PRTS - THEFT PROTECTION THEFT PROTECTION M In order to protect against theft, a Vehicle Identification Number (VIN) is attached as a plate or label to the following major parts of the engine and transaxle, as well as main outer panels: Engine cylinder block, Transaxle housing, Fender, Doors, Trunk lid, Quarter panel, Hood, umpers In addition, a theft-protection label is attached to replacement parts for the body outer panel main components, and the same data is stamped into replacement parts for the engine and the transaxle. FOR REPLCEMENT PRTS C00 CUTION Cautions regarding panel repairs:. When repainting original parts, do so after first masking the theft-protection label. fter painting, be sure to peel off the masking tape.. The theft-protection label for replacement parts is covered by masking tape, so such parts can be painted as is. The masking tape should be removed after painting is finished.. The theft-protection label should not be removed from original parts or replacement parts.

26 -6 THEFT PROTECTION LOCTIONS LEL RE (: FOR ORIGINL EQUIPMENT PRTS, : FOR REPLCEMENT PRTS) ENGINE MNUL TRNSXLE C C FENDER QURTER PNEL OUTER C060 THE ILLUSTRTION INDICTES LEFT OUTER SIDE. RIGHT SIDE IS SYMMETRICLLY OPPOSITE. C0606 THE ILLUSTRTION INDICTES LEFT OUTER SIDE. RIGHT SIDE IS SYMMETRICLLY OPPOSITE.

27 - THEFT PROTECTION LEL RE (: FOR ORIGINL EQUIPMENT PRTS, : FOR REPLCEMENT PRTS) FRONT DOOR RER DOOR THE ILLUSTRTION INDICTES LEFT INNER SIDE. RIGHT SIDE IS SYMMETRICLLY OPPOSITE. C060 THE ILLUSTRTION INDICTES LEFT INNER SIDE. RIGHT SIDE IS SYMMETRICLLY OPPOSITE. C0608 HOOD TRUNK LID C6 C0 FRONT UMPER RER UMPER C C8

28 NOTES

BODY CONSTRUCTION A-1 CONTENTS BODY COMPONENTS... 2 BODY MAIN CROSS-SECTIONAL VIEWS. 4 SILENCER APPLICATION LOCATIONS.. 21

BODY CONSTRUCTION A-1 CONTENTS BODY COMPONENTS... 2 BODY MAIN CROSS-SECTIONAL VIEWS. 4 SILENCER APPLICATION LOCATIONS.. 21 A- BODY CONSTRUCTION CONTENTS BODY COMPONENTS... BODY MAIN CROSS-SECTIONAL VIEWS. MAINTENANCE, SERVICEABILITY... BODY CONSTRUCTION CHARACTERISTICS... 8 FRONT BODY... 8 SIDE BODY... REAR BODY... ROOF...