ILX Body Repair Manual INTRODUCTION

Transcription

1 ILX ody Repair Manual INTRODUTION How to Use This Manual This manual covers the repairs of a model-series that has been involved in a collision, and it describes the work related to the replacement of damaged body parts. Please read through these instructions and familiarize yourself with them before actually using this manual. NOTE: Refer to the appropriate ILX Service Manual for speci cations, wire harness locations, safety stand support points, etc. Special Information You N be HURT if you don t follow instructions. WRNING You N be KILLED or SERIOUSLY HURT if you don t follow instructions. UTION 1 General Information 2 3 Paint Information *Replacement NOTE: Gives helpful information. UTION Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Please note that this manual does contain warnings and cautions against some specific service methods which could cause PERSONL INJURY, damage a vehicle, or make it unsafe. Please understand that these warnings cannot cover all conceivable ways in which service, whether or not recommended by Honda, might be done or of the possible hazardous consequences of each conceivable way, nor could Honda investigate all such ways. nyone using service procedures or tools, whether or not recommended by Honda, must satisfy himself thoroughly that neither personal safety or vehicle safety will be jeopardized. 4 5 ody Dimensional Drawings Rust Prevention ll information contained in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at any time without notice. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables. General Safety Precautions Honda Motor o., Ltd. ustomer Service Technology Development Division Reference Sections with an * include SRS components; special caution is required when servicing. First Edition 05/2012 ll Rights Reserved

2 Few Words bout Safety Service Information The repair information contained in this manual is intended for use by qualified, professional technicians. ttempting repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition. This manual describes the proper methods and procedures for doing repairs. Some procedures require the use of specially designed tools and dedicated equipment. ny person who intends to use a replacement part, a repair procedure, or a tool that is not recommended by cura, must determine the risks to their personal safety and the safe operation of the vehicle. If you need to replace a part, use cura parts with the correct part number, or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. FOR YOUR LIENT'S SFETY Proper repair is essential to the client's safety and the reliability of the vehicle. ny error or oversight while repairing a vehicle can result in faulty operation, damage to the vehicle, or injury to others. Improper repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this manual and other service materials carefully. FOR YOUR SFETY ecause this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety practices (for example, hot part - wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe repairing practices, we recommend that you do not attempt to do the procedures described in this manual. Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in doing repair procedures. Only you can decide whether or not you should do a given task. IMPORTNT SFETY PREUTIONS Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When doing any repair task, follow these precautions: Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to do the tasks safely and completely. Protect your eyes by using proper safety glasses, goggles, or face shields any time you hammer, drill, grind, or work around pressurized air or liquids and springs or other stored-energy components. If there is any doubt, put on eye protection. Use other protective wear when necessary, for example, gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. efore you grab something that looks like it can hurt you, stop and put on gloves. Protect yourself and others whenever you have the vehicle up in the air. ny time you raise the vehicle, either with a lift or a jack, make sure that it is always securely supported. Use jack stands if needed. Protect yourself by wearing an approved welding helmet, gloves, and safety shoes any time you are welding. Protect yourself from burns from hot parts; allow the parts to cool before working in that area. Protect yourself from paints and harmful chemicals by wearing an approved respirator, eye protection, and gloves whenever you are painting. Spray paint only in an approved paint booth that is well ventilated. Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this manual carefully.

3 Reference Symbols Replacement The welding symbols in the removal/installation have these meanings. : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MG plug welding : MG welding (butt or fillet) L=Welding length unit: mm (in) ( ): The number of welds ody Dimensional Drawings ody measuring dimensions show the distance between the forward or upper edge of positioning bosses and/or holes shown in the detail illustration. Front lack dots: Measuring point Front Front lack Dot (9) 2-Plate spot welding (9) Fillet welding 3-Plate spot welding (1) (12) L=190 (7.48) (20) (6) L=10 (0.39) (2) utt welding Detail Illustration However, the measuring points in the frame repair chart are always the centers of the holes. Rust Prevention The following type of illustration shows the areas where sealant is to be applied. F 4-Plate spot welding DMPER HOUSING SELNT WHEELHOUSE UPPER EXTENSION (8) MG plug welding L=330 (12.99) (6)

4 General Information General Information Supplemental Restraint System (SRS) 1 2 SRS omponent Replacement/Inspection fter Deployment 1 4 attery Terminal Disconnection and Reconnection 1 5 Identification Number Locations 1 6 Parts Marking 1 7 Lift and Support Points 1 8 ody Specifications/Wheel lignment 1 9 Exterior Parts Removal/Installation 1 10 Front ody onstruction 1 12 Roof and Side Panel onstruction 1 15 Floor and Rear ody onstruction 1 18 Door and umper Reinforcement eams 1 21 Zinc-Plated Steel Plate Repair 1 22 High-Strength Steel Sheet Framed reas 1 23 Precautions for High-Strength Steel Parts rea Repair 1 24 Parts Replacement Description 1 24

5 General Information Supplemental Restraint System (SRS) This model has an SRS which includes a driver's airbag in the steering wheel hub, a front passenger's airbag in the dashboard above the glove box, front seat belt tensioners in the front seat belt retractors, side airbags in the front seat-backs, and side curtain airbags in the sides of the roof. The SRS unit is separate from the airbag assembly and has built-in sensors. The following precautions should be observed when doing sheetmetal work, paint work, and repair work around the locations of the SRS components. The SRS unit (including the safing sensor and the impact sensor) is located under the dashboard and the side impact sensors are located in each side sill and rear wheel arch. The front impact sensors are located behind the right and left ends of the front bumper. void any strong impact with a hammer or other tools when repairing the front side frame, the lower part of the dashboard, the side sill, and the rear wheel arch. Do not apply heat to these areas with a torch, etc. Take extra care when painting or doing body work in the area below the center pillar. Do not expose the seat belt retractor and tensioner to heat guns, welding, or spraying equipment. SRS electrical connectors are identified with yellow color coding. Take care when repairing this area. Prevent damage to the harness. Do not apply heat of more than 212 F (100 ) when drying painted surfaces anywhere around the SRS components locations. If strong impact or high temperature need to be applied to the areas around the locations of SRS components, remove the components before doing the repair work. If any of the SRS-related components are damaged or deformed, be sure to replace them. NOTE: For after-deployment procedures, and removal and replacement of SRS-related components, refer to the cura ILX Service Manual. LE REEL DRIVER S IRG FRONT PSSENGER S IRG UNDER-DSH FUSE/RELY OX ODS UNIT OPDS SENSOR/ SET-K OVER/PD FRONT PSSENGER'S SIDE IRG FRONT PSSENGER'S SET ELT TENSIONER DT LINK ONNETOR (DL) SRS UNIT RIGHT SIDE IMPT SENSOR (FIRST) FRONT PSSENGER S WEIGHT SENSORS DRIVER'S SIDE IRG DRIVER'S SET POSITION SENSOR DRIVER'S SET ELT TENSIONER LEFT SIDE IMPT SENSOR (FIRST) 1-2

6 LEFT FRONT IMPT SENSOR RIGHT FRONT IMPT SENSOR RIGHT SIDE URTIN IRG RIGHT SIDE IMPT SENSOR (SEOND) LEFT SIDE URTIN IRG LEFT SIDE IMPT SENSOR (SEOND) SET ELT REMINDER INDITOR (RED) SRS INDITOR (RED) SIDE IRG UTOFF INDITOR (MER) US models anada models US models anada models FRONT PSSENGER'S IRG UTOFF INDITOR (MER) 1-3

7 General Information SRS omponent Replacement/Inspection fter Deployment NOTE: If the harness is broken or damaged in the areas relevant to the replacement parts shown below, replace the harness, do not repair it. efore doing any SRS repairs, check for DTs with the HDS; refer to the appropriate cura ILX Service Manual for the less obvious deployed components (front seat belt tensioners, front impact sensors, side impact sensors, etc.). Do not replace the ODS unit unless it is physically damaged or a specific fault was found during DT troubleshooting because it could complicate troubleshooting other DTs. fter a vehicle collision, do the ODS unit operation check; refer to the appropriate cura ILX Service Manual. fter a collision where the front airbag(s) deployed, replace these items: SRS unit Deployed front airbag(s) Front seat belt(s) Front impact sensor(s) Dashboard (deployed front passenger's airbag) fter a collision where the side airbag deployed, replace the items for the side(s) that deployed: SRS unit Deployed side airbag(s) Front seat belt(s) Side impact sensor(s) (first) Side impact sensor(s) (second) -pillar lower trim Seat frame and related parts fter a collision where the side curtain airbag deployed, replace the items for the side(s) that deployed: SRS unit Deployed side curtain airbag(s) Front seat belt(s) Side impact sensor(s) (first) Side impact sensor(s) (second) -pillar trim -pillar upper trim -pillar trim Front grab handle Rear grab handle ll related trim clips Sunvisor Headliner fter a moderate to severe side or rear collision, inspect for any damage on the side curtain airbag or other related components. Replace the components as needed. During the repair process, inspect these areas: Inspect all the SRS wire harnesses. Replace, do not repair, any damaged harnesses. Inspect the cable reel for heat damage. If there is any damage, replace the cable reel; refer to the appropriate cura ILX Service Manual. fter the vehicle is completely repaired, press the engine start/stop button to select the ON mode. If the SRS indicator comes on for about 6 seconds and then goes off, the SRS is OK. If the indicator does not function properly, use the HDS to check for the DTs; refer to the appropriate cura ILX Service Manual. If you cannot retrieve a code, do the SRS Symptom Troubleshooting. 1-4

8 attery Terminal Disconnection and Reconnection Disconnection 1. Make sure the vehicle ignition is in the OFF mode. 2. Disconnect and isolate the negative cable with the battery sensor () from the battery. NOTE: lways disconnect the negative side first. To protect the battery sensor connector () from damage, do not hold it when removing the negative terminal. Do not disconnect the battery sensor from the negative terminal (). R205 Engine Reconnection NOTE: If the battery performs abnormally, test the battery; refer to the appropriate cura ILX Service Manual. 1. lean the battery terminals. 2. onnect the positive cable and the battery terminal () to the battery. NOTE: lways connect the positive side first. R205 Engine N m ( kgf m, lbf ft) D K24Z7 Engine K24Z7 Engine N m ( kgf m, lbf ft) D 3. Disconnect the positive cable and the battery terminal (D) from the battery. 3. onnect the negative cable and the battery sensor () to the battery. NOTE: To protect the battery sensor connector () from damage, do not hold it when installing the negative terminal. 4. pply multipurpose grease to the terminals to prevent corrosion. 1-5

9 General Information Identification Number Locations Vehicle Identification Number (VIN) Vehicle Identification Number, Federal Motor Vehicle Safety Standard ertification, and Paint ode Label Vehicle Identification Number, anadian Motor Vehicle Safety Standard ertification, and Paint ode Label Engine Number (R205) utomatic Transmission Number Engine Number (K24Z7) Manual Transmission Number PINT ODE INTERIOR OLOR ODE Front Passenger's Under Floor Vehicle Identification Number (VIN) 1-6

10 Parts Marking To deter vehicle theft, certain major components are marked with the vehicle identification number (VIN). Original parts have self-adhesive labels. Replacement body parts have generic self-adhesive labels. These labels should not be removed. The original engine or transmission VIN plates are not transferable to the replacement engine or transmission. NOTE: e careful not to damage the parts marking labels during body repair. Mask the labels before repairing the part. 1-7

11 General Information Lift and Support Points NOTE: If you are going to remove heavy components such as suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with tall safety stands. When substantial weight is removed from the rear of the vehicle, the center of gravity can change, causing the vehicle to tip forward on the lift. Vehicle Lift 1. Position the lift pads () under the vehicle's front support points () and rear support points (). e sure the lift pads are properly placed to avoid damaging the vehicle. This vehicle has low ground clearance. To avoid damaging the vehicle, make sure there is enough clearance around the support points. Floor Jack 1. When lifting the front of the vehicle, set the parking brake. When lifting the rear of the vehicle, put the shift lever in reverse for manual tramsmission, or in P for automatic transmission. 2. lock the wheels that are not being lifted. 3. Position the floor jack under the front jacking bracket () or the rear jacking bracket (). enter the jacking bracket on the jack lift platform (), and jack up the vehicle high enough to fit the safety stands under it. e sure the floor jack is properly placed to avoid damaging the vehicle. This vehicle has low ground clearance. To avoid damaging the vehicle, make sure there is enough clearance around the support points. 2. Raise the lift a few inches, and rock the vehicle gently to be sure it is firmly supported. 3. Raise the lift to its full height, and inspect the vehicle support points for solid contact with the lift pads. Safety Stands To support the vehicle on safety stands, use the same support points as for a vehicle lift. lways use safety stands when working on or under any vehicle that is supported only by a jack. 4. Position the safety stands under the front or rear support points, and adjust them so the vehicle is level side-to-side. 5. Lower the vehicle onto the stands. 1-8

12 ody Specifications/Wheel lignment ody Specifications *1: 1,412 mm (55.6 in) *2: 1,423 mm (56.0 in) 1,509 mm (59.4 in) 1,794 mm (70.6 in) 2,670 mm (105.1 in) 1,532 mm (60.3 in) 4,550 mm (179.1 in) *1: Without antenna *2: With antenna Front Wheel lignment amber aster Total toe-in 0 2 mm( in) Wheel turning angle Inward Outward (Reference) Rear Wheel lignment amber Total toe-in mm ( in) 1-9

13 General Information Exterior Parts Removal/Installation NOTE: To adjust the doors in or out, replace the mounting bolts () with adjusting bolts; refer to the appropriate Parts atalog for the necessary adjusting bolts. pply spot sealer to the mating surface, then install the front fenders, the hood, the doors, the fuel fill door, and the hinges. heck the hood, the doors, and the trunk lid positions; refer to the external parts fitting positions (see page 4-12). HOOD 6 x 1.0 mm 9.3 N m (0.95 kgf m, 6.9 lbf ft) 6 x 1.0 mm 18 N m (1.8 kgf m, 13 lbf ft) TRUNK LID HINGE TRUNK LID HOOD HINGE 6 x 1.0 mm 8.3 N m (0.85 kgf m, 6.1 lbf ft) FUEL FILL DOOR 6 x 1.0 mm 9.3 N m (0.95 kgf m, 6.9 lbf ft) 6 x 1.0 mm 9.3 N m (0.95 kgf m, 6.9 lbf ft) UPPER RER DOOR HINGE 6 x 1.0 mm 9.3 N m (0.95 kgf m, 6.9 lbf ft) UPPER FRONT DOOR HINGE LOWER RER DOOR HINGE RER DOOR TORX OLT 8 x 1.25 mm 29 N m (3.0 kgf m, 22 lbf ft) FRONT DOOR () 8 x 1.25 mm 8 x 1.25 mm 29 N m (3.0 kgf m, 22 lbf ft) 29 N m (3.0 kgf m, 21 lbf ft) FRONT FENDER 6 x 1.0 mm 9.3 N m (0.95 kgf m, 6.9 lbf ft) LOWER FRONT DOOR HINGE () 8 x 1.25 mm 6 x 1.0 mm 29 N m (3.0 kgf m, 22 lbf ft) 9.3 N m (0.95 kgf m, 6.9 lbf ft) 1-10

14 6 x 1.0 mm 18 N m (1.8 kgf m, 13 lbf ft) 8 x 1.25 mm 29 N m (3.0 kgf m, 22 lbf ft) RER ULKHED GUSSETS 6 x 1.0 mm 9.3 N m (0.95 kgf m, 6.9 lbf ft) 8 x 1.25 mm 22 N m (2.2 kgf m, 16 lbf ft) ENTER ONSOLE OX SUPPORT 6 x 1.0 mm 18 N m (1.8 kgf m, 13 lbf ft) RER UMPER EM EXTENSION RER UMPER EM 8 x 1.25 mm 22 N m (2.2 kgf m, 16 lbf ft) 8 x 1.25 mm 22 N m (2.2 kgf m, 16 lbf ft) FRONT UMPER ENTER UPPER EM RER UMPER SIDE RKET TTERY SE [X] FRONT UMPER EM EXTENSION 6 x 1.0 mm 9.3 N m (0.95 kgf m, 6.9 lbf ft) RER FLOOR UPPER ROSSMENER GUSSET FRONT UMPER EM 8 x 1.25 mm 22 N m (2.2 kgf m, 16 lbf ft) FRONT UMPER ENTER UPPER EM DJUST RKET 6 x 1.0 mm 9.3 N m (0.95 kgf m, 6.9 lbf ft) FLOOR UNDER RE [VIEW: X] 8 x 1.25 mm 22 N m (2.2 kgf m, 16 lbf ft) DSHORD UPPER GUSSET 10 x 1.25 mm 38 N m (3.9 kgf m, 28 lbf ft) 6 x 1.0 mm 9.3 N m (0.95 kgf m, 6.9 lbf ft) 1-11

15 NOTE: To confirm which parts are sold as repair parts, refer to the appropriate Parts atalog a b a b e b a f h c e d -3 c -3 a b a c d l f c d d e c g i f e f h i g j i k h g Right side a b b General Information Front ody onstruction 1-12

16 NOTE: The parts marked with numbers are sold as repair parts. The parts marked with letters are not sold separately and are shown only for reference. [ ]: Thickness unit: mm (in) High-strength steel sheet: Tensile strength 340 to 590 MPa. No. Part Name Tensile Strength (MPa) Hood Skin [1.0 (0.039)] luminum alloy Frame [0.9 (0.035)] luminum alloy Zinc-Plating Front Fender [0.7 (0.028)] 270 Front ulkhead omplete -1 Front ulkhead Upper enter Frame Set a: ulkhead Upper enter Frame, [0.8 (0.031)]/ [0.6 (0.024)] 270 b: ulkhead Upper Side Frame [1.0 (0.039)] Front ulkhead Side Stay Set c: ulkhead Side Stay [0.6 (0.024)] 270 d: ulkhead Side Stay Plate [0.6 (0.024)] 270 e: ulkhead Side Stay Gusset [0.6 (0.024)] 270 f: Side Stay Stiffener [1.0 (0.039)] Front ulkhead Lower rossmember Set g: ulkhead Lower rossmember [0.6 (0.024)] 270 h: ulkhead Lower rossmember Plate [0.6 (0.024)] 270 i: Radiator Lower Mount racket [1.0 (0.039)] 270 Front Wheelhouse Upper Member omplete a: Wheelhouse Upper Member [0.9 (0.035)] b: Wheelhouse Upper Member Patch [1.2 (0.047)] Left side only 590 Front Damper Housing omplete a: Front Damper ase [2.6 (0.102)] 440 b: Front Damper Housing [0.9 (0.035)] 270 c: Front Damper Housing Extension [0.9 (0.035)] 590 d: Torque Rod racket [2.0 (0.079)] 270 e: Torque Rod racket Stay [2.8 (0.110)] 270 f: Front Wheelhouse, Left [0.65 (0.0256)]/Right [1.4 (0.055)] Front Damper Extension Set g: Mission Mounting racket [1.8 (0.071)] 270 h: Front Damper Extension / [1.0 (0.039)] 590 i: Front Damper Outer Extension [0.7 (0.028)] 590 j: Front Damper Extension racket [2.0 (0.079)] 590 k: Front Damper Extension Gusset [1.8 (0.071)] 590 l: Front Fender racket [1.2 (0.047)] (cont'd) 1-13

17 General Information Front ody onstruction (cont'd) No. Part Name Tensile Strength (MPa) Zinc-Plating Front Side Frame omplete a: Front Side Frame [1.4 (0.055)]/ackplate [1.6 (0.063)] 590 b: Front Side Frame Front Outrigger [1.8 (0.071)] 590 c: Front Side Frame Rear Outrigger [1.8 (0.071)] 590 d: Front Subframe Rear racket [1.8 (0.071)] 270 e: enter Frame Extension [1.6 (0.063)] 590 f: Front Floor Frame Extension [1.6 (0.063)] Front Subframe Front racket Set g: Front Subframe Front racket [1.4 (0.055)] 590 h: Front Subframe Front Plate [0.8 (0.031)] 270 i: Front Subframe Front ulkhead [0.8 (0.031)] Front umper eam Extension Flange [2.0 (0.079)] Front Side Frame Support [1.8 (0.071)] 590 Dashboard Upper omplete a: Dashboard Upper [0.8 (0.031)] 270 b: Front Windshield Lower [0.6 (0.024)] 270 c: Dashboard Upper Side Member [2.0 (0.079)] 590 d: Dashboard Upper Side Member Extension [1.6 (0.063)] 590 e: Dashboard Upper rossmember [0.7 (0.028)] 270 Dashboard Lower omplete a: Dashboard Lower [0.8 (0.031)] 440 b: Dashboard Lower enter Frame [0.8 (0.031)] c: Dashboard Lower rossmember [1.4 (0.055)]

18 Roof and Side Panel onstruction NOTE: To confirm which parts are sold as repair parts, refer to the appropriate Parts atalog. a b c b d d a c b c b a f e a -1 a c c d a d b c b b d c a Rear Front portion portion Front portion Rear portion (cont'd) 1-15

19 General Information Roof and Side Panel onstruction (cont'd) NOTE: The parts marked with numbers are sold as repair parts. The parts marked with letters are not sold separately and are shown only for reference. [ ]: Thickness unit: mm (in) High-strength steel sheet: Tensile strength 340 to 590 MPa. No. Part Name Tensile Strength (MPa) Zinc-Plating Roof Panel omplete a: Roof Panel [0.6 (0.024)] 340 b: Front Roof Rail [1.0 (0.039)] c: Rear Roof Rail [0.7 (0.028)] d: Roof Panel Stiffener Patch [1.4 (0.055)] Side Sill Panel [0.7 (0.028)] 270 Front Side Outer Panel Set [0.7 (0.028)] 270 Rear Side Outer Panel Set [0.7 (0.028)] 270 Front Pillar Upper Stiffener [1.6 (0.063)] 590 enter Pillar Stiffener omplete a: Roof Side Stiffener [1.8 (0.071)] 590 b: enter Pillar Stiffener [1.8 (0.071)] 590 c: enter Pillar Reinforcement [1.8 (0.071)] Side Sill Reinforcement omplete a: Front Pillar Lower Stiffener [1.0 (0.039)] 590 b: Side Sill Reinforcement [1.6 (0.063)] 590 c: Side Sill Reinforcement Extension [1.6 (0.063)] 590 d: Side Sill Reinforcement Patch [1.4 (0.055)] 780 Rear Gutter omplete a: Rear Gutter Upper [0.65 (0.0256)] 270 b: Rear ombination dapter [0.6 (0.024)] 270 c: Rear Gutter Upper Extension [0.6 (0.024)] 270 d: Rear Gutter Front Extension [0.6 (0.024)] 270 Front Inner Pillar omplete a: Front Inner Upper Pillar [1.8 (0.071)] b: Front Pillar Inner Upper Extension [1.4 (0.055)] c: Front Inner Lower Pillar [0.8 (0.031)] 590 d: Front Jack-Up ase [1.8 (0.071)] 590 enter Inner Pillar omplete a: Roof Side Rail [1.4 (0.055)] b: enter Inner Pillar [2.0 (0.079)] c: enter Pillar Inner Extension [1.0 (0.039)]

20 No. Part Name Tensile Strength (MPa) Zinc-Plating Rear Inner Panel omplete a: Rear Inner Panel [0.6 (0.024)] 270 b: Rear Damper Stiffener [0.6 (0.024)] c: Rear Wheelhouse [0.6 (0.024)] 270 d: Rear Damper ase [2.0 (0.079)] Rear Wheel rch Extension omplete e: Rear Wheel rch Extension [0.6 (0.024)] 270 f: Rear Inside Extension [1.6 (0.063)] Front Door Skin [0.8 (0.031)] 340 Panel, 270 Front portion [1.4 (0.055)]/Rear portion [0.7 (0.028)] Rear Door Skin [0.8 (0.031)] 340 Panel, Front portion [1.2 (0.047)]/Rear portion [0.65 (0.0256)]

21 NOTE: To confirm which parts are sold as repair parts, refer to the appropriate Parts atalog. a b c -1-3 a b a c d -1 a b a c e b b a -1 h g -1 c f -2 b c d c b a c a b c d e d h g i j d f General Information Floor and Rear ody onstruction 1-18

22 NOTE: The parts marked with numbers are sold as repair parts. The parts marked with letters are not sold separately and are shown only for reference. [ ]: Thickness unit: mm (in) High-strength steel sheet: Tensile strength 340 to 980 MPa. No. Part Name Tensile Strength (MPa) Zinc-Plating Front Floor omplete a: Front Floor [0.6 (0.024)] 270 b: Front Floor Frame [0.8 (0.071)] 590 c: enter Tunnel Frame [1.0 (0.039)] 590 d: Front Floor rossmember [1.2 (0.047)] e: enter Tunnel Frame Stiffener [2.0 (0.079)] Driver's side only Front Inside Sill omplete f: Front Inside Sill [1.4 (0.055)] 780 g: Front Inside Sill Stiffener [1.2 (0.047)] 980 h: Front Inside Sill Stiffener, Driver [1.2 (0.047)] 980 Rear Floor omplete a: Rear Floor [0.65 (0.0256)] 270 b: Rear Seat elt nchor [1.0 (0.039)] 590 c: Rear Floor Stiffener [1.2 (0.047)] Rear Jack-Up Stiffener [1.2 (0.047)] 270 Rear Frame omplete a: Side Sill Extension [1.6 (0.063)] 590 b: Side Sill Extension Patch [2.0 (0.079)] 590 c: Jack-Up racket [2.0 (0.079)] 590 d: Rear Frame [2.0 (0.079)] 590 e: Rear Frame Stiffener [1.6 (0.063)] 590 f: Rear Floor rossmember Extension [2.0 (0.079)] Rear Floor Side Stiffener Rear [0.65 (0.0256)] Rear Panel Gusset [1.2 (0.047)] Rear Frame omplete g: Rear Frame [1.0 (0.039)] 590 h: Rear Frame Patch [0.6 (0.024)] 270 i: Rear Frame Reinforcement [1.6 (0.063)] 590 j: Rear umper eam racket [2.3 (0.091)] 440 Rear Floor Upper rossmember omplete a: Rear Floor Upper rossmember [1.2 (0.047)] b: Rear Floor Side Stiffener Front [1.4 (0.055)] 590 c: Rear Floor Side Stiffener Middle [1.0 (0.039)] 590 (cont'd) 1-19

23 General Information Floor and Rear ody onstruction (cont'd) No. Part Name Tensile Zinc-Plating Strength (MPa) Middle Floor rossmember omplete a: Middle Floor rossmember [0.65 (0.0256)] 590 b: Middle Floor rossmember Stiffener [1.4 (0.055)] 590 c: Rear Frame Extension [1.6 (0.063)] 590 d: Middle Floor rossmember Stiffener Patch [0.6 (0.024)] 270 Rear Floor rossmember omplete a: Rear Floor rossmember [1.2 (0.047)] 270 b: Lower rm racket [1.6 (0.063)] 270 c: Lower rm racket [1.6 (0.063)] 270 Rear Panel omplete a: Rear Panel [0.55 (0.022)] 270 b: Rear Panel Upper Stiffener [0.8 (0.031)] c: Rear Panel Side Stiffener [1.0 (0.039)] d: Rear Panel enter Stiffener [0.65 (0.0256)] Rear umper Face Stiffener [1.0 (0.039)] Rear Shelf omplete a: Rear Shelf [0.55 (0.0217)] b: Rear Shelf Stiffener Rear [0.55 (0.0217)] c: Rear Shelf Stiffener Front [0.55 (0.0217)] d: Rear Shelf Extension Front [0.8 (0.031)] Trunk Lid Skin, Upper [0.7 (0.028)]/Lower [0.6 (0.024)] 270 Frame [0.6 (0.024)]

24 Door and umper Reinforcement eams The door and rear bumper reinforcement beams are made from high-strength steel. If high-strength steel is heated, the strength of the steel is reduced. If high-strength steel is damaged, for example, in a collision, and the door and bumper reinforcement beams are bent, the beams may crack when attempting to straighten them. If a door beam is damaged, the whole door panel assembly must be replaced. The front bumper reinforcement beam is made of aluminum alloy. For this reason, the door and bumper reinforcement beams should NEVER be repaired; they must be replaced if they are damaged. RER UMPER REINFOREMENT EM Do not repair. FRONT UMPER REINFOREMENT EM Do not repair. RER DOOR REINFOREMENT EMS Do not repair. FRONT DOOR REINFOREMENT EM Do not repair. 1-21

25 General Information Zinc-Plated Steel Plate Repair The zinc-plated steel plate used in some panels of the cure ILX require different repair techniques than ordinary steel plate. Refer to Front ody onstruction (see page 1-12), Roof and Side Panel onstruction (see page 1-15), and Floor and Rear ody onstruction (see page 1-18) for the locations of the zinc-plated panels. ZIN PLTING (5-6 microns) STEEL PLTE 1. efore spot welding the zinc-plated steel plate, remove the paint from both sides of the flange to be welded. pply sealer to the flange after welding. NOTE: Seal the sanded surfaces thoroughly to prevent rust. 2. The electric continuity properties for zinc-plated steel plates differ from ordinary steel plates. When spot welding, increase the current by 10 to 20 percent, or increase the resistance welding time. lso increase the number of weld spots by 10 to 20 percent. NOTE: The MG welding procedures for zinc-plated steel plates are similar to ordinary steel plates. 3. efore applying putty or body filler to the zinc-plated steel plates, sand the zinc plating thoroughly, and apply epoxy primer to promote adhesion and prevent blistering. NOTE: Use putties (one part putty, one part hardener) for zinc-plated steel plates, and follow the manufacturer's specifications. 4. When doing paint work, protect the ground wire and the ground wire mounting hole threads with a bolt or a plug. GROUND WIRE SPEIL OLT GROUND WIRE MOUNTING HOLE PLUG 1-22

26 High-Strength Steel Sheet Framed reas The new high-strength steel sheet has greater tensile strength than conventional high-strength steel sheet. lthough it's a thinner sheet, it is as strong as the previous thicker ones. ecause the manufacturing press process has improved, its usage has expanded. For this vehicle, the new high-strength steel sheet is used for the main frame and the passenger compartment to make this model lightweight and to improve the high-crush absorption frame. : New high-strength ( MPa) steel sheet FRONT INSIDE SILL ENTER INNER PILLR FRONT ROOF RIL SIDE SILL EXTENSION ROOF SIDE RIL ROOF PNEL STIFFENER PTH RER FLOOR SIDE STIFFENER FRONT RER FLOOR SIDE STIFFENER MIDDLE RER FLOOR SIDE STIFFENER RER ROOF SIDE STIFFENER FRONT FLOOR ROSSMEMER RER FLOOR STIFFENER FRONT INNER UPPER PILLR RER SET ELT NHOR FRONT INNER LOWER PILLR FRONT FLOOR FRME FRONT DMPER EXTENSION / RER FRME RER FRME RER INSIDE EXTENSION SIDE SILL REINFOREMENT EXTENSION FRONT SIDE FRME FRONT SIDE FRME FRONT OUTRIGGER ENTER PILLR STIFFENER MIDDLE FLOOR ROSSMEMER STIFFENER/ROSSMEMER FRONT PILLR UPPER STIFFENER ENTER FRME EXTENSION FRONT UMPER EM EXTENSION FLNGE DSHORD UPPER SIDE MEMER FRONT WHEELHOUSE UPPER MEMER FRONT DMPER OUTER EXTENSION SIDE SILL REINFOREMENT ENTER TUNNEL FRME FRONT PILLR LOWER STIFFENER FRONT SIDE FRME RER OUTRIGGER 1-23

27 General Information Precautions for High-Strength Steel Parts rea Repair The new high-strength steel parts of the frame are all spot welded together. To disassemble, drill a hole in the sections that are spot welded together with a very sharp spot weld bit. The new high-strength steel sheet is more rigid than previous steel sheets, making it difficult to straighten. When an automobile's frame is partially constructed with the new high-strength steel sheet, it must be straightened using an accurate frame straightening system. Inspect the body and frame for stress-related damage to the sections that are not made from the new high-strength steel after the repair is complete. High-strength steel has more memory than normal steel, and it is necessary to monitor the body dimensions closely during the straightening process. Spot welding is acceptable for replacement parts as long as the proper number of welds is used in the repair. For replacement part welding locations, refer to the appropriate replacement procedures in this manual. If spot welding does not provide acceptable repairs, plug the welds using an MG welder. Parts Replacement Description ecause of changes in body structure to improve collision safety and body rigidity, the materials and thickness of steel sheets and internal reinforcements (patch, stiffener) of components have become very specific. High-strength steel is extensively used. To ensure the same level of body performance as when it is produced, avoid cut and joining replacement (sectioning); repair by assembly replacement. NOTE: ut and joint replacement should basically be avoided except for outer panels and floor panels. onfirm in what state the component to be replaced is delivered, and replace the component as an assembly as much as possible. IR DRILL SPOT UTTER SPOT UTTER GRINDING MHINE 1-24

28 Paint Information Paint Information Paint Safety Precautions 2 2 General 2 3 olor hart Paint Specifications 2 4 Features of Plastic Materials 2 5 Types and Materials of Exterior Plastic Parts 2 7 Soft hipping Guard Primer oat General Safety Precautions 2 8 oating reas 2 9

29 Paint Information Paint Safety Precautions Most paints contain substances that are harmful if inhaled or swallowed. Read the paint label before opening the container. Observe the following precautions to maintain a safe painting work area. Wear an approved respirator and eye protection when painting. Wear approved gloves and appropriate clothing when painting. void contact with skin. Spray paint only in a well ventilated area. over spilled paint with sand, or wipe it up at once. If paint gets in your mouth or on your skin, rinse and wash thoroughly with water. If paint gets in your eyes, flush with water and get prompt medical attention. fter the painting work is finished, wash your face and gargle with water. Paint is flammable. Store it in a safe place, and keep it away from sparks, flames, or cigarettes. 2-2

30 General The 3-coat 3-bake (3 3) paint finish gives the cura ILX a deep gloss and stunning finish. This manual provides information on paint defects, repair, and refinishing. Throughout, the objective is to explain in a simple yet comprehensive manner the basic items you should know about paint repairs. Select the correct material for the defect and repaint or refinish in the correct manner as described in this manual. asic Rules for Repairing a Paint Finish To repair paint damage, always use the 2-part acrylic urethane paints designated; polish and bake each of the three coats, as in production, to maintain the original film thickness, and to assure the same quality as the original finish. Outline of factory painting process Pretreatment Electrodeposition of primer (hipping Primer) Intermediate coat Top coat Features In Each Work Process Pretreatment and electrodeposition In the pretreatment process, the entire body is degreased, cleaned, and coated with zinc phosphate by dipping. fter the body has been cleaned with pure water, it is placed in an electrolytic bath of soluble primer (cationic electrodeposition). This produces a thorough corrosion inhibiting coating on the inner surface and corners of the body, the pillars, the sills, and the panel joints. hipping primer is then applied to the most susceptible areas (see page 2-9). Intermediate coat The intermediate coat is applied to the prepared surface to further protect against damage. Top coat Enamel paint and either polyester or acrylic resin paint are used in the top coat for higher solidity, smoothness, brightness, and weather resistance. Sectional view of paint coats ENMEL OT INTERMEDITE OT LER OT 3-OT PERL PINT (White pearl) LER OT PERL SE OT HIPPING PRIMER OLOR SE OT UNDEROT (Electrodeposition) SE METL bout 120 microns (0.12 mm) 2-3

31 Paint Information olor hart Paint Specifications NOTE: For model year paint code information, refer to the appropriate service manual. pply black paint to the visible surfaces of the front wheelhouse, the rear wheelhouse, and the rear jack-up bracket after repairing and painting (except vehicles painted with black color). FRONT GRILLE SE: umper dark gray (NH-533) MOLDING: hrome plated (NH-762X) UPPER MOLDINGS: Platinum chrome plated (NH-772X) OWL OVER and HOOD HINGE OVERS lack (NH-696) ROOF MOLDING lack (NH-70) DOOR OUTER SSH MOLDINGS Stainless steel DOOR GLSS OUTER WETHERSTRIPS Stainless steel FRONT UMPER FE ody color FRONT UMPER ENTER LOWER GRILLE umper dark gray (NH-533) FRONT FOG LIGHT TRIM umper dark gray (NH-533) FRONT UMPER SIDE LOWER GRILLE umper dark gray (NH-533) DOOR SSH OUTER TRIM lack (NH-70 Gloss 20) DOOR MIRROR HOUSING: lack SKULLP: ody color OUTER SE: lack SE OVER: lack RDIO NTENN OVER ody color FRONT SPLSH GURD (anada model) ody color DOOR OUTER HNDLE OVERS and FRONT SE OVERS ody color TRUNK LOWER TRIM ody color RER UMPER FE ody color 2-4

32 Features of Plastic Materials heck each of the plastic parts for solvent resistance and heat resistance before you do any repair work. Select the repair material according to materials of the plastic parts. lcohol can be used for degreasing in small amounts, and for short periods of time. Do not soak. ontact your paint and material supplier for other recommended cleaners for the type of plastic you are working on. Standard Symbol Name Heat Resistance Temperature F ( ) Note S crylonitrile acrylic styrene 176 (80) S crylonitrile butadiene styrene 176 (80) ES crylonitrile ethylene styrene 176 (80) /EPDM/S crylonitrile/ethylene propylene diene monomer (rubber)/styrene 176 (80) S crylonitrile styrene acrylate 176 (80) ellulose acetate butylate 176 (80) E/V Ethylene-vinyl acetate 176 (80) P Polyamide 176 (80) PT Polybutylene terephtalate 320 (160) P Polycarbonate plastics 248 (120) PE Polyethylene 176 (80) attery acid (sulfuric acid) can damage the material. Solvent can damage the material. rake fluid, and wax and grease remover can damage the material. Solvent can damage the material. PF Phenol formaldehyde 176 (80) PMM Polymethyl methacrylate 176 (80) POM Polyoxymethylene polyacetal 212 (100) PP Polypropylene 176 (80) Wash remover off with water thoroughly. Solvent can damage the material. Solvent can damage the material. PPO (PPE) Polyphenylene oxide 212 (100) (cont'd) 2-5

33 Paint Information Features of Plastic Materials (cont'd) Standard Symbol Name Heat Resistance Temperature F ( ) Note PS Polystyrene 140 (60) PUR Polyurethane 176 (80) PV Polyvinyl chloride 176 (80) SN Styrene acrylonitrile 176 (80) SM Sheet molding compound 356 (180) Solvent can damage the material. TPE Thermoplastic polyester elastomer 176 (80) Wash remover off with water thoroughly. TPS Thermoplastic styrene elastomer 176 (80) Wash remover off with water thoroughly. TPO Thermoplastic olefin/elastomer 176 (80) Wash remover off with water thoroughly. TPU Thermoplastic polyurethane/elastomer 176 (80) Wash remover off with water thoroughly. UP Unsaturated polyester 230 (110) lkali can damage the material. 2-6

34 Types and Materials of Exterior Plastic Parts NOTE: For the full plastic name, refer to the features of plastic materials (see page 2-5). standard symbol is stamped on the underside of each plastic part to show the type of material used. Example: FRONT GRILLE SE: (EPDS) MOLDING: (S) UPPER MOLDING: (S) OWL OVER and HOOD HINGE OVERS OVER: (PP) LIP: (TPO) ROOF MOLDING (TPO) FRONT UMPER FE (PP) FRONT UMPER ENTER LOWER GRILLE (PP) FRONT UMPER SIDE LOWER GRILLE (PP) DOOR SSH OUTER TRIM (EPDS) FRONT FOG LIGHT TRIM (PP) DOOR MIRROR HOUSING: (S) SKULLP: (S) OUTER SE: (S) SE OVER: (S) RDIO NTENN OVER (P+PET) FRONT SPLSH GURD (anada model) (TPO) DOOR OUTER HNDLE OVERS and FRONT SE OVERS (PT+P) TRUNK LOWER TRIM (S) RER UMPER FE (PP) 2-7

35 Soft hipping Guard Primer oat General Safety Precautions The removal of paint and undercoating by stone chips immediately exposes metal to the atmosphere, causing it to oxidize. The thickness of this oxidation increases if the process continues unchecked. The soft chipping guard primer protects against damage due to the impact of such objects. The soft chipping guard primer coat is applied over the E. D. (electrostatically deposited) primer. It is followed by the guide coating and the top coating. The soft chipping guard primer produces a smooth surface when dry. It should be sprayed so the thickness of the protective film is 20 microns. Sectional view of paint coats: Top coat Intermediate coat + hipping guard primer Electrodeposition ase metal soft chipping guard primer coat is then applied to the most susceptible area (see page 2-9). Spray the primer surface (2-part urethane primer surfacer) on the soft chipping guard primer coating areas when you replace parts using soft chipping guard primer coat. oating Procedures 2. ir blowing/degreasing. Use alcohol, and wax and grease remover. 3. Protect from overspray. Use masking tape and paper to protect the related areas from overspray. 4. Spraying primer surfacer. Spray about four to five coats to get 20 microns of thickness. One coat deposits about 5 to 7 microns. Do not try to cover the surface with one heavy coat. pplying several thin coats is recommended. Use a 2-part urethane primer surfacer and a spray gun. Mix the primer surfacer with the correct ratio of additive and solvent. Follow the primer surfacer manufacturer's instructions. Wear goggles or safety glasses to prevent eye injury. Ventilate when spraying undercoat. 1. Sanding the replacement part. Use a double action sander and 400 grit sandpaper. NOTE: Do not oversand the edges or corners of the part. Do not expose base metal. 5. Drying. fter spraying primer surfacer, allow 7 to 10 minutes of drying time, then force dry it with infrared lamps or an industrial dryer. 6. Fine sanding. heck that the primer surfacer has dried thoroughly, then sand the primer surfacer. Use a double action sander and grit sandpaper. 7. Intermediate coating and top coating. 2-8

36 oating reas : Indicates chipping guard primer coating areas. NOTE: Make sure to coat the flanges on the front and rear wheel arches. Unit: mm (in) RER SIDE OUTER PNEL HOOD SKIN 300 (11.81) MOONROOF OPENING FLNGE pply all around flange. HOOD RER SIDE OUTER PNEL FRONT FENDER SIDE SILL OUTER PNEL DOORS RER SIDE OUTER PNEL FRONT FENDER DOOR PNEL 180 (7.09) 100 (3.94) 120 (4.72) FRONT FENDER pply all around flange. Round end SIDE SILL OUTER PNEL 2-9

37 Replacement Front ulkhead Removal 3 2 Installation 3 4 Front Wheelhouse/Damper Housing Removal 3 6 Installation 3 10 Front Side Frame/Outrigger Removal 3 14 Installation 3 17 Front Pillar Outer Panel Removal 3 19 Installation 3 22 Side Sill Outer Panel Removal 3 25 Installation 3 27 enter Pillar Outer Panel Removal 3 29 Installation 3 33 Roof Panel Removal 3 39 Installation 3 41 Rear Side Outer Panel Removal 3 43 Installation 3 45 Rear Panel Removal 3 48 Installation 3 50 Rear Floor/Rear Frame Removal 3 52 Installation 3 56 Floor Insulators Insulator Locations 3 59 Insulator Sizes 3 60

38 Front ulkhead Removal Mass production body welding positions and numbers NOTE: Welding symbols : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MG plug welding; : MG welding L=Welding length unit: mm (in) ( ): The number of welds MOUNTING OLTS (2) 6 x 1.0 mm FRONT DMPER EXTENSION (3) With bulkhead upper center frame removed (2) [VIEW: Z] [Z] ULKHED UPPER SIDE FRME Front ULKHED SIDE STY ULKHED UPPER ENTER FRME (2) MOUNTING OLT (1) 6 x 1.0 mm ULKHED UPPER SIDE FRME (1) SIDE STY PLTE ULKHED SIDE STY UMPER EM EXTENSION FLNGE (2) () (10) FRONT DMPER EXTENSION RDITOR LOWER MOUNT RKET ULKHED LOWER ROSSMEMER () Front (1) Rear (2) (2) SUFRME FRONT RKET (): ulkhead side stay gusset, bulkhead side stay, side stay plate, and bulkhead lower crossmember SUFRME FRONT RKET ULKHED SIDE STY GUSSET ULKHED SIDE STY (2) ULKHED SIDE STY GUSSET 3-2

39 onstruction NOTE: This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate service manual. The component replacement procedure described here is only for new cura-supplied parts, as needed, according to the area and the degree of damage on the body. Remove the bulkhead upper center frame and the bulkhead upper side frame, and replace them. Replace the bulkhead side stay and the bulkhead lower crossmember. Replace the bulkhead side stay, the side stay plate, and the bulkhead side stay gusset as an assembly. ULKHED UPPER SIDE FRME FRONT DMPER EXTENSION ULKHED UPPER ENTER FRME MOUNTING OLTS 6 x 1.0 mm MOUNTING OLT 6 x 1.0 mm ULKHED SIDE STY SIDE STY PLTE UMPER EM EXTENSION FLNGE SUFRME FRONT RKET ULKHED SIDE STY GUSSET RDITOR LOWER MOUNT RKET ULKHED LOWER ROSSMEMER 3-3

40 Front ulkhead Installation NOTE: Welding symbols : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MG plug welding : MG welding L=Welding length unit: mm (in) ( ): The number of welds 5. Do the main welding. Weld the bulkhead side stay set () and the bulkhead lower crossmember () to the bumper beam extension flange () and the subframe front bracket (D). Weld the bulkhead side stay set and the bulkhead lower crossmember. [VIEW: Z] 1. lamp the new bulkhead side stay set, the bulkhead lower crossmember, and the bulkhead upper side frame, and install the bulkhead upper center frame. Measure the front compartment diagonally. 2. heck the body dimensions. (2) Front Front bulkhead position (see page 4-3) (2) Engine compartment (see page 4-4) Front damper extension position (see page 4-7) Engine compartment and front floor, under view (see page 4-14) Repair chart, top view (see page 4-18) Repair chart, side view (see page 4-20) 3. Tack weld the new parts into position. 4. Temporarily install the front fender, the hood, and the door(s), then check for differences in level and clearance. heck the external parts fitting positions (see page 4-12). If necessary, check the headlight and the front bumper positions. Make sure the body lines flow smoothly. [Z] (10) D (1) (2) (2) Front 3-4

41 6. Weld the bulkhead upper side frame () to the bulkhead side stay () and front damper extension. 7. ttach the bulkhead upper center frame () with the mounting bolts. [Z] 6 x 1.0 mm 9.3 N m (0.95 kgf m, 6.9 lbf ft) (3) (2) 6 x 1.0 mm 9.3 N m (0.95 kgf m, 6.9 lbf ft) [VIEW: Z] (1) (2) 3-5

42 Front Wheelhouse/Damper Housing Removal Mass production body welding positions and numbers (Wheelhouse upper member and bulkhead side member) NOTE: Welding symbols : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MG plug welding; : MG welding L=Welding length unit: mm (in) ( ): The number of welds With front bulkhead removed (1) L=10 (0.39) WHEELHOUSE UPPER MEMER (16) MOUNTING OLT 8 x 1.25 mm (1) L=10 (0.39) FRONT DMPER OUTER EXTENSION (1) L=10 (0.39) (15) MOUNTING OLT 8 x 1.25 mm DMPER EXTENSION GUSSET FRONT SIDE FRME SUPPORT [VIEW: X] FRONT DMPER EXTENSION FRONT DMPER EXTENSION (2) FRONT WHEELHOUSE (4) FRONT DMPER EXTENSION [X] MISSION MOUNT RKET FRONT DMPER EXTENSION (4) DMPER OUTER EXTENSION (11) (2) (3) DMPER HOUSING UMPER EM EXTENSION FLNGE FRONT WHEELHOUSE [Y] FRONT WHEELHOUSE [VIEW: Y] FRONT SIDE FRME (2) UMPER EXTENSION RKET [Right side] (13) (2) FRONT DMPER EXTENSION (4) 3-6

43 Mass production body welding positions and numbers (Front damper extension and damper housing) NOTE: Welding symbols : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MG plug welding; : MG welding L=Welding length unit: mm (in) ( ): The number of welds DSHORD UPPER (2) DMPER HOUSING EXTENSION DMPER SE DMPER HOUSING DSHORD UPPER SIDE MEMER (5) FRONT DMPER EXTENSION DMPER SE DSHORD UPPER SIDE MEMER EXTENSION FRONT DMPER EXTENSION DSHORD UPPER (5) (3) DMPER HOUSING (10) (5) FRONT SIDE FRME Left side (7) Right side (8) DMPER HOUSING EXTENSION DSHORD LOWER DMPER HOUSING EXTENSION (cont'd) 3-7

44 Front Wheelhouse/Damper Housing Removal (cont'd) onstruction (Wheelhouse upper member and bulkhead side member) NOTE: This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual. The component replacement procedure described here is only for new cura-supplied parts, as needed, according to the area and the degree of damage on the body. Remove the wheelhouse upper member, and replace the front damper extension /damper outer extension. heck the front wheelhouse, the front side frame support, and the bumper beam extension flange for damage. If necessary, replace them. MOUNTING OLTS 8 x 1.25 mm WHEELHOUSE UPPER MEMER FRONT DMPER EXTENSION FRONT WHEELHOUSE/ MISSION MOUNT RKET (left side) FRONT DMPER EXTENSION / DMPER OUTER EXTENSION DMPER HOUSING FRONT SIDE FRME SUPPORT FRONT SIDE FRME UMPER EM EXTENSION FLNGE SUFRME FRONT RKET 3-8

45 onstruction (Damper housing and front damper housing extension ) NOTE: This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual. The component replacement procedure described here is only for new cura-supplied parts, as needed, according to the area and the degree of damage on the body. heck front damper extension and the damper housing positions for damage. If necessary, replace the damper housing and the damper housing extension as an assembly. DMPER SE DSHORD UPPER SIDE MEMER DSHORD UPPER DMPER HOUSING DMPER HOUSING EXTENSION FRONT DMPER EXTENSION 3-9

46 Front Wheelhouse/Damper Housing Installation NOTE: Welding symbols : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MG plug welding : MG welding L=Welding length unit: mm (in) ( ): The number of welds 1. lamp the new damper housing, the front wheelhouse, front damper extensions and, the front side frame support, the bumper beam extension flange, and the bulkhead, and measure the front compartment diagonally. 6. Do the main welding. Weld front damper extension and the damper base () to the dashboard upper side member (). Weld the damper base and the dashboard upper (D). (5) 2. heck the body dimensions. Front bulkhead position (see page 4-3) Engine compartment (see page 4-4) Engine and transmission mount positions (see page 4-6) Front damper extension position (see page 4-7) Engine compartment and front floor, under view (see page 4-14) Repair chart, top view (see page 4-18) Repair chart, side view (see page 4-20) D (2) 7. Weld the damper housing () and the damper housing extension () to the front side frame (). 3. Tack weld the new parts and the front bulkhead into position. 4. Temporarily install the front subframe, and check the front suspension position. 5. Temporarily install the front fender, the hood, and the door(s), then check for differences in level and clearance. heck the external parts fitting positions (see page 4-12). If necessary, check the headlight and the front bumper positions. Make sure the body lines flow smoothly. (7) 3-10

47 8. From the passenger's compartment, plug weld the holes in the dashboard lower () and the damper housing extension (). 10. Weld front damper extensions and, and the front wheelhouse (). (1) (3) (5) (6) 9. Weld front damper extension and the damper housing extension () to the dashboard upper (). Weld front damper extension to the damper base (D), the damper housing extension, and the damper housing (E). D 11. Weld the upper portion of front damper extensions and. Weld the front wheelhouse () to the damper housing (D) and the front side frame (E). Left side D E (3) (13) (2) (7) (2) E (3) (cont'd) 3-11

48 Front Wheelhouse/Damper Housing Installation (cont'd) Right side [X] (3) D (3) 12. Weld the front side frame support () and the bumper beam extension flange (). (3) (1) (5) (4) (3) (1) [Y] [VIEW: X] (5) (4) (3) (4) [VIEW: Y] (2) (5) (2) (6) 13. Weld the front bulkhead (see page 3-4). 3-12

49 14. Weld the wheelhouse upper member (). When reusing the wheelhouse upper member, weld it with MG plug welding. (2) L=10 (0.39) (16) (12) [Z] (1) L=10 (0.39) 8 x 1.25 mm 29 N m (3.0 kgf m, 21 lbf ft) [VIEW: Z] (3) 3-13

50 Front Side Frame/Outrigger Removal Mass production body welding positions and numbers (Front side frame) NOTE: Welding symbols : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MG plug welding; : MG welding L=Welding length unit: mm (in) ( ): The number of welds With front bulkhead removed FRONT OUTRIGGER (2) DSHORD LOWER ROSSMEMER FRONT SIDE FRME (2) ROSSMEMER EXTENSION FRONT WHEELHOUSE Left side (10) Right side (11) ROSSMEMER EXTENSION [Z] FRONT SIDE FRME [VIEW:Z] DMPER HOUSING Inside (6) Outside (4) KPLTE (9) DSHORD LOWER FRONT OUTRIGGER (4) UMPER EXTENSION RKET UMPER EM EXTENSION FLNGE 3-14

51 Mass production body welding positions and numbers (Outrigger and side frame gusset) NOTE: Welding symbols : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MG plug welding; : MG welding L=Welding length unit: mm (in) ( ): The number of welds ENTER FRME EXTENSION ENTER TUNNEL FRME Left side shape FRONT OUTRIGGER FRONT FLOOR FRME EXTENSION Left side (36) Right side (28) FRONT FLOOR FRME FRONT FLOOR ottom of the front floor RER OUTRIGGER (4) Rear outrigger and inside sill INSIDE SILL (6) FRONT OUTRIGGER (8) ENTER FRME EXTENSION RER OUTRIGGER (2) RER OUTRIGGER (4) (1) Rear outrigger and inside sill (3) φ7 (0.28) DSHORD LOWER (1) φ11 (0.43) (cont'd) 3-15

52 Front Side Frame/Outrigger Removal (cont'd) onstruction NOTE: This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual. The component replacement procedure described here is only for new cura-supplied parts, as needed, according to the area and the degree of damage on the body. Replace the front side frame and the crossmember extension as an assembly. If necessary, replace the front damper extension gusset and the bumper extension bracket. heck the subframe rear bracket and the outrigger positions for damage. If necessary, replace the front outrigger, the rear outrigger, the front floor frame extension, and the center frame extension as an assembly. DSHORD LOWER ROSSMEMER DMPER HOUSING FRONT WHEELHOUSE FRONT DMPER EXTENSION GUSSET FRONT OUTRIGGER ENTER TUNNEL FRME FRONT FLOOR FRME ROSSMEMER EXTENSION FRONT SIDE FRME UMPER EXTENSION RKET DSHORD LOWER FRONT OUTRIGGER SUFRME RER RKET RER OUTRIGGER ENTER FRME EXTENSION FRONT FLOOR FRME EXTENSION MOUNTING OLT 8 x 1.25 mm 3-16

53 Installation NOTE: Welding symbols : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MG plug welding : MG welding L=Welding length unit: mm (in) ( ): The number of welds 1. lamp the new side frame and the front bulkhead, and measure the front compartment diagonally. 6. Do the main welding. Weld the rear outrigger () to the inside sill () and the outer panel complete (). (2) 2. heck the body dimensions. Front bulkhead position (see page 4-3) Engine compartment (see page 4-4) Engine and transmission mount positions (see page 4-6) Front damper extension position (see page 4-7) Engine compartment and front floor, under view (see page 4-14) Repair chart, top view (see page 4-18) Repair chart, side view (see page 4-20) 8 x 1.25 mm 22 N m (2.2 kgf m, 16 lbf ft) 7. When replacing the front side frame () only, weld the front side frame and the front outrigger (). (9) 3. Tack weld the new parts and the front bulkhead into position. Inside Outside 4. Temporarily install the front subframe, and check the suspension position. 5. Temporarily install the front fender, the hood, and the door(s), then check for differences in level and clearance. heck the external parts fitting positions (see page 4-12). If necessary, check the headlight and the front bumper positions. Make sure the body lines flow smoothly. (6) (2) (4) (cont'd) 3-17

54 Front Side Frame/Outrigger Installation (cont'd) 8. From the passenger's compartment, weld the front side frame (), the front outrigger (), the rear outrigger (), the front floor frame extension (D), and the center frame extension (E) to the dashboard lower (F), the front floor (G), the floor frame (H), and the center tunnel frame (I). 9. Weld the front side frame () to the front wheelhouse () and the damper housing (). (10) [VIEW: X] (5) I F (9) E (4) 10. Weld the front side frame support () and the bumper beam extension flange () to the bumper extension bracket () and the damper extension gusset (D). [X] G [Y] (4) (7) E [Z] (2) (15) [Z] [X] [VIEW: X] [VIEW: Z] H [VIEW: Y] D (13) [VIEW: Z] I D (3) (3) (3) D (1) 11. Weld the front bulkhead (see page 3-4). 3-18

55 Front Pillar Outer Panel Removal Mass production body welding positions and numbers (Outer panel) NOTE: Welding symbols : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MG plug welding; : MG welding L=Welding length unit: mm (in) ( ): The number of welds With wheelhouse upper member removed (20) FRONT PILLR LOWER STIFFENER (11) (1) (18) (1) (22) FRONT PILLR OUTER SEPRTOR (3) (1) (8) (cont'd) 3-19

56 Front Pillar Outer Panel Removal (cont'd) Mass production body welding positions and numbers (Front pillar lower stiffener) NOTE: Welding symbols : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MG plug welding; : MG welding L=Welding length unit: mm (in) ( ): The number of welds With outer panel removed FRONT PILLR LOWER STIFFENER (3) FRONT PILLR UPPER STIFFENER [VIEW: Z] FRONT PILLR LOWER STIFFENER FRONT PILLR LOWER STIFFENER (4) L=10 (0.39) [Z] (4) L=10 (0.39) INNER LOWER PILLR FRONT PILLR INNER SEPRTOR (2) (5) FRONT PILLR LOWER STIFFENER 3-20

57 onstruction NOTE: This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual. The component replacement procedure described here is only for new cura-supplied parts, as needed, according to the area and the degree of damage on the body. Remove the wheelhouse upper member (see page 3-6). ut and pry off the outer panel at the front pillar and side sill portions. NOTE: Select the cutting positions in consideration of the front side outer panel repair part (see page 1-15). When cutting the outer panel, be careful not to damage the front pillar outer separator. heck the front pillar lower stiffener position for damage. If necessary, replace it. Replace the front pillar outer separator and the front pillar inner separator. INNER UPPER PILLR FRONT PILLR UPPER STIFFENER OUTER PNEL [] [] Section 1mm (0.039 in) FRONT PILLR UPPER STIFFENER 15 mm (0.59 in) OUTER PNEL INNER UPPER PILLR 8.5 mm (0.335 in) [] Section 5mm (0.20 in) INSIDE SILL 5mm (0.20 in) [] 17.5 mm (0.689 in) INNER LOWER PILLR FRONT PILLR INNER SEPRTOR SIDE SILL REINFOREMENT FRONT PILLR LOWER STIFFENER FRONT PILLR OUTER SEPRTOR OUTER PNEL SIDE SILL REINFOREMENT 3-21

58 Front Pillar Outer Panel Installation NOTE: Welding symbols : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MG plug welding : MG welding L=Welding length unit: mm (in) ( ): The number of welds 1. Remove the front pillar lower stiffener from the new side sill reinforcement complete. 2. Install the new front pillar outer separator () to the new front pillar lower stiffener (). Insert the tab () of the inner separator (D) into the hole (E) of the outer separator. D 4. Set the new front pillar lower stiffener, and tack weld it into position. 5. Rough-cut the front side outer panel repair part, clamp it to the body, and check the dimensions. Front damper extension position (see page 4-7) Door hinge positions (see page 4-8) Windshield and door openings (see page 4-10) 6. Temporarily install the windshield, the door(s), the hood, and the front fender, then check for differences in level and clearance. heck the external parts fitting positions (see page 4-12). Make sure the body lines flow smoothly. 7. Trim the cut and joint areas of the outer panel repair part as needed, and prepare the butt-welding areas. 8. Remove the outer panel repair part. If necessary, weld the patches at the cut sections of the body side outer panel. 9. Weld the front pillar lower stiffener () to the upper stiffener () and the side sill reinforcement (). D (5) E 3. pply the sealer () without gaps all the way around the inner separator () and the inner lower pillar (). (2) (2) (5) 3-22

59 10. Weld the front pillar lower bulkhead (), lower bulkhead, and the door hinge lower nut () to the front inner lower pillar (D). 13. Do the main welding. Weld the outer panel repair part (). Windshield opening D (2) L=10 (0.39) (7) (2) L=10 (0.39) Flange notch (10) (4) L=10 (0.39) 11. pply the sealer () without gaps all the way around the outer separator () and inside the outer panel repair part (). 12. lamp the outer panel repair part, and recheck the clearance and alignment of the door(s), the front fender, and the windshield. (cont'd) 3-23

60 Front Pillar Outer Panel Installation (cont'd) Door opening and side sill lower flange L=190 (7.48) (7) (13) (18) (1) (2) (3) (8) L=350 (13.78) (8) 14. Weld the wheelhouse upper member (see step 14 on page 3-13). 3-24

61 Side Sill Outer Panel Removal Mass production body welding positions and numbers NOTE: Welding symbols : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MG plug welding; : MG welding L=Welding length unit: mm (in) ( ): The number of welds The figure shows the size of the side sill outer panel repair part. Top end position of the side sill outer repair part Rear edge position of the side sill outer repair part (2) (17) (2) (7) (7) (37) ENTER PILLR OUTER SEPRTOR (cont'd) 3-25

62 Side Sill Outer Panel Removal (cont'd) onstruction NOTE: This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual. The component replacement procedure described here is only for new cura-supplied parts, as needed, according to the area and the degree of damage on the body. ut and pry off the side sill outer panel, and replace it. NOTE: Select the cutting positions in consideration of the side sill outer panel repair part (see page 1-15). Replace the center pillar outer separator. [] Section [] Section [] Section INNER LOWER ENTER INNER PILLR PILLR 9.5 mm (0.374 in) 20 mm (0.79 in) 4mm (0.16 in) 13.5 mm (0.531 in) 3mm (0.12 in) 11 mm (0.43 in) ENTER PILLR STIFFENER 6mm (0.24 in) 7mm (0.28 in) 5.5 mm (0.217 in) INSIDE SILL 4.5 mm (0.177 in) 4.5 mm (0.177 in) 19 mm (0.75 in) OUTER PNEL FRONT PILLR LOWER STIFFENER OUTER PNEL OUTER PNEL SIDE SILL REINFOREMENT FRONT PILLR LOWER STIFFENER SIDE SILL REINFOREMENT ENTER PILLR OUTER SEPRTOR [] [] OUTER PNEL ENTER PILLR STIFFENER [] 3-26

63 Installation NOTE: Welding symbols : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MG plug welding : MG welding L=Welding length unit: mm (in) ( ): The number of welds 6. Install the new center pillar outer separator () on the center pillar stiffener (). pply the sealer () without gaps all the way around the separator and inside the outer panel repair part (D). 1. Rough-cut the side sill outer panel repair part, and clamp it to the body. 2. heck the dimensions. Front damper extension position (see page 4-7) Door hinge positions (see page 4-8) Windshield and door openings (see page 4-10) 3. Temporarily install the door(s), the hood, and the front fender, then check for differences in level and clearance. heck the external parts fitting positions (see page 4-12). Make sure the body lines flow smoothly. 4. Trim the cut and joint areas of the outer panel repair part as needed, and prepare the butt-welding areas. D 7. lamp the outer panel repair part, and recheck the clearance and alignment of the door(s) and the front fender. 5. Remove the outer panel repair part. If necessary, weld the patches at the cut sections of the body side outer panel. (cont'd) 3-27

64 Side Sill Outer Panel Installation (cont'd) 8. Do the main welding. Weld the outer panel repair part (). L=360 (14.17) (23) (9) L=340 (13.39) [Z] (36) [VIEW: Z] L=320 (12.60) (7) 3-28

65 enter Pillar Outer Panel Removal Mass production body welding positions and numbers (Outer panel) NOTE: Welding symbols : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MG plug welding; : MG welding L=Welding length unit: mm (in) ( ): The number of welds ENTER PILLR STIFFENER Front side outer panel repair part rear upper edge (13) (2) (26) (26) (3) RER WHEEL RH SEPRTOR Refer to the front pillar outer panel. (1) (18) (6) (9) (4) [Z] (37) ENTER PILLR OUTER SEPRTOR (7) Front side outer panel repair part rear lower edge [VIEW: Z] (2) (cont'd) 3-29

66 enter Pillar Outer Panel Removal (cont'd) Mass production body welding positions and numbers (enter pillar stiffener, side sill reinforcement complete, and center inner pillar) NOTE: Welding symbols : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MG plug welding; : MG welding L=Welding length unit: mm (in) ( ): The number of welds With outer panel removed ROOF SIDE RIL (3) [VIEW: X] (4) ENTER INNER PILLR (7) MOUNTING OLTS (2) 8 x 1.25 mm (3) [X] ENTER PILLR STIFFENER ROOF SIDE STIFFENER ENTER PILLR REINFOREMENT FRONT PILLR UPPER STIFFENER [W] ENTER PILLR INNER SEPRTOR SIDE SILL REINFOREMENT [Y] SIDE SILL REINFOREMENT EXTENSION (8) [Z] FRONT PILLR LOWER STIFFENER [VIEW: W] (4) L=10 (0.39) [VIEW: Y] ENTER INNER PILLR ENTER PILLR STIFFENER [VIEW: Z] (2) RER WHEEL RH EXTENSION SIDE SILL REINFOREMENT (2) L=15 (0.59) (4) L=10 (0.39) SIDE SILL REINFOREMENT (5) (1) L=10 (0.39) INSIDE SILL (2) (1) L=10 (0.39) SIDE SILL REINFOREMENT EXTENSION 3-30

67 onstruction NOTE: This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual. The component replacement procedure described here is only for new cura-supplied parts, as needed, according to the area and the degree of damage on the body. If there is any damage to the center pillar, cut the [] position and pry off the outer panel, and replace it. NOTE: Select the cutting positions in consideration of the front side outer panel repair part (see page 1-15). Replace the center pillar outer separator. heck the center pillar stiffener and the side sill reinforcement positions for damage. If necessary, cut the [] and [] positions of the outer panel, and replace the center pillar stiffener. When replacing the side sill reinforcement, carefully cut the [D] position at the front pillar and the [E] position at the rear wheel arch portion of the outer panel. [] Section ENTER PILLR STIFFENER [] 10 mm (0.39 in) 10 mm (0.39 in) OUTER PNEL [] Section 15 mm (0.59 in) OUTER PNEL [D] Section 1mm (0.039 in) UPPER STIFFENER 8mm (0.31 in) OUTER PNEL FRONT PILLR LOWER STIFFENER [D] 5mm (0.20 in) 5mm (0.20 in) 5mm (0.20 in) [] ENTER PILLR STIFFENER [] [] ROOF SIDE STIFFENER 6mm (0.24 in) [] ROOF SIDE STIFFENER ENTER PILLR STIFFENER ENTER PILLR OUTER SEPRTOR 17 mm (0.67 in) [E] Section OUTER PNEL 27 mm (1.06 in) 28 mm (1.10 in) 10 mm (0.39 in) OUTER PNEL RER WHEEL RH EXTENSION OUTER PNEL SIDE SILL REINFOREMENT Refer to the side sill outer panel for the side sill cutting section. [E] OUTER PNEL Reuse. SIDE SILL REINFOREMENT EXTENSION (cont'd) 3-31

68 enter Pillar Outer Panel Removal (cont'd) Remove the roof arch gusset, and replace the center pillar stiffener. Replace the front pillar lower stiffener, the side sill reinforcement, and the side sill reinforcement extension as an assembly. Replace the front pillar outer and inner separators, the center pillar inner separator, and the rear wheel arch separator. ENTER PILLR STIFFENER ENTER PILLR REINFOREMENT ROOF RH GUSSET FRONT PILLR INNER SEPRTOR FRONT PILLR OUTER SEPRTOR ENTER INNER PILLR MOUNTING OLTS 8 x 1.25 mm FRONT PILLR LOWER STIFFENER SIDE SILL REINFOREMENT ULKHED ENTER PILLR INNER SEPRTOR ULKHED SIDE SILL REINFOREMENT EXTENSION RER WHEEL RH SEPRTOR 3-32

69 Installation NOTE: Welding symbols : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MG plug welding : MG welding L=Welding length unit: mm (in) ( ): The number of welds 4. lamp the side sill reinforcement complete () on the body. Install the center pillar inner separator () and the rear wheel arch separator (). 1. lamp the new center inner pillar. 2. Install the new front pillar inner and outer separators to the front pillar lower stiffener (see step 2 on page 3-22). 3. pply the sealer () without gaps all the way around the front pillar inner separator () and the inner lower pillar (). 5. Remove the center pillar stiffener from the new center pillar stiffener complete. 6. Grind away the upper edge [X] position of the new center pillar stiffener () as shown. [X] (cont'd) 3-33

70 enter Pillar Outer Panel Installation (cont'd) 7. Insert the center pillar reinforcement () into the roof side stiffener (), and clamp the center pillar stiffener (). 8. From the passenger's compartment, install the roof arch gusset (), and secure the center pillar reinforcement (). 8 x 1.25 mm 25 N m (2.5 kgf m, 18 lbf ft) 9. heck the body dimensions. Passenger's compartment (see page 4-9) Engine compartment and front floor, under view (see page 4-14) Front floor and rear floor, under view (see page 4-15) Inside sill positions (see page 4-16) Repair chart, top view (see page 4-18) Repair chart, side view (see page 4-20) 10. Tack weld the new parts into position. 3-34

71 11. pply the sealer () without gaps all the way around the rear wheel arch separator () and inside the outer panel reused part (). Tack weld the outer panel reused part. 16. From the passenger's compartment, weld the holes in the inner lower pillar (), the front pillar lower bulkheads and, and the door hinge lower nuts (D). Weld the front edge of the side sill reinforcement (E). (4) L=10 (0.39) D (4) L=10 (0.39) E 12. Rough-cut the front side outer panel repair part, and clamp it to the body. 13. Temporarily install the doors, the hood, and the front fender, then check for differences in level and clearance. heck the external parts fitting positions (see page 4-12). Make sure the body lines flow smoothly. 14. Trim the cut and joint areas of the outer panel repair part as needed, and prepare the butt-welding areas. 15. Remove the outer panel repair part. If necessary, weld the patches at the cut section of the body side outer panel. (2) L=15 (0.59) 17. From the passenger's compartment, weld the side sill reinforcement () and the center inner pillar () to the inside sill (). (1) L=10 (0.39) (5) (1) L=10 (0.39) (cont'd) 3-35

72 enter Pillar Outer Panel Installation (cont'd) 18. Weld the upper edge of the center inner pillar () and the roof side rail (). 20. Weld the front pillar lower stiffener () to the front pillar upper stiffener () and the inner lower pillar (). (5) (2) 19. Weld the center pillar stiffener () to the roof side stiffener () and the side sill reinforcement (). (10) (2) (2) (3) (8) 3-36

73 21. Weld the side sill reinforcement extension () to the rear wheel arch extension () and the rear jack-up base (). 25. Do the main welding. Weld the outer panel repair part () and the outer panel reused part (). Front pillar outer panel welding points (see step 13 on page 3-23) Side sill outer panel welding points (see step 8 on page 3-28) L=140 (5.51) L=400 (15.75) (2) (3) (2) L=145 (5.71) (27) (2) 22. Install the new center pillar outer separator () on the center pillar stiffener (). pply the sealer () without gaps all the way around the separator and inside the outer panel repair part (D). [Z] (27) (3) (7) L=340 (13.39) [VIEW: Z] D 23. pply the sealer to the front pillar outer separator and inside the outer panel repair part (see step 11 on page 3-23). 24. lamp the outer panel repair part, and recheck the clearance and alignment of the doors and the front fender. (1) (cont'd) 3-37

74 enter Pillar Outer Panel Installation (cont'd) In case of the outer panel replacement only. Side sill rear lower and wheel arch portions L=155 (6.10) (23) (4) (23) (2) Side sill rear portion L=290 (11.42) (8) (10) 26. Insert the nozzle through the hole of the center inner pillar (), and apply the sealer () without gaps between the center pillar stiffener () and the side sill reinforcement (D). D 3-38

75 Roof Panel Removal Mass production body welding positions and numbers NOTE: Welding symbols : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MG plug welding; : MG welding L=Welding length unit: mm (in) ( ): The number of welds FRONT ROOF RIL MOUNTING OLTS 6 x 1.0 mm MOUNTING OLTS 8 x 1.25 mm RER ROOF RIL (2) (3) (4) (11) ROOF PNEL OUTER PNEL (23) Roof side rails and outer panel welding positions with roof panel removed (cont'd) 3-39

76 Roof Panel Removal (cont'd) onstruction NOTE: This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual. Remove the mounting bolts and the roof arch gussets from both sides. Drill the welded flange of the front roof rail, the rear roof rail (passenger's compartment side), and the side flanges of the roof panel. ROOF PNEL ROOF RH GUSSET MOUNTING OLTS 8 x 1.25 mm MOUNTING OLTS 6 x 1.0 mm 3-40

77 Installation NOTE: Welding symbols : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MG plug welding : MG welding L=Welding length unit: mm (in) ( ): The number of welds 1. lamp the new roof panel (), install the roof arch gusset (), and tighten the mounting bolts. 3. heck the body dimensions. Door hinge positions (see page 4-8) Passenger's compartment (see page 4-9) Windshield and door openings (see page 4-10) Rear window and trunk lid openings (see page 4-11) 4. Tack weld the front and rear corner edges of the roof panel. 5. Temporarily install the roof molding, the windshield, the rear window, and the doors, then check for differences in level and clearance. heck the external parts fitting positions (see page 4-12). Make sure the body lines flow smoothly. 6. Do the main welding. From the passenger's compartment, weld the rear roof rail () to the rear damper stiffener (). (2) 8 x 1.25 mm 22 N m (2.2 kgf m, 16 lbf ft) 2. ttach the front roof rail () to the front pillar inner upper extension () with the mounting bolts. 6 x 1.0 mm 9.3 N m (0.95 kgf m, 6.9 lbf ft) (cont'd) 3-41

78 Roof Panel Installation (cont'd) 7. Weld the front, rear, and side flanges of the roof panel (). NOTE: The roof area must be free of burrs and/or sharp edges to prevent damage to the side curtain airbag during deployment. (5) (3) (6) (4) 3-42

79 Rear Side Outer Panel Removal Mass production body welding positions and numbers (Outer panel and rear gutter) NOTE: Welding symbols : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MG plug welding; : MG welding L=Welding length unit: mm (in) ( ): The number of welds RER SHELF ottom of the rear shelf Front upper edge position of the rear side outer panel repair part (11) (3) (1) RER PNEL RER PILLR INNER SEPRTOR (7) RER GUTTER OMPLETE (21) RER DMPER STIFFENER RER GUTTER OMPLETE (15) WHEEL RH OUTER SEPRTOR (18) (3) (5) [X] (6) (5) (7) (4) (12) [Z] INNER PNEL [VIEW: X] (7) Front lower edge position of the rear side outer panel repair part [VIEW: Z] OUTER PNEL 65 (2) RER GUTTER OMPLETE RER PNEL (2) OUTER PNEL (4) (cont'd) 3-43

80 Rear Side Outer Panel Removal (cont'd) onstruction NOTE: This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual. The component replacement procedure described here is only for new cura-supplied parts, as needed, according to the area and the degree of damage on the body. ut and pry off the rear side outer panel, and replace it. NOTE: Select the cutting positions in consideration of the rear side outer panel repair part (see page 1-15). heck the rear gutter complete for damage. If necessary, replace it. Replace the rear wheel arch outer separator. [] Section OUTER PNEL 12 mm (0.47 in) RER SHELF 5mm (0.20 in) RER DMPER STIFFENER RER INNER PNEL RER DMPER STIFFENER SIDE SILL REINFOREMENT EXTENSION RER WHEEL RH OUTER SEPRTOR [] RER INNER PNEL RER PNEL RER WHEEL RH EXTENSION RER GUTTER OMPLETE Refer to the side sill outer panel for the side sill cutting section. OUTER PNEL RER FLOOR SIDE STIFFENER RER 3-44

81 Installation NOTE: Welding symbols : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MG plug welding : MG welding L=Welding length unit: mm (in) ( ): The number of welds 6. pply the sealer () to the rear damper stiffener () and around the fuel fill door opening of the damper stiffener extension (). 1. lamp the new rear gutter complete, rough-cut the rear side outer panel repair part, and clamp it to the body. 2. heck the body dimensions. Door hinge positions (see page 4-8) Passenger's compartment (see page 4-9) Windshield and door openings (see page 4-10) Rear window and trunk lid openings (see page 4-11) 3. Temporarily install the rear door, the rear window, and the trunk lid, then check for differences in level and clearance. heck the external parts fitting positions (see page 4-12). Make sure the body lines flow smoothly. 4. Trim the cut and joint areas of the outer panel repair part as needed, and prepare the butt-welding areas. 5. Remove the outer panel repair part. If necessary, weld the patches at the cut sections of the body side outer panel. 7. Install the new wheel arch outer separator () on the rear wheel arch extension (). pply the sealer () without gaps all the way around the separator and inside the outer panel repair part (D). D 8. lamp the outer panel repair part, and recheck the clearance and alignment of the rear door, the rear window, and the trunk lid. (cont'd) 3-45

82 Rear Side Outer Panel Installation (cont'd) 9. Do the main welding. Weld the outer panel repair part () and the rear gutter complete (). Wheel arch area L=225 (8.86) (4) (6) (18) (5) Outer panel rear area (2) (7) L=340 (13.39) Side sill lower flange (6) (14) (8) 3-46

83 Rear gutter complete Rear window opening (5) (5) (8) (2) (9) (5) Trunk gutter area (4) (5) 10. Left side: From inside the rear wheelhouse, apply the sealer () to fill the gap between the rear side outer panel () and the rear damper stiffener extension () around the fuel fill door opening. (7) (1) 3-47

84 Rear Panel Removal Mass production body welding positions and numbers NOTE: Welding symbols : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MG plug welding; : MG welding L=Welding length unit: mm (in) ( ): The number of welds [VIEW: Z] RER OMINTION DPTER RER PNEL GUSSET RER FLOOR SIDE STIFFENER RER (4) OUTER PNEL [Z] RER PNEL (3) (1) ottom of the rear floor [Y] (10) [VIEW: Y] (1) L=8 (0.31) Inside (2) Inside (27) RER PNEL SIDE STIFFENER RER FLOOR (3) (4) (5) 3-48

85 onstruction NOTE: This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual. The component replacement procedure described here is only for new cura-supplied parts, as needed, according to the area and the degree of damage on the body. Move the rear panel downward while turning it forward, and remove it from the rear combination adapter. If necessary, replace the rear panel gussets. RER OMINTION DPTER RER PNEL SIDE STIFFENER UPPER RER PNEL RER OMINTION DPTER RER FLOOR OUTER PNEL RER UMPER EM RKET RER PNEL GUSSET RER PNEL RER PNEL SIDE STIFFENER UPPER 3-49

86 Rear Panel Installation NOTE: Welding symbols : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MG plug welding : MG welding L=Welding length unit: mm (in) ( ): The number of welds 1. Set the rear panel gussets on both sides, and clamp the rear panel. 5. Do the main welding. Weld the rear panel gusset (), and weld the rear pannel () to the rear combination adapter () and the rear damper stiffener (D). (7) D (1) L=8 (0.31) (3) 2. heck the body dimensions. Passenger's compartment (see page 4-9) Rear window and trunk lid openings (see page 4-11) Front floor and rear floor, under view (see page 4-15) Repair chart, top view (see page 4-18) Repair chart, side view (see page 4-20) 3. Tack weld the rear panel into position. 4. Temporarily install the trunk lid, then check for differences in level and clearance. heck the external parts fitting positions (see page 4-12). If necessary, check the taillight and the rear bumper positions. Make sure the body lines flow smoothly. (10) 6. Weld the rear panel () to the rear combination adapter (), the outer panel (), and the rear floor side stiffener rear (D). (4) (6) (3) D 3-50

87 7. Weld the rear panel () to the rear floor (). (27) 3-51

88 Rear Floor/Rear Frame Removal Mass production body welding positions and numbers (Rear floor and rear floor side stiffener rear) NOTE: Welding symbols : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MG plug welding; : MG welding L=Welding length unit: mm (in) ( ): The number of welds With rear panel removed ut line (9) RER FLOOR RER FLOOR ROSSMEMER []: ottom of the rear floor side stiffener middle RER FLOOR SIDE STIFFENER MIDDLE (3) [] RER FLOOR SIDE STIFFENER RER (1) (9) RER FLOOR SIDE STIFFENER MIDDLE RER FLOOR SIDE STIFFENER RER RER FRME STIFFENER (10) RER FRME OUTER PNEL (4) (5) RER WHEELHOUSE 3-52

89 Mass production body welding positions and numbers (Rear frame and rear floor crossmember) NOTE: Welding symbols : 2-Plate spot welding; : 3-Plate spot welding; : 4-Plate spot welding; : MG plug welding; : MG welding L=Welding length unit: mm (in) ( ): The number of welds RER FLOOR ROSSMEMER (6) (22) (3) RER FLOOR ROSSMEMER RER FRME RER FLOOR ROSSMEMER EXTENSION (3) RER FLOOR ROSSMEMER With rear floor and rear floor side stiffener rear Under view (4) RER FRME STIFFENER RER FRME (3) RER FLOOR (ody side) RER FLOOR ROSSMEMER EXTENSION RER FLOOR ROSSMEMER (3) (cont'd) 3-53

90 Rear Floor/Rear Frame Removal (cont'd) onstruction (Rear floor) NOTE: This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual. The component replacement procedure described here is only for new cura-supplied parts, as needed, according to the area and the degree of damage on the body. ut the rear floor 15 mm (0.59 in) from the welded flange of the rear floor crossmember, and replace it. ut line 15 mm (0.59 in) RER FLOOR SIDE STIFFENER MIDDLE RER FLOOR RER WHEELHOUSE RER FLOOR ROSSMEMER RER FLOOR SIDE STIFFENER RER RER FRME RER FLOOR ROSSMEMER RER FLOOR 3-54

91 onstruction (Rear frame and rear floor crossmember) NOTE: This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual. The component replacement procedure described here is only for new cura-supplied parts, as needed, according to the area and the degree of damage on the body. If necessary, replace the rear floor side stiffener rear. heck the rear frame and the rear floor crossmember positions for damage. If necessary, replace them. RER FLOOR SIDE STIFFENER RER RER FRME STIFFENER RER FRME RER FLOOR ROSSMEMER 3-55

92 Rear Floor/Rear Frame Installation NOTE: Welding symbols : 2-Plate spot welding : 3-Plate spot welding : 4-Plate spot welding : MG plug welding : MG welding L=Welding length unit: mm (in) ( ): The number of welds 6. Temporarily install the rear panel and the trunk lid, then check for differences in level and clearance. heck the external parts fitting positions (see page 4-12). If necessary, check the taillight and the rear bumper positions. Make sure the body lines flow smoothly. 7. Do the main welding. Plug weld rear frame and the rear floor crossmember () to the rear frame stiffener () and the rear floor crossmember extension (D). 1. Set the new rear flame and the rear floor crossmember (). Measure the rear frame diagonally. (5) [Z] D (4) 2. heck the body dimensions. [X] Front floor and rear floor, under view (see page 4-15) Repair chart, top view (see page 4-18) Repair chart, side view (see page 4-20) [VIEW: Z] 3. Tack weld the new parts into position. 4. Temporarily install the rear suspension, and check the rear frame stiffener, rear frame, and the rear floor crossmember positions. (4) 5. Tack weld the new rear floor side stiffener rear () into position. [VIEW: X] (3) D (1) 3-56

93 8. Plug weld the rear floor crossmember () and the body side rear floor (), and finish the welded area. NOTE: Do not grind the plug welds excessively. 10. Plug weld the rear floor side stiffener rear () and the new rear floor () to rear frame and the rear floor side stiffener middle (D). (5) D (7) (22) (9) 9. ut the new rear floor () so it overlaps the body side rear floor () by about 40 mm (1.57 in). Set the new rear floor into position, and align it with the body, and recheck the rear panel position. Overlaps 40 mm (1.57 in) 11. Weld the new rear floor () and the body side rear floor (). Trunk compartment side L=1070 (42.13) Under floor side L=1070 (42.13) (cont'd) 3-57

94 Rear Floor/Rear Frame Installation (cont'd) 12. Plug weld the rear floor side stiffener rear () to the outer panel () and the rear wheelhouse (). (4) (5) 13. Weld the rear panel (see page 3-50). 3-58

95 Floor Insulators Insulator Locations ut new insulators, and apply them in areas shown in this illustration. NOTE: efore applying, clean and degrease the floor. RIGHT-FRONT FLOOR FRONT INSULTOR FRONT FLOOR RER INSULTOR MIDDLE FLOOR SIDE INSULTOR RIGHT-RER FLOOR INSULTOR RER FLOOR ENTER INSULTOR RIGHT-RER FLOOR END INSULTOR [X] [Y] RER FLOOR ENTER END INSULTOR [Z] LEFT-RER FLOOR END INSULTOR LEFT-FRONT FLOOR FRONT INSULTOR MIDDLE FLOOR LEFT-RER FLOOR ENTER INSULTOR INSULTOR RER WHEELHOUSE INSULTOR RIGHT-MIDDLE FLOOR ROSSMEMER INSULTOR LEFT-MIDDLE FLOOR ROSSMEMER INSULTOR Front [VIEW: Y] RER WHEELHOUSE INSULTOR [VIEW: X] [VIEW: Z] Front 3-59

96 Floor Insulators Insulator Sizes Unit: mm (in) RIGHT-FRONT FLOOR FRONT INSULTOR 461 (18.15) 702 (27.64) LEFT-FRONT FLOOR FRONT INSULTOR 702 (27.64) 461 (18.15) 3-60

97 Unit: mm (in) FRONT FLOOR RER INSULTOR 678 (26.70) RIGHT-MIDDLE FLOOR ROSSMEMER INSULTOR 238 (9.37) 645 (25.39) 647 (25.47) (cont'd) 3-61

98 Floor Insulators Insulator Sizes (cont'd) Unit: mm (in) LEFT-MIDDLE FLOOR ROSSMEMER INSULTOR 238 (9.37) 647 (25.47) MIDDLE FLOOR SIDE INSULTOR MIDDLE FLOOR ENTER INSULTOR 466 (18.35) 470 (18.50) RER WHEELHOUSE INSULTOR 218 (8.58) 219 (8.62) 234 (9.21) 301 (11.85) 3-62

99 Unit: mm (in) RIGHT-RER FLOOR INSULTOR LEFT-RER FLOOR INSULTOR 303 (11.93) 344 (13.54) 391 (15.39) RER FLOOR ENTER INSULTOR RER FLOOR ENTER END INSULTOR 220 (8.66) 560 (22.05) 175 (6.89) 241 (9.49) 333 (13.11) (cont'd) 3-63

100 Floor Insulators Insulator Sizes (cont'd) Unit: mm (in) RIGHT-RER FLOOR END INSULTOR LEFT-RER FLOOR END INSULTOR 245 (9.65) 274 (10.79) 374 (14.72) 243 (9.57) 3-64

101 ody Dimensional Drawings Upper ody Measuring Dimensions Front Fender Positions 4 2 Front ulkhead Position 4 3 Engine ompartment 4 4 Engine and Transmission Mount Positions 4 6 Front Damper Extension Position 4 7 Door Hinge Positions 4 8 Passenger's ompartment 4 9 Windshield and Door Openings 4 10 Rear Window and Trunk Lid Openings 4 11 External Parts Fitting Positions 4 12 Under ody Measuring Dimensions Front Subframe Position 4 13 Engine ompartment and Front Floor, Under View 4 14 Front Floor and Rear Floor, Under View 4 15 Inside Sill Positions 4 16 Frame Repair hart Repair hart, Top View 4 18 Repair hart, Side View 4 20

102 Upper ody Measuring Dimensions Front Fender Positions Reference NOTE: The front bumper grille cover and the cowl cover are removed in the illustrations. Unit: mm (in) φ: Inner diameter, a ulkhead Upper enter Frame Locating Hole φ20 (0.79), b Front Fender Front Mounting olt (enter of the bolt) F D, d Front Fender Rear Mounting olt (enter of the bolt), c Front Fender Middle Mounting olt (enter of the olt) F F 272 (10.71) d 1488 (58.58) 1466 (57.72) D c 1459 (57.44) 745 (29.33) 473 (18.62) 1482 (58.35) 1592 (62.68) b 993 (39.09) 1351 (53.19) 397 (15.63) a 4-2

103 Front ulkhead Position Unit: mm (in) φ: Inner diameter 1, a1 ir Guide Mounting Hole right: φ11 (0.43)/left: φ9 (0.35) 2, a2 Radiator Side Seal Mounting Hole φ10 (0.39) F F 3, a3 Front umper eam Mounting Hole φ12 (0.47) 4, a4 Radiator Upper Mount racket Mounting Hole φ9 (0.35) F a (47.80) F 3 a4 481 (18.94) 914 (35.98) 1137 (44.76) (18.98) a1 a3 a4 929 (36.57) 914 (35.98) (14.69) 3 1 a3 a1 244 (9.61) 259 (10.20) a2 774 (30.47) 1027 (40.43) 820 (32.28) 1137 (44.76) 330 (12.99) (10.24) 3 a (39.76) 1 4-3

104 Upper ody Measuring Dimensions Engine ompartment Unit: mm (in) φ: Inner diameter 1, b1 ulkhead Upper enter Frame Locating Hole φ15 (0.59) 2, b2 ulkhead Upper Side Frame Locating Hole φ11 (0.43) F F 3, b3 Front Damper Mounting Hole φ11.5 (0.453) 4, b4 Hood Hinge Rear Mounting Hole φ7 (0.28) F F b (53.50) 1035 (40.75) (59.65) 1232 (48.50) 331 (13.03) 627 (24.68) b2 b3 668 (26.30) 1400 (55.12) 1051 (41.38) 1264 (49.76) 1040 (40.94) 1350 (53.15) 994 (39.13) (15.12) 494 (19.45) 2 b

105 Unit: mm (in) φ: Inner diameter 1, b1 ulkhead Upper enter Frame Locating Hole φ15 (0.59) 5, b5 Front Fender Front Mounting Hole φ7 (0.28) F F 6, b6 Front Fender Middle Mounting Hole φ7 (0.28) 7, b7 Front Fender Rear Mounting Hole φ7 (0.28) F F 1467 (57.76) b (58.62) 273 (10.75) b6 746 (29.37) 1460 (57.48) (29.49) 1594 (62.76) 1482 (58.35) 473 (18.62) b5 994 (39.13) 1207 (47.52) 1352 (53.23) 398 (15.67) 5 b

106 Upper ody Measuring Dimensions Engine and Transmission Mount Positions Unit: mm (in) φ: Inner diameter 3, b3 Front Damper Mounting Hole φ11.5 (0.453) 1 Engine Side Mount Front Mounting Hole φ15 (0.59) F F 3 Transmission Mount Mounting Hole φ13 (0.51) wheelhouse side 4 Torque Rod Mounting Hole φ14.5 (0.571) x 19.5 (0.768) slot F F 2 Transmission Mount Front Mounting Hole φ15 (0.59) b (19.72) 338 (13.31) (39.33) 1129 (44.45) 1080 (42.52) 1027 (40.43) 1015 (39.96) 981 (38.62) 1069 (42.09) 290 (11.42) (16.38) 1 4-6

107 Front Damper Extension Position Unit: mm (in) φ: Inner diameter D2 Front Fender Front Mounting Hole φ7 (0.28) D3 Front Wheelhouse Upper Member Locating Hole φ15 (0.59) F D1 Front Damper Outer Extension Locating Hole φ16 (0.63) F D4 Front Fender Upper Mounting Hole φ9 (0.35) D5 Front Fender Lower Mounting Hole φ7 (0.28) F F D1 D2 D3 946 (37.24) 1038 (40.87) 864 (34.02) 724 (28.50) 711 (27.99) D4 963 (37.91) 969 (38.15) D5 4-7

108 Upper ody Measuring Dimensions Door Hinge Positions Unit: mm (in) φ: Inner diameter E1 Front Door Upper Hinge Front Mounting Hole φ13 (0.51) E2 Front Door Lower Hinge Upper Mounting Hole φ13 (0.51) E3 Rear Door Upper Hinge Upper Mounting Hole φ13 (0.51) F F F E4 Rear Door Lower Hinge Front Mounting Hole φ13 (0.51) E5 Rear Door Switch Mounting Hole φ8 (0.31) F F E (46.14) E3 305 (12.01) E (42.68) 1146 (45.12) 1198 (47.17) 341 (13.43) 793 (31.22) 875 (34.45) E5 E4 4-8

109 Passenger's ompartment Unit: mm (in) φ: Inner diameter F1, f1 Front Floor rossmember Stiffener Locating Hole φ17 (0.67) F2, f2 Rear Seat elt Lower nchor Mounting Hole φ13 (0.51) F3, f3 Rear Damper Mounting Hole φ24 (0.94) F F F F4, f4 Rear Floor Side Stiffener Rear Locating Hole φ11 (0.43) F5, f5 Trunk Trim Panel lip Mounting Hole φ8.5 (0.335) F F 690 (27.17) f (69.02) 1660 (65.35) f (82.17) f (55.63) 1209 (47.60) f (52.60) 1140 (44.88) f (44.02) 1004 (39.53) F2 637 (25.08) F3 F5 F4 884 (34.80) 1125 (44.29) 1182 (46.54) F1 4-9

110 Upper ody Measuring Dimensions Windshield and Door Openings Unit: mm (in) Windshield Lower Dashboard Installing Pin center, Outer Panel and Roof Panel Windshield Opening Flange Notch (3 places) D, E, F, G, H, I, J, K Outer Panel Door Opening Flange Notch (16 places) F 1446 (56.93) 1417 (55.79) H 779 (30.67) 1439 (56.65) 783 (30.83) 1355 (53.35) 1098 (43.23) D 980 (38.58) G I 611 (24.06) 933 (36.73) 510 (20.08) K 1008 (39.68) J 700 (27.56) E F 492 (19.37) 4-10

111 Rear Window and Trunk Lid Openings Unit: mm (in) L Roof Panel Rear Window Opening Flange Notch M Outer Panel Rear Window Opening Flange Notch (2 places) N Rear Shelf onvex ead F F F O Rear Gutter Upper Flange End (2 places) F P Rear Panel Upper Stiffener Striker Jig Upper Hole enter F L M 641 (25.24) 1065 (41.93) 652 (25.67) N 1057 (41.61) 605 (23.82) 547 (21.54) O 1096 (43.15) 591 (23.27) 489 (19.25) 625 (24.61) P 4-11

112 Upper ody Measuring Dimensions External Parts Fitting Positions Unit: mm (in) Hood 3.0 (0.118) Front Fender Front Fender 2.0 (0.079) Front Pillar Outer Panel Rear Side 5.0 Outer Panel (0.197) 1.3 (0.051) Trunk Lid 3.4 (0.134) Trunk Lid 1.3 (0.051) Rear Side Outer Panel Front Fender 2.0 (0.079) Side Sill Outer Panel 4.0 (0.157) Rear Side Outer Panel 0.7 (0.028) Trunk Lid Front Fender 3.5 (0.138) Front Door Front Door 4.5 (0.177) Rear Door Rear Door 3.5 (0.138) Rear Side Outer Panel Front Door Rear Door 4.0 (0.157) 4.0 (0.157) 6.1 (0.240) Side Sill Outer Panel 6.1 (0.240) Side Sill Outer Panel 4-12

113 Under ody Measuring Dimensions Front Subframe Position Reference Unit: mm (in), a Front Subframe Front Mounting olt (enter of the clip), b Front Subframe Rear Mounting olt (enter of the bolt), c Engine Under over Mounting olt (enter of the bolt) or Front Floor Under over Mounting olt (enter of the bolt) F F F a 978 (38.50) 1382 (54.41) 1150 (45.28) 748 (29.45) 1056 (41.57) b 782 (30.79) 855 (33.66) 312 (12.28) c 818 (32.20) 4-13

114 Under ody Measuring Dimensions Engine ompartment and Front Floor, Under View Unit: mm (in) φ: Inner diameter, a Front ulkhead Lower rossmember Drain Hole φ15 (0.59), b Front Subframe Front Mounting Hole φ16 (0.63), c Front Subframe Middle Mounting Hole φ13 (0.51) F E, e enter Frame Extension Rear Locating Hole φ11 (0.43) F F G, g enter Tunnel Frame Locating Hole φ15 (0.59) D, d Front Subframe Rear Mounting Hole φ16 (0.63) F F, f Front Floor Frame Extension Mounting Hole φ13 (0.51) F 747 (29.41) Left side Right side 980 (38.58) a 699 (27.52) 1152 (45.35) 1140 (44.88) b 1042 (41.02) 1073 (42.24) 867 (34.13) c D 852 (33.54) 851 (33.50) 783 (30.83) d 368 (14.49) 404 (15.91) F 881 (34.68) 657 (25.87) E f 1091 (42.95) 742 (29.21) 897 (35.31) 341 (13.43) 1197 e (47.13) G g (12.20) (32.24) 563 (22.17) 243 (9.57) 4-14

115 Front Floor and Rear Floor, Under View Unit: mm (in) φ: Inner diameter G, g enter Tunnel Frame Locating Hole φ15 (0.59) H, h Rear Frame Locating Hole φ20 (0.79) I, i Rear Upper rm Mounting Hole φ14 (0.55) F F F J, j Rear Floor rossmember Locating Hole left φ15 (0.59)/right φ13 (0.51) K, k Rear Frame Locating Hole φ25 (0.98) F F Left side Right side G 310 (12.20) g 882 (34.72) 1360 (53.54) 1265 (49.80) 1077 (42.40) H 1234 (48.58) h 814 (32.05) 1528 (60.16) 1129 (44.45) 1075 (42.32) 809 (31.85) I i 536 (21.10) 474 (18.66) 1047 (41.22) 1083 (42.64) J j 466 (18.35) 800 (31.50) 791 (31.14) K 410 (16.14) k 800 (31.50) 1004 (39.53) 4-15

116 Under ody Measuring Dimensions Inside Sill Positions Unit: mm (in) φ: Inner diameter D, d Front Subframe Rear Mounting Hole φ16 (0.63) L, l Inside Sill Front Locating Hole φ25 (0.98) F F M, m Inside Sill Rear Locating Hole φ25 (0.98) N, n Rear Frame Stiffener Locating Hole φ11 (0.43) F F 527 (20.75) Left side D L 955 (37.60) M 1288 (50.71) N 783 (30.83) 1176 (46.30) 1410 (55.51) 1703 (67.05) 1410 (55.51) 1750 (68.90) 995 (39.17) Right side d n l m 4-16

117 Frame Repair hart Repair hart, Top View Unit: mm (in) φ: Inner diameter Torque rod mount positions d1 d2 d3 b1 102 (4.02) a2 100 (3.94) e4 57 (2.24) e3 54 (2.13) e1 5 (0.20) e2 320 (12.60) b1 184 b2 (7.24) b2 166 b3 (6.54) 675 (26.57) 425 (16.73) f 292 (11.50) a3 e2 e1 g1 e4 e3 a3 f g1 482 (18.98) 88 (3.46) d3 93 (3.66) d2 97 (3.82) d1 a1 ENTER LINE SE LINE ENTER LINE 980 (38.58) a1 494 (19.45) b1 670 (26.38) b2 479 (18.86) b3 b (47.05) e (45.08) e1 852 (33.54) a2 a (40.79) e (47.48) e4 783 (30.83) 940 (37.01) 1010 (39.76) 511 (20.12) c2 479 (18.86) c1 477 (18.78) c3 c3 a1 a2 a3 b1 b2 b3 c1 c2 c3 d1 d2 d3 e1 e2 e3 e4 f g1 For front subframe mount φ16 (0.63) front For front subframe mount φ13 (0.51) middle c1 For front subframe mount φ16 (0.63) rear c2 For engine side mount φ15 (0.59) front For engine side mount φ12 (0.47) outer For engine side mount φ15 (0.59) rear For transmission mount φ15 (0.59) front 88 (3.46) For transmission mount φ13 (0.51) 143 (5.63) 198 (7.80) wheelhouse side For transmission mount φ15 (0.59) rear For torque rod mount upper φ14.5 (0.571) x 19.5 (0.768) slot Torque rod center point For torque rod mount lower φ14 (0.55) x 22 (0.87) slot Front damper center hole φ74 (2.91) For front damper mount φ11.5 (0.453) front For front damper mount φ11.5 (0.453) center side For front damper mount φ11.5 (0.453) rear Outrigger locating hole φ25 (0.98) Front floor locating hole φ50 (1.97) front c3 c2 c1 447 (17.60) a1 SE LINE 4-18

118 g2 h i j1 j2 k1 k2 l1 l2 Front floor locating hole φ25 (0.98) rear Rear floor locating hole φ25 (0.98) front Rear frame locating hole φ20 (0.79) For trailing arm mount φ17 (0.67) outer For trailing arm mount φ17 (0.67) inner For upper arm mount φ14 (0.55) front For upper arm mount φ14 (0.55) rear Rear spring upper seat φ5 (0.20) For rear damper mount φ24 (0.94) m1 m2 m3 n1 n2 o p For lower arm mount φ13.8 (0.543) front Lower arm center point For lower arm mount φ13 (0.51) rear Rear floor crossmember locating hole φ13 (0.51) right Rear floor crossmember locating hole φ15 (0.59) left Rear frame locating hole φ25 (0.98) Rear floor locating hole φ50 (1.97) rear g2 h i j1 j2 k1 k2 l1 l2 m1 n1 m2 m3 o p 944 (37.17) 1243 (48.94) 400 (15.75) 1193 (46.97) 1013 (39.88) 800 (31.50) 752 (29.61) 940 (37.01) 364 (14.33) 200 (7.87) 210 (8.27) 135 (5.31) 1004 (39.53) 1141 (44.92) n (63.19) g (82.60) i 2172 (85.51) h 2186 (86.06) j (91.26) j (101.26) k (105.28) k (108.82) m (109.02) l (109.61) l (110.00) m2, n1, n (110.98) m (118.78) 3135 (123.42) p o m1 50 (1.97) [SETION: ] m2 m3 4-19

119 Frame Repair hart Repair hart, Side View Unit: mm (in) φ: Inner diameter a1 a2 a3 b1 b2 b3 c1 c2 c3 For front subframe mount φ16 (0.63) front For front subframe mount φ13 (0.51) middle For front subframe mount φ16 (0.63) rear For engine side mount φ15 (0.59) front For engine side mount φ12 (0.47) outer For engine side mount φ15 (0.59) rear For transmission mount φ15 (0.59) front For transmission mount φ13 (0.51) wheelhouse side For transmission mount φ15 (0.59) rear d1 d2 d3 e1 e2 e3 e4 f g1 For torque rod mount upper φ14.5 (0.571) x 19.5 (0.768) slot Torque rod center point For torque rod mount lower φ14 (0.55) x 22 (0.87) slot Front damper center hole φ74 (2.91) For front damper mount φ11.5 (0.453) front For front damper mount φ11.5 (0.453) center side For front damper mount φ11.5 (0.453) rear Outrigger locating hole φ25 (0.98) Front floor locating hole φ50 (1.97) front c1 M12 x 1.25 c3 M12 x 1.25 b3 M12 x 1.25 c2 M12 x 1.25 b2 M10 x 1.25 e1 e2 5.7 Z e4 638 (25.12) e2 631 (24.84) e1 525 (20.67) b2 421 (16.57) c2 e3 627 (24.68) e3 629 (24.76) e4 SE LINE Torque rod mount positions SE LINE 560 (22.05) d1 528 (20.79) d2 497 (19.57) d3 d2 d3 a1 M14 x 1.5 b1 M12 x 1.25 d1 SE LINE 49 (1.93) a1 304 (11.97) b1 307 (12.09) c1 309 (12.17) b3 311 (12.24) c e2 150 (5.91) a2 SE LINE (0.08) a3 [VIEW: Z] 36 (1.42) f a3 M14 x 1.5 a2 M12 x φ11.5 (0.453) e3 e4 e1 f φ110 (4.33) 3 (0.12) g1 g1 4.1 e1 φ74 (2.91) [SETION: ] 4-20

120 g2 h i j1 j2 k1 k2 l1 l2 Front floor locating hole φ25 (0.98) rear Rear floor locating hole φ25 (0.98) front Rear frame locating hole φ20 (0.79) For trailing arm mount φ17 (0.67) outer For trailing arm mount φ17 (0.67) inner For upper arm mount φ14 (0.55) front For upper arm mount φ14 (0.55) rear Rear spring upper seat φ5 (0.20) For rear damper mount φ24 (0.94) m1 m2 m3 n1 n2 o p For lower arm mount φ13.8 (0.543) front Lower arm center point For lower arm mount φ13 (0.51) rear Rear floor crossmember locating hole φ13 (0.51) right Rear floor crossmember locating hole φ15 (0.59) left Rear frame locating hole φ25 (0.98) Rear floor locating hole φ50 (1.97) rear k2 M12 x l2 k1 M12 x 1.25 l1 n1, n2 i h 533 (20.98) l2 28 (1.10) g2 g2 136 (5.35) h 81 (3.19) i, j1 j1 M12 x (2.80) j2 j2 M12 x (7.76) k1, k2 m3 m2 m1 M12 x (0.012) m1, m2, m3 56 (2.20) n1, n2 175 (6.89) l1 p o 72 (2.83) p 194 (7.64) o 2.9 l2 [SETION: ] 4-21

121 Rust Prevention Sealing reas General 5 2 Engine ompartment, Front Wheelhouse, and Damper Housing 5 3 Dashboard Upper, Dashboard Lower, and Front Floor 5 4 Front Floor and Rear Floor 5 5 Roof Panel, Rear Side Outer Panel, and Rear Panel 5 6 Rear Wheelhouse 5 7 Under Floor, Front 5 8 Under Floor, Rear 5 9 Rust-Preventive Treatments General 5 10 Undercoating reas 5 11 reas to be overed by Internal nti-rust gents 5 14

122 Sealing reas General NOTE: Follow the sealant manufacturer's instructions, and apply the sealer. Note the following items: lean the areas to be sealed with wax and grease remover. Wipe off any excess spot sealant with thinner. fter the primer is sprayed, sealant will fill the area where the spot sealant was wiped. Make sure you can see the sealant when the sealed part is in its proper location. For the details, refer to these diagrams: Engine compartment, front wheelhouse, and damper housing (see page 5-3) Dashboard upper, dashboard lower, and front floor (see page 5-4) Front floor and rear floor (see page 5-5) Roof panel, rear side outer panel, and rear panel (see page 5-6) Rear wheelhouse (see page 5-7) Under floor, front (see page 5-8) Under floor, rear (see page 5-9) When applying sealant to the engine compartment, the door opening, and the rear gutter, try to match the appearance of the factory sealant. Wipe off any excess sealant. pply sealant to any area that a replacement part will cover. Smooth the sealant with a brush if necessary. 5-2

123 Engine ompartment, Front Wheelhouse, and Damper Housing FRONT WHEELHOUSE DSHORD LOWER ROSSMEMER JOINT OVER ROSSMEMER EXTENSION DSHORD UPPER DMPER SE DMPER HOUSING FRONT DMPER EXTENSION [X] MISSION MOUNT RKET [VIEW: X] TORQUE ROD RKET FRONT WHEELHOUSE DMPER HOUSING ENTER FRME EXTENSION DMPER SE SUFRME MIDDLE RKET FRONT SIDE FRME INNER LOWER PILLR KPLTE OUTER PNEL DMPER HOUSING STIFFENER [VIEW: Z] DMPER HOUSING DSHORD LOWER DMPER HOUSING STIFFENER [Z] RER OUTRIGGER DMPER HOUSING EXTENSION FRONT OUTRIGGER SUFRME RER RKET RER OUTRIGGER FRONT FLOOR FRME EXTENSION 5-3

124 Sealing reas Dashboard Upper, Dashboard Lower, and Front Floor OUTER PNEL DSHORD SIDE MEMER EXTENSION INNER UPPER PILLR WINDSHIELD LOWER INNER UPPER PILLR WINDSHIELD LOWER INNER LOWER PILLR [Z] DSHORD LOWER [Y] INSIDE SILL FRONT FLOOR RIGHT FRONT FLOOR LEFT INNER UPPER PILLR ENTER TUNNEL DSHORD UPPER DSHORD UPPER SIDE FRME SIDE MEMER WINDSHIELD MEMER EXTENSION EXTENSION WINDSHIELD LOWER LOWER [VIEW: Z] [VIEW: Y] INNER UPPER PILLR INNER LOWER PILLR INNER LOWER PILLR DSHORD LOWER EXTENSION DSHORD LOWER DSHORD LOWER 5-4

125 Front Floor and Rear Floor [DETIL: ] RER INSIDE EXTENSION RER WHEELHOUSE SIDE SILL EXTENSION [] 35 mm (1.38 in) INSIDE SILL SIDE SILL EXTENSION RER FLOOR SIDE STIFFENER FRONT FRONT FLOOR RIGHT [DETIL: ] 87 mm (3.43 in) ENTER TUNNEL FRME OUTER PNEL RER PNEL FRONT FLOOR LEFT [] RER FLOOR SIDE STIFFENER FRONT MIDDLE FLOOR ROSSMEMER STIFFENER RER FLOOR RER WHEELHOUSE 50 mm (1.97 in) RER PNEL REER PNEL GUSSET 136 mm (5.35 in) RER WHEELHOUSE RER FLOOR RER FLOOR SIDE STIFFENER RER RER FLOOR SIDE STIFFENER FRONT RER FLOOR RER FLOOR SIDE STIFFENER MIDDLE RER FLOOR SIDE STIFFENER RER 5-5

126 Sealing reas Roof Panel, Rear Side Outer Panel, and Rear Panel ROOF PNEL [VIEW: X] OUTER PNEL OUTER PNEL RER SHELF RER GUTTER FRONT EXTENSION RER OMINTION DPTER [VIEW: Y] OUTER PNEL RER GUTTER UPPER [X] FUEL FILL DOOR HINGE [Y] RER GUTTER UPPER EXTENSION RER PNEL RER INNER PNEL [VIEW:Z] OUTER PNEL RER PNEL [Z] RER FLOOR 38 mm (1.50 in) RER JK-UP STIFFENER 5-6

127 Rear Wheelhouse Left side RER DMPER STIFFENER EXTENSION RER WHEELHOUSE RER DMPER SE RER INNER PNEL HOLE φ7mm (0.28 in ) 13 mm (0.51 in) 23 mm (0.91 in) [Z] 20 mm (0.79 in) RER INNER PNEL [VIEW:Z] RER FRME RER FRME STIFFENER RER FRME Right side RER INNER PNEL RER DMPER SE STIFFENER RER DMPER SE RER WHEEL RH EXTENSION OUTER PNEL SIDE SILL EXTENSION SIDE SILL EXTENSION END FLNGE RER WHEELHOUSE 5-7

128 Sealing reas Under Floor, Front RER OUTRIGGER FRONT FLOOR FRME EXTENSION FRONT FLOOR FRME INSIDE SILL FRONT SET OUTSIDE RKET INSIDE SILL END PTH MIDDLE FLOOR ROSSMEMER SUFRME RER RKET FRONT FLOOR LEFT ENTER FRME EXTENSION ENTER TUNNEL FRME DSHORD LOWER FRONT FLOOR RIGHT FLOOR ENTER ROSSMEMER RER OUTRIGGER Right side FRONT OUTRIGGER DSHORD LOWER Left side FRONT OUTRIGGER SUFRME MIDDLE RKET ENTER FRME EXTENSION RER OUTRIGGER SUFRME RER RKET FRONT FLOOR FRME SUFRME RER RKET INSIDE SILL FRONT FLOOR RIGHT FRONT FLOOR FRME EXTENSION FRONT FLOOR FRME EXTENSION FRONT FLOOR LEFT INSIDE SILL 5-8

129 Under Floor, Rear RER FRME RER FLOOR SIDE STIFFENER FRONT RER UPPER RM RKET RER FLOOR ROSSMEMER EXTENSION RER FLOOR SIDE STIFFENER RER RER FRME RER FRME EXTENSION [Y] [X] RER FLOOR RER FLOOR FUEL TNK ND RKET 125 mm (4.92 in) RER JK-UP STIFFENER MIDDLE FLOOR ROSSMEMER RER FLOOR ROSSMEMER RER FLOOR ROSSMEMER [VIEW: Y] EXTENSION [VIEW: X] RER FLOOR RER UPPER RM RKET FUEL TNK RKET RER FLOOR ROSSMEMER LOWER RM RKET RER STILIZER RKET LOWER RM RKET RER FLOOR ROSSMEMER 5-9

130 Rust-Preventive Treatments General Undercoat nti-rust gents Wear goggles or safety glasses to prevent eye injury. Ventilate when spraying undercoat. NOTE: Mask the exhaust system, the oxygen sensors, and the suspension mounting areas to protect them from undercoat overspray. Follow the undercoating manufacturer's instructions. lean the body with wax and grease remover before the undercoat is sprayed. pply the undercoat to the front wheelhouse, the rear wheelhouse, and the undersides of the front and rear floors; refer to undercoating areas (see page 5-11). oat the bottom of the fuel tank. nti-rust agents contain substances that are harmful if you breathe or swallow them, or get them on your skin. Wear coveralls, gloves, eye protection, and an approved respirator while using such agents. Ventilate when spraying an anti-rust agent as it contains a small amount of organic solvent. Keep sparks, flames and cigarettes away. NOTE: Do not spray an anti-rust agent on the brake system components, exhaust system components and related parts, emission control devices in the engine compartment, ball joint covers, the fuel strainer, or exterior and interior parts. Wipe the excess agent with a clean rag dampened with light oil. Follow the anti-rust agent manufacturer's instructions. efore applying an anti-rust agent, thoroughly clean the area to be coated with a steam cleaner, etc., and let it dry. Waxoyl may be applied to a wet surface. pply the anti-rust agent from the installation holes and the access holes to parts in the outer panels and the frame (see page 5-14). Spray the anti-rust agent sufficiently until the excess amount oozes out when filling the side sill. 5-10

131 Undercoating reas 1. pply the undercoat to the areas shown. NOTE: oating thickness: 0.4 mm (0.016 in) min. Front wheelhouse and dashboard lower coating thickness 0.5 mm (0.020 in). : Indicates undercoating areas. Unit: mm (in) FRONT WHEELHOUSE FRONT FENDER RER OUTRIGGER 155 (6.10) FRONT FLOOR OUTER PNEL RER FLOOR JK-UP STIFFENER 45 (1.77) ENTER FRME EXTENSION 35 (1.38) 165 (6.50) 84 (3.31) 236 (9.29) 30 (1.18) 30 (1.18) 40 (1.57) FLOOR ENTER ROSSMEMER ENTER TUNNEL FRME 40 (1.57) 40 (1.57) 50 (1.97) [SIDE SILL SETION] FRONT FLOOR Round end point Round end point bout 36 (1.12) oating area INSIDE SILL OUTER PNEL Gradation coating area 0.3 (0.012) to 0 [RER FLOOR SETION] Round end points JK-UP STIFFENER RER FRME RER FLOOR oating areas (cont'd) 5-11

132 Rust-Preventive Treatments Undercoating reas (cont'd) : Indicates undercoating areas. Unit: mm (in) [FRONT WHEELHOUSE] FRONT WHEELHOUSE DMPER HOUSING DMPER HOUSING EXTENSION DSHORD LOWER RER OUTRIGGER 30 (1.18) FRONT OUTRIGGER SUFRME RER RKET [FRONT WHEELHOUSE SETION] DMPER SE DMPER HOUSING oating areas DMPER EXTENSION FRONT SIDE FRME 5-12

133 2. Spray the soundproof coating on the areas shown. NOTE: oating thickness: Wet 1.3 mm (0.051 in) min. Unit: mm (in) : Indicates soundproof coat coating areas. FRONT FENDER RER OUTRIGGER OUTER PNEL RER WHEELHOUSE INSIDE SILL INSIDE SILL EXTENSION RER FRME [X] [SIDE SILL SETION] Left side rear wheelhouse INSIDE SILL FRONT FLOOR SIDE SILL REINFOREMENT Front 240 (9.45) 230 (9.06) OUTER PNEL [Z] [Z]: Overlap soundproof coating with undercoat 10 (0.39). oating area [Z] [VIEW: X] OUTER PNEL RER INNER PNEL 32 (1.26) Right side rear wheelhouse INSIDE SILL 230 (9.06) 260 (10.24) Front JK-UP SE OUTER PNEL RER FLOOR SIDE STIFFENER RER 32 (1.26) 16 (0.63) 5-13

134 Rust-Preventive Treatments reas to be overed by Internal nti-rust gents : Indicates anti-rust agents. TRUNK LID HOOD HOOD HINGE RER FRME RER SET ELT NHOR RER FLOOR ROSSMEMER EXTENSION FRONT SET OUTSIDE RKET FRONT FLOOR FRME MIDDLE FLOOR ROSSMEMER RER FLOOR ROSSMEMER/ LOWER RM RKET RER JK-UP STIFFENER RER FRME DSHORD UPPER FRONT SIDE FRME FUEL FILL DOOR SIDE SILL EXTENSION RER WHEEL RH DSHORD LOWER ROSSMEMER ULKHED LOWER ROSSMEMER ENTER FRME EXTENSION MISSION MOUNTING RKET SIDE SILL ENTER TUNNEL FRME RER OUTRIGGER/ FRONT FLOOR FRME EXTENSION FRONT DMPER EXTENSION RER DOOR RER DOOR HINGE FRONT DOOR FRONT FENDER FRONT DOOR HINGE 5-14