FOREWORD

This repair manual has been prepared to provide essential in-

formation on body panel repair methods (including cutting and
welding operations, but excluding painting) for the TOYOTA
CAMRY.

Applicable models: ACV 40 series

GSV 40 series

This manual consists of body repair methods, exploded dia-

grams and illustrations of the body components and other in-
formation relating to body panel replacement such as handling
precautions, etc. However, it should be noted that the front fend-
ers of this TOYOTA model are bolted on and require no welding.

When repairing, don’t cut and join areas that are not shown in
this manual. Only work on the specified contents to maintain
body strength.

Body construction will sometimes differ depending on specifica-

tions and country of destination. Therefore, please keep in mind
that the information contained herein is based on vehicles for
general destinations.

For the repair procedures and specifications other than collision-

damaged body components of the TOYOTA CAMRY refer to the
repair manuals.

If you require the above manuals, please contact your TOYOTA

dealer.

All information contained in this manual is the most up-to-date at

the time of publication. However, specifications and procedures
are subject to change without prior notice.
ABOUT THIS MANUAL
Scope of the repair work explanation

This text explains the welding panel replacement instructions from the vehicle’s white body condi-
tion. We have abbreviated the explanations of the removal and reinstallation of the equipment parts
up to the white body condition and of the installation, inspection, adjustment and final inspection of
equipment parts after replacing the weld panel.
Section categories

This manual has been divided as shown below.
Section Title Contents Examples
Explanation of general body repair. Cautionary items.
INTRODUCTION
Views of weld panel replacement instructions. Views of weld panel replacement instructions.
Instructions for replacing the weld panels Front side member replacement.
from the white body condition, from which Quarter panel replacement.
BODY PANEL REPLACEMENT
bolted parts have been removed, with
individual supply parts.
BODY DIMENSIONS Body aligning measurements. Dimension diagrams.
Scope and type of anti-rust treatment, etc. Under coating.
PAINT
COATING
together with weld panel replacement. Body sealer.

Contents omitted in this manual.

Make sure to perform the following essential procedures, although they are omitted in this manual.
(1) Clean and wash removed parts, if necessary.
(2) Visual inspection.
 INTRODUCTION IN-1

PRECAUTION
GENERAL REPAIR INSTRUCTIONS
1. WORK PRECAUTIONS
(a) VEHICLE PROTECTION
Glass Cover
(1) When welding, protect the painted surfaces, windows,
seats and carpet with heat resistant, fireproof covers.

Seat Cover

F33000

(b) SAFETY
(1) Never stand in a direct line with the chain when using a
puller on the body or frame, and be sure to attach a
safety cable.

WRONG
F33001

(2) Before performing repair work, check for fuel leaks.

If a leak is found, be sure to close the opening com-
pletely.
(3) If it is necessary to use a flame in the area of the fuel
tank, first remove the tank and plug the fuel line.

WRONG F33002

(c) SAFETY WORK CLOTHES

(1) In addition to the usual mechanic’s wear, cap and
safety shoes, the appropriate gloves, head protector,
glasses, ear plugs, face protector, dust-prevention
mask, etc. should be worn as the situation demands.
Code Name
A Dust-Prevention Mask
B Face Protector
F33003 C Eye Protector
D Safety Shoes
E Welder’s Glasses
F Ear Plugs
G Head Protector
H Welder’s Gloves
IN-2 INTRODUCTION

PRECAUTIONS FOR REPAIRING BODY

STRUCTURE PANELS

1. HEAT REPAIR FOR BODY STRUCTURE

PANELS
Toyota prohibits the use of the heat repair method on body
structure panels when repairing a vehicle damaged in a col-
lision.
Panels that have high strength and rigidity, as well as a long
life span for the automobile body are in high demand.
At Toyota, in order to fulfill these requirements, we use high
tensile strength steel sheets and rust preventive steel
F33014
sheets on the body. High tensile steel sheets are made with
alloy additives and a special heat treatment in order to im-
prove their strength.
To prevent the occurrence of rust for a long period of time,
the surface of the steel is coated with a zinc alloy.
If body structure parts are heat repaired with an acetylene
torch or other heating source, the crystalline organization of
the steel sheet will change and their strength of the steel
sheet will be reduced. The ability of the body to resist rust is
significantly lowered as well since the rust resistant zinc
coating is destroyed by heat and the steel sheet surface is
oxidized.

2. STRUCTURE PANEL KINKS

A sharp deformation angle on a panel that cannot be re-
turned to its original shape by pulling or hammering is
called a kink.
Structural parts are designed to perform in their original
shape. If parts are deformed in an accident, or if the de-
formed parts are repaired and reused, the parts may be un-
able to perform as intended.
It is necessary to replace the part where the kink has oc-
curred.
F33015
 INTRODUCTION IN-3

3. IMPACT BEAM REPAIR

The impact beam and bracket are necessary and important
parts that help reduce the probability of injury to passen-
gers in side collisions.
For impact beams, we use special high tensile strength
steel.
The high tensile strength steel maintains its special crystal-
line organization by heat treatment or alloy additives.
Structural parts are designed to perform in their original
F33016
shape. If parts are deformed in an accident, or if the de-
formed parts are repaired and reused, the parts may be un-
able to perform as intended.
If the impact beam or bracket is damaged, replace the door
assembly that has the damaged beam.
Also, the bumper reinforcement is a necessary and impor-
tant part that helps reduce the probability of injury to pas-
sengers in front collisions, and for the same reasons ex-
plained above, should be replaced if damaged.

F33017
IN-4 INTRODUCTION

PROPER AND EFFICIENT WORK

PROCEDURES

Body Measument Diagrams 1. REMOVAL

(a) PRE-REMOVAL MEASURING
(1) Before removal or cutting operations, take measure-
ments in accordance with the dimensions diagram. Al-
ways use a puller to straighten a damaged body or
frame.

F33020

Cutting Okay (b) CUTTING AREA

(1) Always cut in a straight line and avoid cutting rein-
forced areas.

Corners

Reinforcement

F33021

(c) PRECAUTIONS FOR DRILLING OR CUTTING

(1) Check behind any area to be drilled or cut to ensure
that there are no hoses, wires, etc., that may be dam-
aged.
HINT: See “Handling Precautions on Related Compo-
nents” on page IN-9.

WRONG F33022

(d) REMOVAL OF ADJACENT COMPONENTS

(1) When removing adjacent components, apply protec-
tive tape to the surrounding body and your tools to pre-
vent damage.
HINT: See “Handling Precautions on Related Compo-
nents” on page IN-9.

F33007
 INTRODUCTION IN-5

2. PREPARATION FOR INSTALLATION

(a) SPOT WELD POINTS
(1) When welding panels with a combined thickness of
Less than over 3 mm (0.12 in.), use a MIG (Metal Inert Gas)
3 mm
welder for plug welding.
HINT: Spot welding does not provide sufficient dura-
bility for panels with a combined thickness of over 3
mm (0.12 in.)
F10011A

(b) APPLICATION OF WELD-THROUGH PRIMER

(SPOT SEALER)
(1) Remove the paint from the portion of the new parts
and body to be welded, and apply weld-through prim-
er.

F33008

(c) MAKING HOLES FOR PLUG WELDING

(1) For areas where a spot welder cannot be used, use a
puncher or drill to make holes for plug welding.
REFERENCE: mm (in.)
Thickness of welded portion Size of plug hole
1.0 (0.04) under ø 5 (0.20) over
1.0 (0.04) − 1.6 (0.06) ø 6.5 (0.26) over
Puncher 1.7 (0.07) − 2.3 (0.09) ø 8 (0.31) over
F33009
2.4 (0.09) over ø 10 (0.39) over

(d) SAFETY PRECAUTIONS FOR ELECTRICAL

COMPONENTS
(1) When welding, there is a danger that electrical compo-
nents will be damaged by the electrical current flowing
through the body.
(2) Before starting work, disconnect the negative terminal
of the battery and ground the welder near the welding
location of the body.
F33023

(e) ROUGH CUTTING OF JOINTS

20 − 30 mm Overlap
Air Saw (1) For joint areas, rough cut the new parts, leaving 20 −
30 mm (0.79 − 1.18 in.) of overlap.

F33024
IN-6 INTRODUCTION

3. INSTALLATION
(a) PRE-WELDING MEASUREMENTS
(1) Always take measurements before installing under-
body or engine components to ensure correct assem-
bly. After installation, confirm proper fit.

F33025

(b) WELDING PRECAUTIONS

(1) The number of welding spots should be as follows.
Spot weld: 1.3 X No. of manufacturer’s spots.
Plug weld: More than No. of manufacturer’s plugs.
(2) Plug welding should be done with a MIG (Metal Inert
Gas) welder. Do not gas weld or braze panels at areas
other than where specified.

WRONG F10017A

(c) POST-WELDING REFINISHING

(1) Always check the welded spots to ensure that they are
secure.
(2) When smoothing out the weld spots with a disc grind-
er, be careful not to grind off too much as this will weak-
en the weld.

CORRECT WRONG
F10018A

Old Spot Locations

(d) SPOT WELD LOCATIONS
(1) Avoid welding over previously welded areas.

New Spot Locations

F33010

(e) SPOT WELDING PRECAUTIONS

(1) The shape of the tip point of the spot welder signifi-
cantly affects the strength of the weld. Therefore,
maintain the tip point in the proper shape, and allow it
to cool after every five or six spots.
(2) Completely remove the paint from the areas to be spot
welded, including the seams and the surfaces that
come in contact with the welding tip.
(3) Use a sander to remove any burrs that are created
Tip Cutter F10019A during spot welding.
 INTRODUCTION IN-7

Sealer Gun 4. ANTI-RUST TREATMENT AFTER

INSTALLATION (BEFORE PAINTING
PROCESS)
(a) BODY SEALER APPLICATION
(1) For water-proofing and anti-corrosion measures, al-
ways apply the body sealer to the body panel seams
and hems of the doors, hood, etc.

F33011

(b) UNDERCOAT APPLICATION

(1) To prevent corrosion and protect the body from dam-
age by flying stones, always apply sufficient under
coating to the bottom surface of the under body and
inside of the wheel housings.

F33012

5. ANTI-RUST TREATMENT AFTER

INSTALLATION (AFTER PAINTING PROCESS)
(a) ANTI-RUST AGENT (WAX) APPLICATION
(1) To preserve impossible to paint areas from corrosion,
always apply sufficient anti-rust agent (wax) to the in-
side of the hemming areas of the doors and hood, and
around the hinges, or the welded surfaces inside the
box-shaped cross sections of the side members, body
pillars, etc.
F33013
IN-8 INTRODUCTION

6. ANTI-RUST TREATMENT BY PAINTING

REFERENCE:
Painting prevents corrosion and protects the sheet
metal from damage. In this section, anti-chipping paint
only for anti-corrosion purposes is described.
(a) ANTI-CHIPPING PAINT
(1) To prevent corrosion and protect the body from dam-
age by flying stones, etc., apply anti-chipping paint to
the rocker panel, wheel arch areas, balance panel,
etc.
HINT:
Depending on the model or the application area, there
are cases where the application of anti-chipping paint
is necessary before the second coat or after the top
coat.

Apply the anti-chipping paint after
Apply the anti-chipping paint before
the top coat. the second coat.

Top Coat
Anti-Chipping Paint
Second Coat
Top Coat
Anti-Chipping Paint
Second Coat
Under Coat (ED Primer) Under Coat (ED Primer)
Steel Metal Steel Metal
F10024A
 INTRODUCTION IN-9

HANDLING PRECAUTIONS ON RELATED COMPONENTS

1. BRAKE SYSTEM
The brake system is one of the most important safety components. Always follow the directions and
notes given in the brake section of the repair manual for the relevant model year when handling brake
system parts.
NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC sys-
tem.
2. DRIVE TRAIN AND CHASSIS
The drive train and chassis are components that can have great effects on the running performance and
vibration resistance of the vehicle. After installing components in the sections listed in the table below,
perform alignments to ensure correct mounting angles and dimensions. Body repair must be particularly
accurate to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Always follow the directions giv-
en in the repair manual for the relevant model year during alignment and in section DI of this section.

Section of repair manual

Component to be aligned
for relevant model
Front Wheels Front Suspension section
Rear Wheels Rear Suspension section

3. COMPONENTS ADJACENT TO THE BODY PANELS

Various types of component parts are mounted directly on or adjacently to the body panels. Strictly ob-
serve the following precautions to prevent damaging these components and the body panels during han-
dling.

Before repairing the body panels, remove their components or apply protective covers over the com-
ponents.

Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components and the body paint.

Before removing components from the outer surface of the body, attach protective tape to the body to
ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.

Before drilling or cutting sections, make sure that there are no wires, etc., on the reverse side.
4. ECU (ELECTRONIC CONTROL UNIT)
Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to the ECUs.

Before starting electric welding operations, disconnect the negative (−) terminal cable from the bat-
tery.
When the negative (−) terminal cable is disconnected from the battery, the memory of the clock and
audio systems will be erased. So, before starting work, make a record of the contents memorized by
each memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seats and outside rear view mirrors, which are
all equipped with a memory function, it is not possible to make a record of the memory contents.
When the operation is finished, it will be necessary to explain this fact to the customer, and request the
customer to adjust the features and reset the memory.

Do not expose the ECUs to ambient temperatures above 80C (176F).
NOTICE: Since it is possible that the ambient temperature may reach 80C (176F) or more, remove
the ECUs from the vehicle before starting work.

Be careful not to drop the ECUs and not to apply physical shocks to them.
IN-10 INTRODUCTION

DAMAGED VEHICLE DISPOSAL PRECAUTION (SRS AIRBAG SYSTEM)

For SRS airbag system adjustment methods, refer to the TOYOTA Repair Manual.
(1) When using an electric welder, first remove all airbags and the seat belt pretensioner.
(2) If impacts are likely to occur to the front airbag sensor, side airbag sensor, rear airbag sensor or seat
position sensor, remove each sensor as necessary beforehand.
(3) Do not allow the front airbag sensor, side airbag sensor, rear airbag sensor or seat position sensor to
become heated to high temperatures.

COMBINATION METER ASSEMBLY: CLOCK ASSEMBLY:

SRS WARNING LIGHT PASSENGER AIRBAG ON / OFF INDICATOR

CURTAIN SHIELD AIRBAG

ASSEMBLY LH

FRONT PASSENGER AIRBAG ASSEMBLY

CURTAIN SHIELD AIRBAG ASSEMBLY RH

FRONT SEAT OUTER

BELT ASSEMBLY RH

DRIVER SIDE KNEE

AIRBAG ASSEMBLY

SPIRAL CABLE

STEERING PAD

CENTER AIRBAG SENSOR ASSEMBLY

FRONT SEAT OUTER BELT ASSEMBLY LH

C123719
 INTRODUCTION IN-11

FRONT SEAT SIDE AIRBAG ASSEMBLY LH

REAR AIRBAG SENSOR RH

REAR AIRBAG SENSOR LH

FRONT SEAT SIDE AIRBAG ASSEMBLY RH

SIDE AIRBAG SENSOR RH

SIDE AIRBAG SENSOR LH

SEAT POSITION SENSOR

FRONT SEAT INNER BELT ASSEMBLY LH

OCCUPANT CLASSIFICATION ECU

FRONT AIRBAG SENSOR LH

FRONT AIRBAG SENSOR RH

C123718
IN-12 INTRODUCTION

HANDLING PRECAUTIONS OF PLASTIC BODY PARTS

1. The repair procedure for plastic body parts must conform with the type of plastic material.
2. Plastic body parts are identified by the codes in the following table.
3. When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, paint-
ing etc.), consideration must be given to the properties of the plastic.

Heat*
Material resistant Resistance to
Code Notes
name temperature alcohol or gasoline
limit
C (
F)

80 Alcohol is harmless if applied only for

Acrylonitrile Avoid gasoline and organic
AAS short time in small amounts (e.g., quick
Acrylic Styrene (176) or aromatic solvents.
wiping to remove grease).

80 Alcohol is harmless if applied only for

Acrylonitrile Avoid gasoline and organic
ABS short time in small amounts (e.g., quick
Butadiene Styrene (176) or aromatic solvents.
wiping to remove grease).

80 Alcohol is harmless if applied only for

Acrylonitrile Avoid gasoline and organic
AES short time in small amounts (e.g., quick
Ethylene Styrene (176) or aromatic solvents.
wiping to remove grease).

Acrylonitrile 80 Alcohol is harmless if applied only for

Avoid gasoline and organic
ASA Styrene short time in small amounts (e.g., quick
(176) or aromatic solvents.
Acrylate wiping to remove grease).

100 Alcohol is harmless. Most solvents are harmless

Ethylene
EPDM Gasoline is harmless if applied only for but avoid dipping in gasoline,
Propylene (212) short time in small amounts. solvents, etc.

Polyamide 80
PA Alcohol and gasoline are harmless. Avoid battery acid.
(Nylon) (176)

Polybutylene 160
PBT Alcohol and gasoline are harmless. Most solvents are harmless.
Terephthalate (320)

120 Avoid gasoline, brake fluid,

PC Polycarbonate Alcohol is harmless. wax, wax removers and
(248) organic solvents. Avoid alkali.

Polyoxymethylene 100
POM Alcohol and gasoline are harmless. Most solvents are harmless.
(Polyacetal) (212)

80
PP Polypropylene Alcohol and gasoline are harmless. Most solvents are harmless.
(176)

80 Avoid dipping or immersing

Polymethyl Alcohol is harmless if applied only for
PMMA in alcohol, gasoline,
Methacrylate (176) short time in small amounts.
solvents, etc.

Alcohol and gasoline are harmless if

80 Avoid dipping or immersing
Polyvinylchloride applied only for short time in small
PVC in alcohol, gasoline,
(Vinyl) (176) amounts (e.g., quick wiping to remove
solvents, etc.
grease).

80 Alcohol is harmless. Most solvents are harmless

Thermoplastic
TPO Gasoline is harmless if applied only for but avoid dipping in gasoline,
Olefine (176) short time in small amounts. solvents, etc.

TOYOTA 80
TSOP Super Alcohol and gasoline are harmless. Most solvents are harmless.
Olefine Polymer (176)

*Temperatures higher than those listed here may result in material deformation during repair.
 INTRODUCTION IN-13

Door Window Frame Moulding (PP)

Emblem (AES)

Front Fender To Cowl Side Seal (PP / EPDM)

Cowl Top Ventilator Louver (PP / TSOP)

Wiper Blade (PBT)

Side Turn
Ex. U.S.A:
Signal Light (ABS / PMMA)

Roof Drip Side Finish Moulding (TPO)

Outer Rear View Mirror (ABS / PA / AES)

Front Door Outside Handle (PC)

Foglight (ASA / PBT) Rear Door Outside Handle (PC)
Headlight (PC/PP)
Radiator Grille (ABS)
Front Bumper Extension Mounting Bracket (TSOP)

Front Bumper Cover (TSOP)

F30269
IN-14 INTRODUCTION

97

Door Belt Moulding (POM / PVC)

Door Window Frame Moulding (ASA)

Luggage Compartment Opening
Emblem (ABS) Door Outside Garnish (TSOP)

Licence Plate Light (PC)

Emblem (TSOP)

Rocker Panel Mounting (TSOP)

Rear Light (ASA / PMMA)

Rear Combination Light (ASA / PMMA)

Rear Bumper (TSOP)

F30269A
 INTRODUCTION IN-15

ABOUT THIS VEHICLE

STRUCTUAL OUTLINE

Laser welding (12points)

Adhesive Application Area

. . . Over 590Mpa High strength steel

. . . Over 440Mpa High strength steel

. . . Formed material application areas (refer to PC-8)

F30267
IN-16 INTRODUCTION

NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP VEHICLE

1. NOTICE FOR USING JACK AND SAFETY STAND

Front

: JACK POSITION

: SUPPORT POSITION,
PANTOGRAPH JACK POSITION

: CENTER OF VEHICLE GRAVITY

(unloaded condition)

D100366
 INTRODUCTION IN-17

2. NOTICE FOR USING SWING ARM TYPE LIFT

Center of Lift

CENTER OF VEHICLE
GRAVITY
(unloaded condition)
Rubber Attachment

D100367

3. NOTICE FOR USING PLATE TYPE LIFT

Attachment Dimensions

85 mm (3.35 in.)

70 mm
Attachment (2.76 in.)

100 mm (3.94 in.)

200 mm (7.87 in.)

HINT:
Right and left set position
Place the vehicle over the center of the lift. mm (in.)
HINT:
Front and left set position
Place the attachments at the ends of the rubber plate surface, under the vehicle lift pad (A and C in the illustration).
Raise the plate slightly and reposition the vehicle so the top of the attachment (B in the illustration) is aligned with the
front side notch in the vehicle rocker flange.
F30268
IN-18 INTRODUCTION

DAMAGE DIAGNOSIS

Confirmation Point Collision Direction Collision Force Absorption Direction

Front Body Pillar

Upper Reinforcement

Rocker Panel Reinforecement

Front Bumper
Reinforcement Front Side Member

Roof Reinforcement

Center Pillar Reinforcement

Floor Cross Member

Front Body Pillar

Reinforcement

F30266
 INTRODUCTION IN-19

COMPORNENTS
1. Front bumper

for 2GR-FE:

COOL AIR IN TAKE DUCT SEAL

RADIATOR GRILLE
PROTECTOR

RADIATOR GRILLE
PROTECTOR

FRONT BUMPER ASSEMBLY

B137228
IN-20 INTRODUCTION

FRONT BUMPER
SIDE RETAINER RH

34 (347, 25)

FRONT BUMPER REINFORCEMENT

SUB-ASSEMBLY
34 (347, 25)
FRONT BUMPER
ENERGY ABSORBER

FRONT BUMPER
SIDE RETAINER LH

CAUTION:
The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision.
N.m (kgf.cm, ft..lbf) : Specified torque
B137743
 INTRODUCTION IN-21

2. Rear bumper

REAR BUMPER
SIDE SUPPORT RH

REAR BUMPER
SIDE RETAINER RH

REAR BUMPER REINFORCEMENT

REAR BUMPER SUB-ASSEMBLY
SIDE RETAINER LH

WHEEL HOUSE REINFORCEMENT RH

68 (693, 50)

REAR BUMPER
SIDE SUPPORT LH 68 (693, 50)

REAR BUMPER BAR

WHEEL HOUSE REINFORCEMENT LH

REAR BUMPER PAD

REAR BUMPER PLATE LH REAR BUMPER ENERGY ABSORBER

REAR BUMPER PAD

REAR BUMPER PLATE RH

CAUTION:
The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision.
N.m (kgf.cm, ft..lbf) : Specified torque
B137225
IN-22 INTRODUCTION

3. Instrument panel
INSTRUMENT PANEL NO. 1
SPEAKER PANEL SUB-ASSEMBLY

INSTRUMENT PANEL NO. 2

SPEAKER PANEL SUB-ASSEMBLY

NO. 1 DEFROSTER NOZZLE GARNISH

for LH Side: for RH Side:

FRONT NO. 2 SPEAKER ASSEMBLY FRONT NO. 2 SPEAKER ASSEMBLY

FRONT PASSENGER
AIRBAG ASSEMBLY

INSTRUMENT PANEL
WIRE ASSEMBLY

INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY

INSTRUMENT PANEL NO. 3 REGISTER ASSEMBLY
FRONT PILLAR GARNISH CLIP FRONT PILLAR GARNISH CLIP

FRONT PILLAR GARNISH RH

FRONT PILLAR GARNISH LH

20 (204, 15)
INSTRUMENT PANEL SAFETY PAD ASSEMBLY
COMBINATION METER ASSEMBLY
without Smart Key System:

LOWER INSTRUMENT PANEL

FINISH PANEL
INSTRUMENT CLUSTER FINISH PANEL
with Smart Key System:

NO. 1 INSTRUMENT PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL

FINISH PANEL

CAUTION:
The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision.
N.m (kgf.cm, ft..lbf) : Specified torque Non-reusable part
B137286
 INTRODUCTION IN-23

TURN SIGNAL SWITCH ASSEMBLY

WITH SPIRAL CABLE SUB-ASSEMBLY

STEERING PAD

2.0 (20, 18 in..lbf)

50 (510, 37)

STEERING COLUMN COVER

STEERING WHEEL ASSEMBLY

LOWER NO. 3 STEERING LOWER NO. 2 STEERING

WHEEL COVER WHEEL COVER

SHIFT LEVER KNOB

SUB-ASSEMBLY 8.8 (90, 78 in..lbf)

FLOOR SHIFT POSITION INSTRUMENT PANEL NO. 2

INDICATOR HOUSING REGISTER ASSEMBLY
SUB-ASSEMBLY

UPPER CONSOLE REAR

PANEL SUB-ASSEMBLY

RADIO RECEIVER WITH HEATER

CONTROL PANEL ASSEMBLY

NO. 1 CONSOLE BOX INSERT FRONT

UPPER CONSOLE PANEL SUB-ASSEMBLY

NO. 2 INSTRUMENT CLUSTER

FINISH PANEL GARNISH

NO. 1 INSTRUMENT
CLUSTER FINISH
PANEL GARNISH
NO. 2 CONSOLE BOX INSERT FRONT

17.5 (179, 13) CONSOLE BOX CARPET

CENTER AIRBAG
SENSOR ASSEMBLY

CONSOLE BOX POCKET CONSOLE BOX ASSEMBLY

CAUTION:
The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision.
N.m (kgf.cm, ft..lbf) : Specified torque
B137285
IN-24 INTRODUCTION

with Plasmacluster: NO. 3 INSTRUMENT PANEL STAY

GLOVE BOX LIGHT ASSEMBLY

DEFROSTER NOZZLE
ASSEMBLY
PLASMACLUSTER

NO. 2 HEATER TO REGISTER DUCT

SIDE NO. 2 DEFROSTER
NOZZLE DUCT

SIDE NO. 1 DEFROSTER

NOZZLE DUCT
NO. 3 HEATER TO
REGISTER DUCT

NO. 1 HEATER TO REGISTER DUCT

with Navigation System: NO. 2 ANTENNA CORD

SUB-ASSEMBLY

7.0 (71, 62 in..lbf)

NAVIGATION ANTENNA ASSEMBLY

LOWER INSTRUMENT PANEL SUB-ASSEMBLY

INSTRUMENT PANEL NO. 2

UNDER COVER SUB-ASSEMBLY

LOWER INSTRUMENT PANEL FINISH PANEL LH

COWL SIDE TRIM SUB-ASSEMBLY RH

COWL SIDE TRIM CLIP

FRONT DOOR SCUFF PLATE RH

CAUTION:
The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision.
N.m (kgf.cm, ft..lbf) : Specified torque
B137288
 INTRODUCTION IN-25

4. Interior trim

UPPER CENTER PILLAR GARNISH

REAR DOOR OPENING

TRIM WEATHERSTRIP

FRONT DOOR OPENING

TRIM WEATHERSTRIP

ROOF SIDE INNER GARNISH LH

REAR DOOR SCUFF PLATE
LOWER CENTER PILLAR GARNISH

42 (428, 31)

42 (428, 31) FRONT SHOULDER BELT ANCHOR

ADJUSTER ASSEMBLY
FRONT DOOR SCUFF PLATE
for Reclining Seat Type:

42 (428, 31)
FRONT SEAT OUTER BELT ASSEMBLY

7.5 (77, 66 in..lbf)

18 (184, 13)

42 (428, 31)
LAP BELT OUTER ANCHOR COVER

42 (428, 31) RECLINING REMOTE CONTROL

LEVER SUB-ASSEMBLY LH

CAUTION:
The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision.
N.m (kgf.cm, ft..lbf) : Specified torque
B132005
IN-26 INTRODUCTION

for Reclining Seat Type:

PACKAGE TRAY TRIM PANEL ASSEMBLY PACKAGE TRAY TRIM PANEL ASSEMBLY

REAR SEAT SHOULDER BELT COVER

CHILD RESTRAINT SEAT ANCHOR

BRACKET SUB-ASSEMBLY RH

REAR SEAT OUTER

BELT ASSEMBLY REAR SEAT SHOULDER BELT COVER

42 (428, 31)
18 (184, 13)

REAR SEAT SHOULDER

BELT HOLE COVER

18 (184, 13)
42 (428, 31) CHILD RESTRAINT SEAT
ANCHOR BRACKET
SUB-ASSEMBLY LH
42 (428, 31)

42 (428, 31)

REAR SEAT INNER WITH

REAR SEAT INNER WITH
CENTER BELT ASSEMBLY RH
CENTER BELT ASSEMBLY LH REAR SEAT OUTER
BELT ASSEMBLY
for Fold Down Seat Type:

42 (428, 31)

CHILD RESTRAINT SEAT ANCHOR 18 (184, 13)

BRACKET SUB-ASSEMBLY RH

CHILD RESTRAINT SEAT ANCHOR

BRACKET SUB-ASSEMBLY LH

CAUTION:
The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision.
N.m (kgf.cm, ft..lbf) : Specified torque
B132019
 INTRODUCTION IN-27

without Sliding Roof:

REAR ASSIST GRIP SUB-ASSEMBLY

FRONT ASSIST GRIP

SUB-ASSEMBLY ASSIST GRIP COVER

ASSIST GRIP COVER

ROOF HEADLINING ASSEMBLY

REAR ASSIST GRIP SUB-ASSEMBLY

NO. 1 ROOM LIGHT ASSEMBLY

LENS COVER

VISOR BRACKET COVER

FRONT ASSIST GRIP SUB-ASSEMBLY ASSIST GRIP COVER

VISOR ASSEMBLY RH

VISOR HOLDER
ASSIST GRIP COVER
ROOF CONSOLE BOX ASSEMBLY

VISOR ASSEMBLY LH

VISOR HOLDER VISOR BRACKET COVER

B132051
IN-28 INTRODUCTION

with Sliding Roof:

REAR ASSIST GRIP
FRONT ASSIST GRIP SUB-ASSEMBLY
SUB-ASSEMBLY

ASSIST GRIP COVER

ASSIST GRIP COVER

ROOF HEADLINING ASSEMBLY

with Rear Sunshade:

SUNSHADE TRIM HOLDER

SPOT LIGHT ASSEMBLY

VISOR BRACKET COVER

REAR ASSIST GRIP SUB-ASSEMBLY
VISOR ASSEMBLY RH
ASSIST GRIP COVER
ROOF CONSOLE
BOX ASSEMBLY FRONT ASSIST GRIP
SUB-ASSEMBLY

ASSIST GRIP COVER

VISOR HOLDER

VISOR ASSEMBLY LH

VISOR BRACKET COVER

VISOR HOLDER

SUN ROOF OPENING TRIM MOULDING

B132052
 INTRODUCTION IN-29

5. Front seat

for Manual Seat:

FRONT SEAT HEADREST ASSEMBLY

42 (428, 31)

INNER SEAT TRACK

BRACKET COVER

FRONT SEAT INNER

BELT ASSEMBLY

37 (377, 27)

SEAT TRACK COVER

37 (377, 27)

FRONT SEAT ASSEMBLY

for Power Seat:

FRONT SEAT HEADREST ASSEMBLY

37 (377, 27)

INNER SEAT TRACK

BRACKET COVER

FRONT SEAT INNER

BELT ASSEMBLY
37 (377, 27)

SEAT TRACK COVER

37 (377, 27)

FRONT SEAT ASSEMBLY

CAUTION:
The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision.
N.m (kgf.cm, ft..lbf) : Specified torque
B132031
IN-30 INTRODUCTION

6. Rear seat

for Fixed Seat Type:

REAR SEAT HEADREST ASSEMBLY

REAR CENTER SEAT

HEADREST ASSEMBLY

REAR SEAT BACK ASSEMBLY

18 (184, 13)

18 (184, 13)

REAR SEAT CUSHION ASSEMBLY

CAUTION:
The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision.
N.m (kgf.cm, ft..lbf) : Specified torque
B136589
 INTRODUCTION IN-31

for Fold Down Seat Type:

REAR SEAT HEADREST ASSEMBLY

REAR CENTER SEAT

HEADREST ASSEMBLY

18 (184, 13)

18 (184, 13)

18 (184, 13)

REAR SIDE SEAT

BACK ASSEMBLY RH

SEPARATE TYPE REAR

SEAT BACK ASSEMBLY RH

SEPARATE TYPE REAR

SEAT BACK ASSEMBLY LH

18 (184, 13)
REAR SEAT CUSHION ASSEMBLY

REAR SIDE SEAT

BACK ASSEMBLY LH

CAUTION:
The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision.
N.m (kgf.cm, ft..lbf) : Specified torque
B135415
IN-32 INTRODUCTION

for Reclining Seat Type:

REAR SEAT HEADREST ASSEMBLY

18 (184, 13)
REAR CENTER SEAT
HEADREST ASSEMBLY

CENTER SEAT BACK

REAR SEAT ASSEMBLY
BACK COVER

18 (184, 13)

18 (184, 13)

18 (184, 13)
REAR SEAT
SEPARATE TYPE REAR SEAT BACK BACK COVER
ASSEMBLY RH

18 (184, 13)

SEPARATE TYPE REAR

SEAT BACK ASSEMBLY LH
REAR SEAT CUSHION ASSEMBLY

CAUTION:
The bolts and nuts must be tightened to the torque specification, as they are related to vehicle safety during a collision.
N.m (kgf.cm, ft..lbf) : Specified torque
B139095
 INTRODUCTION IN-33

WHEEL ALIGNMENT STANDARD

1. FRONT WHEEL ALIGNMENT

Standard vehicle height:

for USA and Canada:

Model Front A − B Rear C − D

ACV40L-CEAGKA 125 mm (4.92 in.) 54 mm (2.13 in.)
GSV40L-CETGKA 126 mm (4.96 in.) 55 mm (2.17 in.)
ACV40L-AEAGKA 125 mm (4.92 in.) 53 mm (2.09 in.)
GSV40L-AETGKA 126 mm (4.96 in.) 54 mm (2.13 in.)
ACV40L-CEANKA 125 mm (4.92 in.) 54 mm (2.13 in.)
ACV40L-CEMNKA 125 mm (4.92 in.) 53 mm (2.09 in.)
GSV40L-CETNKA 126 mm (4.96 in.) 55 mm (2.17 in.)
ACV40L-AEANKA 125 mm (4.92 in.) 53 mm (2.09 in.)
ACV40L-AEMNKA 125 mm (4.92 in.) 52 mm (2.05 in.)
GSV40L-AETNKA 126 mm (4.96 in.) 54 mm (2.13 in.)
ACV40L-CEASKA 128 mm (5.04 in.) 57 mm (2.24 in.)
ACV40L-CEMSKA 127 mm (5.00 in.) 55 mm (2.17 in.)
GSV40L-CETSKA 129 mm (5.08 in.) 58 mm (2.28 in.)
C132408
for Mexico:

Model Front A − B Rear C − D

ACV40L-CEAGKA 115 mm (4.53 in.) 40 mm (1.57 in.)
GSV40L-CETGKA 116 mm (4.57 in.) 41 mm (1.61 in.)
ACV40L-CEANKA 115 mm (4.53 in.) 40 mm (1.57 in.)

for General export:

Model Front A − B Rear C − D

ACV40L-AEANKW 115 mm (4.53 in.) 38 mm (1.50 in.)
ACV40R-AEANKW 115 mm (4.53 in.) 38 mm (1.50 in.)
ACV40L-AEMNKW 117 mm (4.61 in.) 42 mm (1.65 in.)
ACV40R-AEMNKW 117 mm (4.61 in.) 42 mm (1.65 in.)
GSV40L-AETGKW 117 mm (4.61 in.) 42 mm (1.65 in.)
GSV40R-AETGKW 117 mm (4.61 in.) 42 mm (1.65 in.)
IN-34 INTRODUCTION

Standard wheel angle:

for USA and Canada:

Outside wheel
Model Inside wheel
(reference) Front
ACV40L-CEAGKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
)
GSV40L-CETGKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
)
ACV40L-AEAGKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
) A: Inside
B: Outside
GSV40L-AETGKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
)
ACV40L-CEANKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
)
ACV40L-CEMNKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
) C132439
GSV40L-CETNKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
)
ACV40L-AEANKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
)
ACV40L-AEMNKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
)
GSV40L-AETNKA 38
22’ +−2
(38.37
+−2
) 33
33’ (33.55
)
ACV40L-CEASKA 38
42’ +−2
(38.70
+−2
) 33
46’ (33.77
)
ACV40L-CEMSKA 38
42’ +−2
(38.70
+−2
) 33
46’ (33.77
)
GSV40L-CETSKA 38
18’ +−2
(38.30
+−2
) 33
32’ (33.53
)

for Mexico:

Outside wheel
Model Inside wheel
(reference)
ACV40L-CEAGKA 38
18’ +−2
(38.30
+−2
) 33
41’ (33.68
)
GSV40L-CETGKA 38
18’ +−2
(38.30
+−2
) 33
41’ (33.68
)
ACV40L-CEANKA 38
18’ +−2
(38.30
+−2
) 33
41’ (33.68
)

for General export:

Outside wheel
Model Inside wheel
(reference)
for General
38
42’ +−2
(38.70
+− 2
) 33
46’ (33.77
)
export
 INTRODUCTION IN-35

Standard camber inclination:

for USA and Canada: Alignment Tester

Gauge
Right-left
Model Camber
difference
ACV40L-CEAGKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less
GSV40L-CETGKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less
ACV40L-AEAGKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less
GSV40L-AETGKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less
ACV40L-CEANKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less
ACV40L-CEMNKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less
C132440
GSV40L-CETNKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less
ACV40L-AEANKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less
ACV40L-AEMNKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less
GSV40L-AETNKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less
ACV40L-CEASKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less
ACV40L-CEMSKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less
GSV40L-CETSKA −0
40’ +−45’ (−0.67
+−0.75
) 45’ (0.75
) or less

for Mexico:
Right-left
Model Camber
difference
ACV40L-CEAGKA −0
35’ +−45’ (−0.58
+−0.75
) 45’ (0.75
) or less
GSV40L-CETGKA −0
35’ +−45’ (−0.58
+−0.75
) 45’ (0.75
) or less
ACV40L-CEANKA −0
35’ +−45’ (−0.58
+−0.75
) 45’ (0.75
) or less

for General export:

Right-left
Model Camber
difference
for General
−0
30’ +−45’ (−0.50
+− 0.75
) 45’ (0.75
) or less
export
IN-36 INTRODUCTION

Standard caster inclination:

for USA and Canada:

Right-left
Model Caster
difference
ACV40L-CEAGKA 3
00’ +−45’ (3.00
+−0.75
) 45’ (0.75
) or less
GSV40L-CETGKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less
ACV40L-AEAGKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less
GSV40L-AETGKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less
ACV40L-CEANKA 3
00’ +−45’ (3.00
+−0.75
) 45’ (0.75
) or less
ACV40L-CEMNKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less
GSV40L-CETNKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less
ACV40L-AEANKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less
ACV40L-AEMNKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less
GSV40L-AETNKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less
ACV40L-CEASKA 3
00’ +−45’ (3.00
+−0.75
) 45’ (0.75
) or less
ACV40L-CEMSKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less
GSV40L-CETSKA 2
55’ +−45’ (2.92
+−0.75
) 45’ (0.75
) or less

for Mexico:
Right-left
Model Caster
difference
ACV40L-CEAGKA 2
45’ +−45’ (2.75
+−0.75
) 45’ (0.75
) or less
GSV40L-CETGKA 2
40’ +−45’ (2.67
+−0.75
) 45’ (0.75
) or less
ACV40L-CEANKA 2
45’ +−45’ (2.75
+−0.75
) 45’ (0.75
) or less

for General export:

Right-left
Model Caster
difference
for General
2
40’ +− 45’ (2.67
+− 0.75
) 45’ (0.75
) or less
export
 INTRODUCTION IN-37

Steering axis inclination:

for USA and Canada:

Right-left
Model Steering axis inclination
difference
ACV40L-CEAGKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less
GSV40L-CETGKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less
ACV40L-AEAGKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less
GSV40L-AETGKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less
ACV40L-CEANKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less
ACV40L-CEMNKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less
GSV40L-CETNKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less
ACV40L-AEANKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less
ACV40L-AEMNKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less
GSV40L-AETNKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less
ACV40L-CEASKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less
ACV40L-CEMSKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less
GSV40L-CETSKA 12
15’ +−45’ (12.25
+−0.75
) 45’ (0.75
) or less

for Mexico:
Right-left
Model Steering axis inclination
difference
ACV40L-CEAGKA 12
00’ +−45’ (12.00
+−0.75
) 45’ (0.75
) or less
GSV40L-CETGKA 12
00’ +−45’ (12.00
+−0.75
) 45’ (0.75
) or less
ACV40L-CEANKA 12
00’ +−45’ (12.00
+−0.75
) 45’ (0.75
) or less

for General export:

Right-left
Model Steering axis inclination
difference
for General
12
00’ +− 45’ (12.00
+− 0.75
) 45’ (0.75
) or less
export
IN-38 INTRODUCTION

Standard Toe-in (total):

A − B: 0 +− 2 mm (0 +− 0.08 in.) Dimension A

Front

C125226

Dimension B

Tread Center
Marks

C125225

2. REAR WHEEL ALIGNMENT

Standard toe-in:

Toe−in (total) — Front

A + B: 0
+− 24’ (0
+− 0.4
)

C − D: 4 +− 2 mm (0.16 +− 0.08 in.)

C132438
 INTRODUCTION IN-39

Standard camber:

for USA and Canada:

Right-left
Model Camber
difference
ACV40L-CEAGKA −1
18’ +−45’ (−1.30
+−0.75
) 45’ (0.75
) or less
GSV40L-CETGKA −1
18’ +−45’ (−1.30
+−0.75
) 45’ (0.75
) or less
ACV40L-AEAGKA −1
15’ +−45’ (−1.25
+−0.75
) 45’ (0.75
) or less
GSV40L-AETGKA −1
15’ +−45’ (−1.25
+−0.75
) 45’ (0.75
) or less
ACV40L-CEANKA −1
18’ +−45’ (−1.30
+−0.75
) 45’ (0.75
) or less
ACV40L-CEMNKA −1
18’ +−45’ (−1.30
+−0.75
) 45’ (0.75
) or less
GSV40L-CETNKA −1
18’ +−45’ (−1.30
+−0.75
) 45’ (0.75
) or less
ACV40L-AEANKA −1
15’ +−45’ (−1.25
+−0.75
) 45’ (0.75
) or less
ACV40L-AEMNKA −1
15’ +−45’ (−1.25
+−0.75
) 45’ (0.75
) or less
GSV40L-AETNKA −1
15’ +−45’ (−1.25
+−0.75
) 45’ (0.75
) or less
ACV40L-CEASKA −1
18’ +−45’ (−1.30
+−0.75
) 45’ (0.75
) or less
ACV40L-CEMSKA −1
18’ +−45’ (−1.30
+−0.75
) 45’ (0.75
) or less
GSV40L-CETSKA −1
18’ +−45’ (−1.30
+−0.75
) 45’ (0.75
) or less

for Mexico:
Right-left
Model Camber
difference
ACV40L-CEAGKA −1
06’ +−45’ (−1.10
+−0.75
) 45’ (0.75
) or less
GSV40L-CETGKA −1
06’ +−45’ (−1.10
+−0.75
) 45’ (0.75
) or less
ACV40L-CEANKA −1
06’ +−45’ (−1.10
+−0.75
) 45’ (0.75
) or less

for General export:

Right-left
Model Camber
difference
for General
−1
00’ +−45’ (−1.00
+−0.75
) 45’ (0.75
) or less
export
IN-40 INTRODUCTION

HOW TO USE THIS MANUAL

1. BODY PANEL REPLACEMENT THIS MANUAL

BODY PANEL REPLACEMENT BP-34

QUARTER PANEL (CUT)

With the body lower back panel removed.

Symbol meaning
: Remove Weld Points : Cut and Join Location
: Cut Location for Supply Parts

REMOVAL

Fuel Filler Opening Lid

150
(5.91)

40
(1.57)
150
(5.91)

mm (in.)

REMOVAL POINT
1. Remove the Fuel Filler Opening Lid at the same time.

REPLACEMENT PART AND METHOD INSTALLATION OF WELD POINTS

QUARTER PANEL (CUT) Weld method and panel position
symbols (See page IN-44)
Replacement method
(ASSY)...Assembly replacement SYMBOLS (See page IN-42)
(CUT)...Major cutting (less than 1/2 of part used)
(CUT-H)...Half cutting (about 1/2 of part used)
(CUT-P)...Partial cutting (most of part used)
Replacement part

PART LOCATION
REMOVAL CONDITIONS
SYMBOL MEANING
REMOVAL DIAGRAM
Describes in detail the removal of the damaged part involving repair by cutting.
REMOVAL GUIDE
Provides additional information to more efficiently help you perform the removal.
F33027
 INTRODUCTION IN-41

BP-36 BODY PANEL REPLACEMENT

Symbol meaning
: Mig Plug Weld : Spot Weld
: Body Sealer : Butt Weld

INSTALLATION

Fuel Filler Opening Lid

Rivets

5
(0.20)

mm (in.)

POINT
1.Before temporarily installing the new parts, apply body sealer to the wheel arch.
HINT
1) Apply body sealer evenly about 5 mm (0.20 in.) from the flange, avoiding any oozing.
2) Apply sealer evenly, about 3 − 4 mm (0.12 − 0.16 in.) in diameter.
2.Temporarily install the new parts and measure each part of the new parts in accordance with
the body dimension diagram. (See the body dimension diagram)
3.After welding, apply body sealer and undercoating to the corresponding parts.

SYMBOLS
INSTALLATION DIAGRAM
Describes in detail the installation to the new parts involving repair by welding and / or
cutting, but excluding painting.
INSTALLATIOLN GUIDE
Provides additional information to more efficiently help you perform the installation.
SYMBOLS (See page IN-42)
INSTALLATION OF WELD POINTS (See page IN-44)
Weld method and panel position symbols
PART NAME
F33026
IN-42 INTRODUCTION

2. SYMBOLS
The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas
and the types of weld required.

SYMBOLS MEANING SYMBOLS MEANING ILLUSTRATION

CUT AND JOIN LOCATION

(Saw Cut)

CUT AND JOIN LOCATION

(Cut Location for
Supply Parts)
CUT

CUT LOCATION

CUT WITH DISC

SANDER ETC.

BRAZE
BRAZE (Removal)

BRAZE
BRAZE
(Installation)

WELD — SPOT WELD OR

POINTS MIG PLUG WELD

CONTINUOUS
MIG WELD
(BUTT WELD)
WELDING
CONTINUOUS
MIG WELD
(TACK WELD)

SEALER BODY SEALER

F33004
 INTRODUCTION IN-43

SYMBOLS MEANING SYMBOLS MEANING ILLUSTRATION

— Assembly Mark —

BODY SEALER
— (Flat Finishing)

—
BODY SEALER
— (Flat Finishing)
F33005
IN-44 INTRODUCTION

3. ILLUSTRATION OF WELD POINT SYMBOLS

EXAMPLE:

REMOVAL INSTALLATION

Weld points Weld points

Remove weld point and panel position Remove weld point and panel position

SYMBOLS MEANING ILLUSTRATION SYMBOLS MEANING ILLUSTRATION

Remove
Weld
Points Spot Weld

(Outside)

MIG Plug Weld

(Middle)

Spot MIG Weld

(Inside)

F33006
INTRODUCTION IN-45

ABBREVIATIONS USED IN THIS MANUAL

For convenience, the following abbreviations are used in this
manual.
ABS Antilock Brake System
A/C Air Conditioner
assy assembly
ECT Electronic Controlled Transmission
ECU Electronic Control Unit
e.g. Exempli Gratia (for Example)
Ex. Except
FWD Front Wheel Drive Vehicles
2WD Two Wheel Drive Vehicles
4WD Four Wheel Drive Vehicles
in. inch
LH Left-hand
LHD Left-hand Drive
MIG Metal Inert Gas
M/Y Model Year
PPS Progressive Power Steering
RH Right-hand
RHD Right-hand Drive
SRS Supplemental Restraint System
SSM Special Service Materials
w/ with
w/o without
 BODY PANEL REPLACEMENT BP-1

RADIATOR UPPER SUPPORT (ASSY): TMC made

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld

F25701A F25701B

REMOVAL.INSTALLATION

Front Fender Gusset

F25701

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-2 BODY PANEL REPLACEMENT

RADIATOR SUPPORT UPPER BRACE (ASSY): TMC made

With the radiator upper support removed.

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld
F25702A F25702B

REMOVAL.INSTALLATION

Front Bumper Upper Arm

Radiator
Support

F25702

REMOVAL POINT
1 Remove the radiator support at the same time.
INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-3

522
(20.55)
1,482
(58.35)

1,218
(47.95) 1,462
(57.56)
872
(34.33) 456
(17.95)

978
(38.50)

mm (in.)
F25704

INSTALLATION POINT
1 Measure the dimensions before installing the headlights.
2 These values are reference values.
BP-4 BODY PANEL REPLACEMENT

RADIATOR SIDE SUPPORT (ASSY): TMMK made

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld

F25703A F25703B

REMOVAL.INSTALLATION

Front Bumper Upper Arm

F25703

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-5

522
(20.55)
1,482
(58.35)

1,218
(47.95) 1,462
(57.56)
872
(34.33) 456
(17.95)

978
(38.50)

mm (in.)
F25704

INSTALLATION POINT
1 Measure the dimensions before installing the headlights.
2 These values are reference values.
BP-6 BODY PANEL REPLACEMENT

FRONT CROSSMEMBER (ASSY)

Symbol meaning

REMOVAL : Remove Weld Points : Cut with disc sander, etc.

INSTALLATION : MIG Plug Weld : Tack Weld

F25705A F25705B

REMOVAL.INSTALLATION

10
(0.39)

mm (in.)
F25705

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-7

RADIATOR SUPPORT (ASSY)

Symbol meaning

REMOVAL : Remove Weld Points : Cut with disc sander, etc.

INSTALLATION : MIG Plug Weld : Tack Weld

F25706A F25706B

REMOVAL.INSTALLATION

10
(0.39)

mm (in.)
F25706

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-8 BODY PANEL REPLACEMENT

FRONT FENDER FRONT APRON (ASSY)

With the radiator support removed.

Symbol meaning

REMOVAL : Remove Weld Points : Cut with disc sander, etc.

INSTALLATION : MIG Plug Weld : Tack Weld
F25707A F25707B

REMOVAL.INSTALLATION

F25707

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
 BODY PANEL REPLACEMENT BP-9

Fender Apron Plate

LH:
RH:

6
(0.24)
Front Fender Apron Front Extension

15
(0.59)
6
(0.24)

mm (in.)
F25708

REMOVAL POINT
1 Remove the front fender apron front extension at the same time.
INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-10 BODY PANEL REPLACEMENT

FRONT APRON TO COWL SIDE UPPER MEMBER (ASSY)

With the front fender front apron and front body pillar lower gusset removed.

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld
F25709A F25709B

REMOVAL.INSTALLATION

Front Apron To Cowl Side Lower Front Member

F25709

REMOVAL POINT
1 After removing the front apron to cowl side lower front member, remove the front apron to cowl side upper
member.
INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After welding the to the front apron to cowl side upper member vehicle side, install the front apron to cowl side
lower front member.
 BODY PANEL REPLACEMENT BP-11

F25805

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-12 BODY PANEL REPLACEMENT

FRONT FENDER APRON (ASSY)

With the radiator support and front body pillar lower gusset removed.

Symbol meaning

REMOVAL : Remove Weld Points : Cut with disc sander, etc.

INSTALLATION : MIG Plug Weld : Tack Weld
F25710A F25710B

REMOVAL.INSTALLATION

CAUTION
Make sure to attach correctly in accordance with the body dimension diagram as this part af-
fects the front wheel alignment.

F25710

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
 BODY PANEL REPLACEMENT BP-13

6
(0.24)

15
(0.59)

6
(0.24)

CAUTION mm (in.)

Make sure to attach correctly in accordance with the body dimension diagram as this part affects
the front wheel alignment.

F25711

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-14 BODY PANEL REPLACEMENT

FRONT SIDE MEMBER (CUT-P)

With the radiator support removed.

Symbol meaning

: Remove Weld Points : Cut and Join Location

F25712A F25712B

REMOVAL

110
(4.33)

Front Side Member Extension

mm (in.)
F25712

REMOVAL POINT
1 Remove the front side member extension at the same time.
 BODY PANEL REPLACEMENT BP-15

Symbol meaning

: MIG Plug Weld : Butt Weld

F25713B

INSTALLATION

Front Side Member Extension

F25713

INSTALLATION POINT
1 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
2 After welding, apply undercoating to the corresponding parts.(See the paint.coating)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-16 BODY PANEL REPLACEMENT

FRONT SIDE MEMBER (CUT-H): TMC made

With the front fender apron removed.

Symbol meaning

: Remove Weld Points

F25714A F25714B

REMOVAL

F25714
 BODY PANEL REPLACEMENT BP-17

Symbol meaning

: MIG Plug Weld

F25715B

INSTALLATION

Front Side Member Extension

CAUTION
Make sure to attach correctly in accordance with the body dimension diagram as this part affects
the front wheel alignment.

F25715

INSTALLATION POINT
1 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
2 After welding, apply body sealer and undercoating to the corresponding parts.(See the paint.coating)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-18 BODY PANEL REPLACEMENT

FRONT SIDE MEMBER (CUT-H): TMMK made

With the front fender apron removed.

Symbol meaning

: Remove Weld Points

F25716A F25716B

REMOVAL

F25716
 BODY PANEL REPLACEMENT BP-19

Symbol meaning

: MIG Plug Weld

F25718B

INSTALLATION

Front Side Member Extension

CAUTION
Make sure to attach correctly in accordance with the body dimension diagram as this part affects
the front wheel alignment.

F25718

INSTALLATION POINT
1 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
2 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-20 BODY PANEL REPLACEMENT

COWL TOP SIDE REINFORCEMENT (ASSY)

Symbol meaning

REMOVAL : Cut with disc sander, etc.

INSTALLATION : Tack Weld

F25720A F25720B

REMOVAL.INSTALLATION

13
(0.51)

15
(0.59) 15
(0.59)

10 25
(0.39) (0.98) mm (in.)
F25720

INSTALLATION POINT
1 After welding, apply body sealer to the corresponding parts. (See the paint.coating)
2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-21

FRONT BODY PILLAR LOWER GUSSET (ASSY)

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld

F25719A F25719B

REMOVAL.INSTALLATION

F25719

INSTALLATION POINT
1 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-22 BODY PANEL REPLACEMENT

COWL TOP OUTER PANEL (ASSY)

With the cowl top side reinforcement and front body pillar lower gusset removed.

Symbol meaning

REMOVAL : Remove Weld Points : Cut with disc sander, etc.

INSTALLATION : MIG Plug Weld : Tack Weld
F25721A F25721B

REMOVAL.INSTALLATION

7
(0.28)

mm (in.)
F25721

INSTALLATION POINT
1 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
2 After welding, apply body sealer to the corresponding parts. (See the paint.coating)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-23

FRONT BODY PILLAR (CUT)

With the cowl top outer panel removed.

Symbol meaning : Cut with disc sander, etc.

: Cut and Join Location

: Remove Weld Points : Cut Location for Supply Parts

F25722A F25722B

REMOVAL

200
(7.87)

140
Urethane Foam (5.51)

160
(6.30) 60
(2.36)

mm (in.)
F25722
BP-24 BODY PANEL REPLACEMENT

Symbol meaning : Cut with disc sander, etc.

: Cut and Join Location

: Remove Weld Points : Cut Location for Supply Parts

F25722B

F25723
 BODY PANEL REPLACEMENT BP-25

Symbol meaning
: MIG Plug Weld : Cut and Join Location

: Tack Weld : Butt Weld : Body Sealer

F25724B

INSTALLATION

Cowl Side Panel

45
(1.77)

Center Body Pillar Lower Reinforce

310
(12.20)

Front Body Pillar Lower Reinforce

20
(0.79)

mm (in.)
F25724

INSTALLATION POINT
1 Before temporarily installing the new parts, weld the center body pillar lower reinforce, front body pillar lower
reinforce and cowl side panel with the standard number of welding points.
BP-26 BODY PANEL REPLACEMENT

Symbol meaning

: MIG Plug Weld : Cut and Join Location

: Tack Weld : Butt Weld : Body Sealer

F25724B

Front Body Pillar

Lower Reinforce

Cowl Side Panel

Center Body Pillar

Lower Reinforce

10
(0.39)

mm (in.)
F25725

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After welding the center body pillar lower reinforce, front body pillar lower reinforce and cowl side panel to the
vehicle side, install the front body upper outer pillar and center body outer pillar.
 BODY PANEL REPLACEMENT BP-27

Front Body Upper Outer Pillar

Urethane Foam

Center Body Outer Pillar

No. 6 Pillar Outer Bracket

Center Body Pillar

Lower Reinforce

F25807

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 Before installing a new part, apply body sealer.
HINT:
1) Apply sealer in an even, continuous bead.
4 After welding the center body pillar lower reinforce and front body pillar lower reinforce to the vehicle side,
install the front body upper outer pillar, center body outer pillar and No.6 pillar outer bracket.
5 After welding, apply the polyurethane foam to the corresponding parts.(See the paint.coating)
6 After welding, apply body sealer and undercoating to the corresponding parts.(See the paint.coating)
7 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-28 BODY PANEL REPLACEMENT

CENTER BODY PILLAR (CUT)

Symbol meaning : Cut with disc sander, etc.

: Remove Weld Points : Cut and Join Location : Cut Location for Supply Parts

F25726A F25726B

REMOVAL

Urethane Foam
20
(0.79)
Urethane Foam

90 80
(3.54) (3.15)

60
(2.36)

mm (in.)
F25726

REMOVAL POINT
1 *1: Take care not to damage the internal reinforcement.
 BODY PANEL REPLACEMENT BP-29

Symbol meaning

: MIG Plug Weld : Cut and Join Location

: Tack Weld : Butt Weld

F25727B

INSTALLATION

Center Body Pillar Lower Reinforce

310
(12.20)

Center Body Pillar Upper Reinforce

Center Body Inner Pillar

mm (in.)
F25727

INSTALLATION POINT
1 Before temporarily installing the new parts, weld the center body pillar lower reinforce, center body pillar upper
reinforce and center body inner pillar with the standard number of welding points.
BP-30 BODY PANEL REPLACEMENT

Symbol meaning

: MIG Plug Weld : Cut and Join Location

: Tack Weld : Butt Weld

F25727B

Center Body Pillar

Upper Reinforce
Center Body
Inner Pillar

Roof Side Outer No.2 Rail

Urethane Foam Urethane Foam

12 (0.47)

Center Body Pillar Lower Reinforce

Center Body Outer Pillar

mm (in.)
F25728

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After welding the center body pillar lower reinforce, center body pillar upper reinforce and center body inner
pillar to the vehicle side, install the center body outer pillar and roof side outer No.2 rail.
 BODY PANEL REPLACEMENT BP-31

20
(0.79)

F25808

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After welding, apply the polyurethane foam to the corresponding parts. (See the paint.coating)
4 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
5 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-32 BODY PANEL REPLACEMENT

FRONT DOOR OUTER PANEL (ASSY)

Symbol meaning

: Remove Weld Points

F25757A F25757B

REMOVAL

Positioning Tape

Installation
Position

Hemming Location

Disc Sander

F25757

REMOVAL POINT
1 Before removing the outer panel, mark the installation position with tape.
2 Before removing the outer panel, establish its exact position in relation to the window frame using a reference
marker, etc.
3 After grinding off the hemming location, remove the outer panel.
 BODY PANEL REPLACEMENT BP-33

Symbol meaning

: MIG Plug Weld : Spot MIG Weld : Body Sealer

F25758B

INSTALLATION

Positioning Tape

10
(0.39) Do not close the
drain hole.

Cloth Tape

30

Hemming Tool

mm (in.)
F25758

INSTALLATION POINT
1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection
beam and backside of the new parts.
HINT:
1) Apply sealer evenly about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer
panel and apply just enough sealer for the reinforcement and side impact protection beam to make
contact.
2 Bend the flange hem about 30
with a hammer and dolly. Then, fasten tightly with a hemming tool.
HINT:
1) Perform hemming in three steps, being careful not to warp the panel.
2) If a hemming tool cannot be used, hem with a hammer and dolly.
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-34 BODY PANEL REPLACEMENT

REAR DOOR OUTER PANEL (ASSY)

Symbol meaning

: Remove Weld Points

F25759A F25759B

REMOVAL

Positioning Tape

Installation
Position

Hemming Location

Disc Sander

F25759

REMOVAL POINT
1 Before removing the outer panel, mark the installation position with tape.
2 Before removing the outer panel, establish its exact position in relation to the window frame using a reference
marker, etc.
3 After grinding off the hemming location, remove the outer panel.
 BODY PANEL REPLACEMENT BP-35

Symbol meaning

: MIG Plug Weld : Spot MIG Weld : Body Sealer

F25760B

INSTALLATION

Positioning Tape

10
(0.39) Do not close the
drain hole.

Cloth Tape

30

Hemming Tool

mm (in.)
F25760

INSTALLATION POINT
1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection
beam and backside of the new parts.
HINT:
1) Apply sealer evenly about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer
panel and apply just enough sealer for the reinforcement and side impact protection beam to make
contact.
2 Bend the flange hem about 30
with a hammer and dolly. Then, fasten tightly with a hemming tool.
HINT:
1) Perform hemming in three steps, being careful not to warp the panel.
2) If a hemming tool cannot be used, hem with a hammer and dolly.
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-36 BODY PANEL REPLACEMENT

ROCKER OUTER PANEL (CUT-P)

Symbol meaning : Cut and Join Location

: Remove Weld Points : Cut Location for Supply Parts

F25729A F25729B

REMOVAL

800
(31.50)

60 50
(2.36) (1.97)

mm (in.)
F25729

REMOVAL POINT
1 *1: Take care not to damage the internal reinforcement.
 BODY PANEL REPLACEMENT BP-37

Symbol meaning

: MIG Plug Weld : Cut and Join Location : Butt Weld

F25730B

INSTALLATION

Center Body Pillar Lower Reinforce

Center Body Outer Pillar

mm (in.)
F25730

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After welding the center body pillar lower reinforce to the vehicle side, install the center body outer pillar.
4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-38 BODY PANEL REPLACEMENT

ROCKER OUTER EXTENSION (ASSY): TMC made

Symbol meaning

: Remove Weld Points : Cut and Join Location : Cut Location for Supply Parts

F25731A F25731B

REMOVAL

Center Body Outer Pillar

280
(11.02)

Quarter Panel

260
(10.24)

70
(2.76)

Center Body Pillar Lower Reinforce

mm (in.)
F25731

REMOVAL POINT
1 *1 in illustration above indicates where the adhesive is.
2 After removing the center body outer pillar and quarter panel, remove the rocker outer extension and center
body pillar lower reinforce.
 BODY PANEL REPLACEMENT BP-39

Symbol meaning

: MIG Plug Weld : Butt Weld : Body Sealer

F25732B

INSTALLATION

Rocker Panel Reinforcement

Center Body Pillar Lower Reinforce

Center Body Outer Pillar

Quarter Panel

F25732

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 Before temporarily installing the new parts, weld the rocker panel reinforcement and rocker outer extension
with the standard number of welding points.
4 Before installing a new part, apply body sealer.
HINT:
1) Apply sealer in an even, continuous bead.
5 After welding the center body pillar lower reinforce and rocker outer extension to the vehicle side, install the
center body outer pillar and quarter panel.
6 After welding, apply body sealer and undercoating to the corresponding parts.(See the paint.coating)
7 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-40 BODY PANEL REPLACEMENT

ROCKER OUTER REINFORCE (ASSY): TMMK made

Symbol meaning

: Remove Weld Points : Cut and Join Location : Cut Location for Supply Parts

F25733A F25733B

REMOVAL

Center Body Outer Pillar

280
(11.02)

Quarter Panel

260
(10.24)

70
(2.76)

Center Body Pillar Lower Reinforce

mm (in.)
F25733

INSTALLATION POINT
1 *1 in illustation above indicates where the adhesive is.
2 After removing the center body outer pillar and quarter panel, remove the rocker outer reinforce and center
body pillar lower reinforce.
 BODY PANEL REPLACEMENT BP-41

Symbol meaning

: MIG Plug Weld : Butt Weld : Body Sealer

F25734B

INSTALLATION

Center Body Pillar Lower Reinforce

Center Body Outer Pillar

Quarter Panel

F25734

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 Before installing a new part, apply body sealer.
HINT:
1) Apply sealer in an even, continuous bead.
4 After welding the rocker outer reinforce to the vehicle side, install the center body outer pillar and quarter panel.
5 After welding, apply body sealer and undercoating to the corresponding parts.(See the paint.coating)
6 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-42 BODY PANEL REPLACEMENT

QUARTER PANEL (CUT)

Quarter Panel Replacement Using Adhesive

F25735A

Work Procedure Precaution

1 Cut the wheel arch portion.

2 Heat the quarter panel adhesive area and remove (1) Using an industrial dryer or oxygen acetylene
the quarter panel. burner, heat the quarter panel to 110 to 140
C.
Make sure the quarter panel does not warp.

3 Clean off any adhesive that remains on the (1) Using a gas burner, heat the adhesive to 110 to
vehicle. 140
C.

(2) Using a scraper, scrape away the adhesive.

(3) If adhesive remains, the strength of any

subsequently applied adhesive will be weak.

4 Using a disc grinder or belt sander, scuff and sand (1) Scuff at a width of approximately 10 mm over the
any adhesive that remains on the vehicle. previous adhesive coating.

5 Apply adhesive to the exposed metal areas on the

vehicle. Using a spatula, spread the adhesive
evenly.

6 Apply adhesive to the vehicle again.

7 Using #60-240 grit sandpaper, scuff the adhesive

application area on the new quarter panel.

8 Apply adhesive to the new quarter panel. Using a

spatula, spread the adhesive evenly.

9 Using a vise or the palms of your hands, press the

quarter panel so that the thickness of the
adhesive is even.

10 Complete installation the new quarter panel.

11 Dry the adhesive areas of the new quarter panel. (1) Hardening Time Estimation
With dryer or equivalent (60
C)
: 60 minutes (complete hardening: 90 minutes)
Ambient temperature (25
C)
: 12 hours (complete hardening: 24 hours)
 BODY PANEL REPLACEMENT BP-43

Symbol meaning : Cut with disc sander, etc. : Cut Location for Supply Parts
: Remove Weld Points : Cut and Join Location : Braze

F25735B

REMOVAL

Urethane Foam

85
(3.35)

260
(10.24)

mm (in.)
F25735

REMOVAL POINT
1 *1 in illustration above indicates where the adhesive is.
2 Roughly cut open the wheel arch of the panel so that the adhesive can be reached. Cut through the adhesive
with a cut chisel to remove the panel.
HINT:
1) If the cut chisel cannot reach the adhesive, heat the adhesive with a heat gun, oxygen-acetylene burner.
When heating, do not deform the quarter housing outer panel.
BP-44 BODY PANEL REPLACEMENT

Symbol meaning
: Cut with disc sander, etc. : Cut Location for Supply Parts
: Remove Weld Points : Cut and Join Location : Braze

F25735B

F25736
 BODY PANEL REPLACEMENT BP-45

Symbol meaning

: Spot Weld : MIG Plug Weld : Butt Weld : Body Sealer : Braze

F25737B

INSTALLATION

TMMK made:
Urethane Foam
Quarter Lock Pillar Reinforcement

Fuel Filler Opening Lid

Water Proof Rivets 3 Spot Tip

(0.12)

5
(0.24)

mm (in.)
F25737

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 Apply adhesive(3MTM AutomixTM Panel Bonding Adhesive #8115) to the area indicated by *1 in illustration.
HINT:
1) Apply enough adhesive for the panels to sick to each other.
4 Perform spot-welding on the flange indicated by *2 in the illustration. Modify/ cut the spot tip as shown in the
illustration (*3) so that it can fit into the narrow flange.
5 Before installing a new part, apply body sealer.
HINT:
1) Apply sealer in an even, continuous bead.
BP-46 BODY PANEL REPLACEMENT

Symbol meaning

: Spot Weld : MIG Plug Weld : Butt Weld : Body Sealer : Braze

F25737B

F25738

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After welding, apply the polyurethane foam to the corresponding parts. (See the paint.coating)
4 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
5 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-47

QUARTER WHEEL HOUSING OUTER PANEL (ASSY): TMC made

With the quarter panel removed.

Symbol meaning : Cut with disc sander, etc.

: Remove Weld Points : Cut and Join Location

REMOVAL
INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld
F25739A F25739B

REMOVAL.INSTALLATION

[LH]

310
(12.20)

Rocker Outer Extension

mm (in.)
F25739

REMOVAL POINT
1 *1: Take care not to damage the internal reinforcement.
2 After removing the rocker outer extension, remove the quarter wheel housing outer panel.
INSTALLATION POINT
1 After welding the quarter wheel housing outer panel to the vehicle side, install the rocker outer extension.
BP-48 BODY PANEL REPLACEMENT

Symbol meaning : Cut with disc sander, etc.

: Remove Weld Points : Cut and Join Location

REMOVAL
INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld
F25739B

[LH]

Roof Side Outer Panel

F25740

REMOVAL POINT
1 After removing the roof side outer panel, remove the quarter wheel housing outer panel.
INSTALLATION POINT
1 After welding the quarter wheel housing outer panel to the vehicle side, install the roof side outer panel.
 BODY PANEL REPLACEMENT BP-49

[LH]

20
(0.79)

mm (in.)
F25742

INSTALLATION POINT
1 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-50 BODY PANEL REPLACEMENT

Symbol meaning : Cut with disc sander, etc.

: Remove Weld Points : Cut and Join Location

REMOVAL
INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld
F25739B

[RH]

310
(12.20)

Rocker Outer Extension

mm (in.)
F25795

REMOVAL POINT
1 *1: Take care not to damage the internal reinforcement.
2 After removing the rocker outer extension, remove the quarter wheel housing outer panel.
INSTALLATION POINT
1 After welding the quarter wheel housing outer panel to the vehicle side, install the rocker outer extension.
 BODY PANEL REPLACEMENT BP-51

[RH]

Roof Side Outer Panel

F25741

REMOVAL POINT
1 After removing the roof side outer panel, remove the quarter wheel housing outer panel.
INSTALLATION POINT
1 After welding the quarter wheel housing outer panel to the vehicle side, install the roof side outer panel.
BP-52 BODY PANEL REPLACEMENT

Symbol meaning : Cut with disc sander, etc.

: Remove Weld Points : Cut and Join Location

REMOVAL
INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld
F25739B

[RH]

20
(0.79)

mm (in.)
F25796

INSTALLATION POINT
1 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-53

QUARTER WHEEL HOUSING OUTER PANEL (ASSY): TMMK made

With the quarter panel removed.

Symbol meaning : Cut with disc sander, etc.

: Remove Weld Points : Cut and Join Location

REMOVAL
INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld
F25797A F25797B

REMOVAL.INSTALLATION

[LH]

310
(12.20)

Rocker Outer Reinforce

mm (in.)
F25797

REMOVAL POINT
1 *1: Take care not to damage the internal reinforcement.
2 After removing the rocker outer reinforce, remove the quarter wheel housing outer panel.
INSTALLATION POINT
1 After welding the quarter wheel housing outer panel to the vehicle side, install the rocker outer reinforce.
BP-54 BODY PANEL REPLACEMENT

Symbol meaning : Cut with disc sander, etc.

: Remove Weld Points : Cut and Join Location

REMOVAL
INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld
F25797B

[LH]

Roof Side Outer Panel

F25798

REMOVAL POINT
1 After removing the roof side outer panel, remove the quarter wheel housing outer panel.
INSTALLATION POINT
1 After welding the quarter wheel housing outer panel to the vehicle side, install the roof side outer panel.
 BODY PANEL REPLACEMENT BP-55

[LH]

20
(0.79)

mm (in.)
F25799

INSTALLATION POINT
1 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-56 BODY PANEL REPLACEMENT

Symbol meaning : Cut with disc sander, etc.

: Remove Weld Points : Cut and Join Location

REMOVAL
INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld
F25797B

[RH]

310
(12.20)

Rocker Outer Reinforce

mm (in.)
F25800

REMOVAL POINT
1 *1: Take care not to damage the internal reinforcement.
2 After removing the rocker outer reinforce, remove the quarter wheel housing outer panel.
INSTALLATION POINT
1 After welding the quarter wheel housing outer panel to the vehicle side, install the rocker outer reinforce.
 BODY PANEL REPLACEMENT BP-57

[RH]

Roof Side Outer Panel

F25801

REMOVAL POINT
1 After removing the roof side outer panel, remove the quarter wheel housing outer panel.
INSTALLATION POINT
1 After welding the quarter wheel housing outer panel to the vehicle side, install the roof side outer panel.
BP-58 BODY PANEL REPLACEMENT

Symbol meaning : Cut with disc sander, etc.

: Remove Weld Points : Cut and Join Location

REMOVAL
INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld
F25797B

[RH]

20
(0.79)

mm (in.)
F25802

INSTALLATION POINT
1 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-59

BODY LOWER BACK PANEL (ASSY)

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld

F25743A F25743B

REMOVAL.INSTALLATION

F25743

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-60 BODY PANEL REPLACEMENT

QUARTER PANEL END HOUSING (ASSY): TMC made

Symbol meaning

REMOVAL : Remove Weld Points : Cut with disc sander, etc.

INSTALLATION : MIG Plug Weld

F25744A F25744B

REMOVAL.INSTALLATION

Luggage Compartment
Opening Trough

Luggage Compartment Trim No. 1 Bracket

F25744

REMOVAL POINT
1 Remove the luggage compartment opening trough at the same time.
INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After welding, apply body sealer to the corresponding parts. (See the paint.coating)
4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-61

QUARTER PANEL END HOUSING (ASSY): TMMK made

Symbol meaning

REMOVAL : Remove Weld Points : Cut with disc sander, etc.

INSTALLATION : MIG Plug Weld

F25745A F25745B

REMOVAL.INSTALLATION

F25745

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After welding, apply body sealer to the corresponding parts. (See the paint.coating)
4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-62 BODY PANEL REPLACEMENT

REAR FLOOR NO. 3 CROSSMEMBER (ASSY)

With the body lower back panel removed.

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : Spot Weld : MIG Plug Weld
F25746A F25746B

REMOVAL.INSTALLATION

F25746

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-63

REAR FLOOR PAN (ASSY)

With the rear floor no.3 crossmember removed.

Symbol meaning

: Remove Weld Points

F25747A F25747B

REMOVAL

Rear Floor Pan Reinforcement

F25747

REMOVAL POINT
1 Remove the rear floor pan reinforcement at the same time.
BP-64 BODY PANEL REPLACEMENT

Symbol meaning

: Remove Weld Points

F25747B

[LH]

[RH]

F285748
 BODY PANEL REPLACEMENT BP-65

Symbol meaning

: MIG Plug Weld

F25749B

INSTALLATION
Spare Wheel Clamp Bracket

Fuel Tube No.3 Bracket

Weld Bolts ( ): TMMK made F25749

INSTALLATION POINT
1 Before temporarily installing the new parts, weld the spare wheel clamp bracket and fuel tube No.3 bracket
with the standard number of welding points.
BP-66 BODY PANEL REPLACEMENT

Symbol meaning
: MIG Plug Weld : Tack Weld

F25749B

[LH]

[RH]

F25804
 BODY PANEL REPLACEMENT BP-67

Rear Floor Pan Reinforcement

F25803

INSTALLATION POINT
1 After welding, apply body sealer and undercoating to the corresponding parts.(See the paint.coating)
2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-68 BODY PANEL REPLACEMENT

REAR FLOOR SIDE PANEL (ASSY)

With the rear floor pan removed.

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld
F25750A F25750B

REMOVAL.INSTALLATION

[LH]

F25750

INSTALLATION POINT
1 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-69

[RH]

F25751

INSTALLATION POINT
1 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-70 BODY PANEL REPLACEMENT

REAR FLOOR SIDE REAR MEMBER (ASSY)

With the rear floor no.3 crossmember removed.

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld
F25752A F25752B

REMOVAL.INSTALLATION

LH:

RH:

F25752

INSTALLATION POINT
1 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
2 After welding, apply undercoating to the corresponding parts.(See the paint.coating)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-71

REAR FLOOR NO. 2 CROSSMEMBER (ASSY)

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld

F25753A F25753B

REMOVAL.INSTALLATION

F25753

INSTALLATION POINT
1 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
2 After welding, apply undercoating to the corresponding parts.(See the paint.coating)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-72 BODY PANEL REPLACEMENT

ROOF PANEL (ASSY): Nomal Roof

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : Spot Weld : MIG Plug Weld : Body Sealer

F25754A F25754B

REMOVAL.INSTALLATION

F25754

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After welding, apply body sealer to the corresponding parts.(See the paint.coating)
4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-73

F25806

INSTALLATION POINT
1 Before temporarily installing the new parts, apply body sealer to the windshield header panel, roof panel
reinforcement and back door opening frame.
HINT:
1) Apply just enough sealer for the new parts to make contact.
BP-74 BODY PANEL REPLACEMENT

ROOF PANEL (ASSY): Moon Roof

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : Spot Weld : MIG Plug Weld : Body Sealer

F25755A F25755B

REMOVAL.INSTALLATION

Cloth Tape

Wooden Hammer

Disc Sander

[Removal]
[Install]

F25755

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish
2 Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimension diagram)
3 After welding, apply body sealer to the corresponding parts.(See the paint.coating)
4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-75

F25756

INSTALLATION POINT
1 Before temporarily installing the new parts, apply body sealer to the windshield header panel, roof panel
reinforcement and back door opening frame.
HINT:
1) Apply just enough sealer for the new parts to make contact.
BP-76 BODY PANEL REPLACEMENT

OUTER PANEL INSTALLATION TORQUE

13 (133, 10)

13 (133, 10)

13 (133, 10)

13 (133, 10)

6.0 (61, 53 in..lbf)

6.0 (61, 53 in..lbf)

8.0 (82, 71 in..lbf)

8.0 (82, 71 in..lbf)

34 (347, 25)

8.0 (82, 71 in..lbf)

N.m (kgf.cm, ft..lbf) : Specified torque

F25761
 BODY PANEL REPLACEMENT BP-77

26 (265, 19)

26 (265, 19)

26 (265, 19)

26 (265, 19)

N.m (kgf.cm, ft..lbf) : Specified torque

F25762
BP-78 BODY PANEL REPLACEMENT

7.5 (77, 66 in..lbf)

7.5 (77, 66 in..lbf)

7.5 (77, 66 in..lbf)

7.5 (77, 66 in..lbf)

68 (694, 50)

68 (693, 50)

N.m (kgf.cm, ft..lbf) : Specified torque

F25763
 BODY PANEL REPLACEMENT BP-79

FIT STANDARD/ADJUSTMENT METHOD/TORQUE SPECIFICATION

HOOD SUB-ASSEMBLY

3.5 (0.138)

3.7 (0.146)
5.1 (0.201)

mm (in.)
F25764

1. ADJUST HOOD SUB-ASSEMBLY

HINT:

Centering bolts are used to mount the hood hinge and hood lock. The hood and hood lock cannot be
adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (with washers)
when making adjustments.
a. Horizontally and vertically adjust the
hood.
i. Loosen the hood’s 4 hinge bolts.
ii. Move the hood and adjust the
clearance between the hood and front
fender.
iii. Tighten the hood’s 4 hinge bolts after
the adjustment.
Torque: B132829
13 N.m (133 kgf.cm, 10 ft..lbf)
BP-80 BODY PANEL REPLACEMENT

b. Adjust the height of the hood front end using the cushion rubber.
i. Adjust the cushion rubber so that the
height of the hood and fender are
aligned.

HINT:
Raise or lower the hood’s front end
by turning the cushion rubber.

B132830

c. Adjust the hood lock.

i. Loosen the 3 bolts.
ii. Tighten the bolts after the adjustment.
Torque:
7.5 N.m (77 kgf.cm, 66 in..lbf)
iii. Adjust the hood lock position so that
the striker can enter it smoothly.

B132832
 BODY PANEL REPLACEMENT BP-81

FRONT DOOR
4.8 (0.189)

4.8 (0.189)

4.3 (0.169)

4.2 (0.165)
4.2 (0.165)

5.0 (0.197)
mm (in.)
F25765

1. ADJUST FRONT DOOR

HINT:

Before adjusting the door position for vehicles equipped with side airbags and curtain shield
airbags, be sure to disconnect the battery. After adjustment, inspect the SRS warning light, the
side airbag system, and the curtain shield airbag system for normal operation. Then initialize
both airbag systems.

Use the same procedures for the RH side and LH side.

The procedures listed below are for the LH side.

Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot
be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (with
washers) when making adjustment.
BP-82 BODY PANEL REPLACEMENT

a. Using SST, loosen the body’s hinge bolts

and adjust the door position.
SST
09812-00010
b. Tighten the body’s hinge bolts after the
adjustment.
Torque:
26 N.m (265 kgf.cm, 19 ft..lbf)
c. Loosen the door’s hinge bolts and adjust
the door position.
d. Tighten the door’s hinge bolts after the
adjustment.
Torque:
26 N.m (265 kgf.cm, 19 ft..lbf)

B136438

e. Using a “torx” socket wrench (T40), adjust

the striker position by slightly loosening
the striker mounting screws and hitting
the striker with a plastic hammer.
f. Using a “torx” socket wrench (T40),
tighten the striker mounting screws after
the adjustment.
Torque:
23 N.m (235 kgf.cm, 17 ft..lbf)

B136440
 BODY PANEL REPLACEMENT BP-83

REAR DOOR
4.8 (0.189)

4.8 (0.189)

4.3 (0.169)

4.2 (0.165)
4.2 (0.165)

4.2 (0.165)

5.0 (0.197)
mm (in.)
B25766

1. ADJUST REAR DOOR

HINT:

Before adjusting the door position for vehicles equipped with side airbags and curtain shield
airbags, be sure to disconnect the battery. After adjustment, inspect the SRS warning light, the
side airbag system, and the curtain shield airbag system for normal operation. Then initialize
both airbag systems.

Use the same procedures for the RH side and LH side.

The procedures listed below are for the LH side.

Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot
be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (with
washers) when making adjustments.
BP-84 BODY PANEL REPLACEMENT

a. Loosen the body’s hinge bolts and adjust

the door position.
SST
09812-00010
b. Tighten the body’s hinge bolts after the
adjustment.
Torque:
26 N.m (265 kgf.cm, 19 ft..lbf)
c. Loosen the door’s hinge bolts and adjust
the door position.
d. Tighten the door’s hinge bolts after the
adjustment.
Torque:
26 N.m (265 kgf.cm, 19 ft..lbf)

B136487

e. Using a “torx” socket wrench (T40), adjust

the striker position by slightly loosening
the striker mounting screws and hitting
the striker with a plastic hammer.
f. Using a “torx” socket wrench (T40),
tighten the striker mounting screws after
the adjustment.
Torque:
23 N.m (235 kgf.cm, 17 ft..lbf)

B136489
 BODY PANEL REPLACEMENT BP-85

LUGGAGE COMPARTMENT DOOR

3.5 (0.138)

3.5 (0.138)

5.7 (0.224)

mm (in.)
F25767

1. ADJUST LUGGAGE COMPARTMENT DOOR

HINT:

Centering bolts are used to mount the door hinge to the door. The door cannot be adjusted with
the centering bolts on. Substitute the centering bolts with standard bolts (with washers) when
making adjustments.
a. Horizontally and vertically adjust the door
by loosening the door side hinge bolts.
Torque:
7.5 N.m (77 kgf.cm, 66 in..lbf)

B136494

b. Adjust the striker position by slightly

loosening the 2 striker mounting screws
and hitting the striker with a plastic-faced
hammer.
c. Tighten the striker mounting screws after
the adjustment.
Torque:
5.5 N.m (56 kgf.cm, 49 in..lbf)

B136495
BP-86 BODY PANEL REPLACEMENT

NAME PLATE APPLICATION PROCEDURE

(a) Heat the double-sided tape remaining on the body with an infrared lamp or equivalent.
HINT:
Heat the tape to 40 to 60
C for approximately 1 to 2 minutes.
(b) Wipe off the remaining double-sided tape using a clean cloth or equivalent.
HINT:
If a name plate is installed without thoroughly removing the remaining double-sided tape from the body, the
name plate will not adhere properly. Make sure to thoroughly wipe off the double-sided tape.
(c) After cleaning the installation area of the body with degreasing agent, attach the name plate to the position
shown in the illustration.
HINT:
The working environment should be 20
C when installing the name plate. If the working environment is below
20
C, heat the installation area of the body to 20 to 30
C and then install the name plate.

[GENERAL EXPORT]

14.8 12.4 11.4

(0.583) (0.488) (0.449)

13.3
(0.524)
154.5
7.2 (6.083)
(0.283)

66.5 64.3
(2.618) (2.531)

122.9
(4.839)

mm (in.)
F25809
 BODY PANEL REPLACEMENT BP-87

[U.S.A., CANADA]

16.0
(0.630)

8.1
(0.319)

5.5
(0.217)

[For name plate LE]

66.8 64.3
(2.630) (2.531)

[For name plate XLE]

134.7
(5.303)

69.6 66.6
(2.740) (2.622)

[For name plate SE] 162.2

(6.386)

64.3
66.9
(2.531)
(2.634)

136.7
(5.382)
mm (in.)
F25810
BP-88 BODY PANEL REPLACEMENT

CAUTION LABEL ATTACHMENT POSITION

After using a degreasing agent to clean the surfaces of the body where the caution labels will be attached, attach the
caution labels to the positions shown in the illustration.
HINT:
1) Attach each caution label with its orientation the same as the numbers shown in the illustration.
2) Make sure the caution label is not attached over a spot weld.
3) When attaching the caution label, make sure not to touch the label’s adhesive surface.
4) To prevent the edges of the caution label from peeling, apply extra pressure to the label’s periphery.
5) If the work area’s temperature is 5
C or less, the caution label’s adhesive will deteriorate. It is
recommended that you heat the label to 20 to 40
C.

[GENERAL EXPORT]

Long Life Coolant Service Label

Cooler Service Caution Label

F25768
 BODY PANEL REPLACEMENT BP-89

[GENERAL EXPORT]
Fuel Infomation Label

Name Plate

Tire Pressure Information Label

Side Air Bag Caution Label

Tire Pressure Information Label

(EUROPE RHD)

Side Air Bag Caution Label

F25769
BP-90 BODY PANEL REPLACEMENT

[U.S.A., CANADA]

Loaded Inspection Maintenance Exemption

Emission Control Information

Long Life Coolant Service Label
Engine Vacuume Hose Information

Cooler Service Caution

F25770
 BODY PANEL REPLACEMENT BP-91

[U.S.A., CANADA]
Fuel infomation Label

Certification Reguration Information Label

Tire Pressure Information

Label

Side Air Bag Caution Label

Mercury Information Label

Side Air Bag Caution Label

Side Air Bag Caution Label

F25771
 PAINT
COATING PC-1

BODY PANEL SEALING AREAS

Be sure to apply body sealer to the body panel joints and door edges (tip of outer panel folded part), etc., to water-
proof and rustproof them.
HINT:
1) Apply degreasing agent to a clean cloth and clean the sealer application areas.
2) After removing the applied spot sealer from the sealer application areas using thinner or equivalent, rustproof
the areas by applying primer or equivalent. Then apply body sealer.
3) If sealer is unnecessarily applied to an area, apply degreasing agent to a clean cloth and clean off the sealer
immediately.
Flat Finishing No Flat Finishing
1. ENGINE COMPARTMENT

F25781
PC-2 PAINT
COATING

2. INSIDE

LHD only

F25782
 PAINT
COATING PC-3

3. OUTSIDE

F25783
PC-4 PAINT
COATING

F25784
 PAINT
COATING PC-5

4. DOOR PARTS

F25785
PC-6 PAINT
COATING

F25786
 PAINT
COATING PC-7

BODY PANEL UNDERCOATING AREAS

Apply PASTAR UWE or PASTAR UC to the chassis, floor underside, sheet metal fitting weld points of the body, and
inside of the wheel house to prevent rust and noise, as well protect the body from flying rocks.
HINT:
1) Work must be performed while wearing the appropriate protective gear and in a well-ventilated area.
2) Apply degreasing agent to a clean cloth and clean any dirt and oil from the application areas.
3) Cover the surrounding areas of the application areas with masking paper to avoid coating unnecessary areas.
4) Do not coat high temperature areas, such as the tailpipe, or moving parts, such as the driveshaft.
5) Do not leave any gaps between the panel joints.
6) Apply sealer to the panel joints in advance.
HINT:
1) Parts coated using the PASTAR UWE should be left until dry to the touch in a 25
C environment for 60 to 75
minutes. Parts coated using PASTAR UC should be left until dry to the touch in a 25
C environment for 15 to 30
minutes.
2) If using a PASTAR gun, one spray applies a 0.5 mm thick coating.
3) PASTAR UWE: Part number V9240 − 0025 PASTAR UC: Spray type: Part number V9240 − 0008
Aerosol type: Part number V9240 − 0021

[LH]

[RH]

F25787

REFERENCE
The undercoating should be applied according to the specifications for your country while referring to the notes
above.
PC-8 PAINT
COATING

FOAMED MATERIAL APPLICATION AREAS

If an increase in temperature or other condition damages the foamed material when repairing or replacing the panel,
fill in the insufficient areas with urethane foam. The following illustration shows the areas for one side, but the
foamed material must be applied equally to both the left and right sides.
HINT:
1) Work must be performed while wearing the appropriate protective gear and in a well-ventilated area.
2) Apply tape or equivalent to any holes, nuts, etc., near the areas to be filled.

[Nomal Roof]

[Moon Roof]

F25788
 PAINT
COATING PC-9

BODY PANEL ANTI-RUST AGENT (WAX) APPLICATION AREAS

Apply RUSTOP W to the doors and hood edges (tips of outer panel folded parts) and undersides, areas around
hinges, etc., to prevent rust. Coat the undersides of the edges using a nozzle and air gun, and coat the areas around
the hinges using a brush.
HINT:
1) If RUSTOP is unnecessarily applied to an area, apply degreasing agent to a clean cloth and clean off the RUS-
TOP immediately.

F25789
PC-10 PAINT
COATING

SILENCER SHEET INSTALLATION AREAS

Substitute silencer sheets for the laminate coat application areas.

[TMC made]

. . . 1.8 (0.071)

. . . 2.6 (0.102)

...
*1 . . 2.6 (0.102)
... *2 . . 2.6 (0.102)
3.0 (0.118)
*3 . . 3.0 (0.118)
. . . 3.0 (0.118)

...
*4 . . 3.0 (0.118)
. . . 3.0 (0.118)
3.9 (0.154)

. . . 3.9 (0.154)

. . . 3.9 (0.154)
5.3 (0.209)

. . . 5.3 (0.209)

*1 U.S.A., CANADA, RHD

*2 U.S.A., CANADA
*3 Ex. U.S.A., CANADA
*4 RHD
mm (in.)
F25790
 PAINT
COATING PC-11

Substitute silencer sheets for the laminate coat application areas.

[TMMK made]

... 1.3 (0.051)

... 1.8 (0.071)

... 1.8 (0.071)
2.3 (0.091)

... 2.3 (0.091)

... 2.3 (0.091)
3.3 (0.130)

... 3.3 (0.130)

... 3.3 (0.130)
4.7 (0.185)

... 4.7 (0.185)

mm (in.)
F25791
PC-12 PAINT
COATING

BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS

To protect the body from damage due to flying rocks, apply the anti-chipping paint to the rocker panels, wheel arch-
es, and lower parts of the doors.
HINT:
1) Work must be performed while wearing the appropriate protective gear and in a well-ventilated area.
2) Apply anti-chipping paint to the indicated areas first, before applying the top coat.
3) If anti-chipping paint is unnecessarily applied to an area, apply degreasing agent to a clean cloth and clean the
paint off immediately.

. . . . . . . . SOFT − CHIP PRIMER

. . . . . . . . ANTI − CHIPPING PAINT

(INTERMEDIATE COAT)

. . . . . . . . PROTECTOR SEAL

F25792
 BODY DIMENSIONS DI-1

Three-dimensional Center-to-center GENERAL INFORMATION

distance straight-line
1. BASIC DIMENSIONS
distance
(a) There are two types of dimensions in the diagram.
(1) (Three-dimensional distance)

Straight-line distance between the centers of two
measuring points.

Two-dimensional Center-to-center horizontal (2) (Two-dimensional distance)

distance distance in forward /
rearward direction

Horizontal distance in forward/rearward between the
centers of two measuring points.

The height from an imaginary standard line.
(b) In cases in which only one dimension is given, left and right
are symmetrical.
Vertical distance Vertical distance (c) The dimensions in the following drawing indicate actual dis-
to center to lower surface tance. Therefore, please use the dimensions as a refer-
ence.
Imaginary Standard Line

(d) The line that connects the places listed below is the imagi-
nary standard line when measuring the height. (The dimen-
sions are printed in the text.)

Under Surface of SYMBOL Name

The Rocker Panel The place that was lowered A mm from the under surface of
1
the rocker panel centered on the front jack up point.
A mm B mm C mm The place that was lowered B mm from the under surface of
2
the rocker panel centered between 1 and 3.
Imaginary Standard Line The place that was lowered C mm from the under surface of
3
the rocker panel centered on the rear jack up point.
DI-2 BODY DIMENSIONS

Plate Looseness 2. MEASURING

(a) Basically, all measurements are to be done with a tracking
Body Looseness
gauge. For portions where it is not possible to use a track-
ing gauge, a tape measure should be used.
(b) Use only a tracking gauge that has no looseness in the
body, measuring plate, or pointers.
Pointer Looseness

Pointer

Master Gauge

HINT:
Wrong Correct 1) The height of the left and right pointers must be equal.
2) Always calibrate the tracking gauge before measuring
or after adjusting the pointer height.
3) Take care not to drop the tracking gauge or otherwise
shock it.
Pointer 4) Confirm that the pointers are securely in the holes.
(c) When using a tape measure, avoid twists and bends in the
tape.
 BODY DIMENSIONS DI-3

BODY DIMENSION DRAWINGS

ENGINE COMPARTMENT (for LHD)

(Three-Dimensional Distance)

1,532
(60.31)
706
(27.80)

1,657
(65.24)

588
(23.15)

1,115 753
(43.90) (29.65)
439 581
(17.28) (23.15)
319
1,520 753 (12.56)
996 (59.84) (29.65)
1,075
(39.21) (42.32)
1,379
1,582 (54.29)
1,467 1,068 (62.28) 237
(57.76) (42.05) 454 (9.33)
(17.87) 788
(31.02)

239
1,513 1,502 (9.41)
(59.57) (59.13) 865
(34.06)
832
(32.76) 826
(32.52)
341 349
(13.43) (13.74)
911
(35.87) 913 656
850 (35.94) (25.83) 355
(33.46)
(13.98)
453
(17.83) 1,037
(40.83)
451
(17.76)
Height from Imaginary Standard Line

A, a C, c K, k

706 794 639

(27.80) (31.26) (25.16)
Vehicle Dimensions
A-M B-c G-n L-m
or or B-f D-E D-e or L-l or M-m
a-m b-C g-N l-M
475 1,345 1,078 869 1,060 989 1,536 1,562 1,552
(18.70) (52.95) (42.44) (34.21) (41.73) (38.94) (60.47) (61.50) (61.10)

HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear). mm (in.)
Symbol Name Hole dia. H, h Radiator support standard hole ø10 (0.39)
A, a Front fender installation nut M6 (0.24) I Hood lock support installation nut M6 (0.24)
B, b Front spring support hole-inner ø12.5 (0.492) J, j Front fender bracket installation nut M6 (0.24)
C, c Hood hinge installation nut M8 (0.31) K, k Radiator upper support installation nut M6 (0.24)
D, d Cowl panel installation nut M6 (0.24) L, l Front fender installation nut M6 (0.24)
E, e Front side member standard hole ø18 (0.71) M, m Front fender installation nut M6 (0.24)
F, f Front side member standard hole ø18 (0.71) N, n Front bumper reinforcement installation nut M10 (0.39)
G, g Radiator upper support installation nut M6 (0.24) — — —
DI-4 BODY DIMENSIONS

BODY DIMENSION DRAWINGS

ENGINE COMPARTMENT (for RHD)

(Three-Dimensional Distance)

1,532
(60.31)
706
(27.80)

1,657
(65.24)

579
(22.80)

1,115 762
(43.90) (30.00)
443 588
(17.44) (23.15)
319
1,520 747 (12.56)
996 (59.84) (29.41)
1,075
(39.21) (42.32)
1,379
1,582 (54.29)
1,467 1,063 (62.28) 237
(57.76) (41.85) 458 (9.33)
(18.03) 788
(31.02)

239
1,513 1,502 (9.41)
(59.57) (59.13) 867
(34.13)
832
(32.76) 826
(32.52)
341 349
(13.43) (13.74)
911
(35.87) 913 656
850 (35.94) (25.83) 355
(33.46)
(13.98)
453
(17.83) 1,037
(40.83)
451
(17.76)
Height from Imaginary Standard Line

A, a C, c K, k

706 794 639

(27.80) (31.26) (25.16)
Vehicle Dimensions
A-M B-c G-n L-m
or or B-f D-E D-e or L-l or M-m
a-m b-C g-N l-M
475 1,345 1,078 875 1,071 989 1,536 1,562 1,552
(18.70) (52.95) (42.44) (34.45) (42.17) (38.94) (60.47) (61.50) (61.10)

HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear). mm (in.)
Symbol Name Hole dia. H, h Radiator support standard hole ø10 (0.39)
A, a Front fender installation nut M6 (0.24) I Hood lock support installation nut M6 (0.24)
B, b Front spring support hole-inner ø12.5 (0.492) J, j Front fender bracket installation nut M6 (0.24)
C, c Hood hinge installation nut M8 (0.31) K, k Radiator upper support installation nut M6 (0.24)
D, d Cowl panel installation nut M6 (0.24) L, l Front fender installation nut M6 (0.24)
E, e Front side member standard hole ø18 (0.71) M, m Front fender installation nut M6 (0.24)
F, f Front side member standard hole ø18 (0.71) N, n Front bumper reinforcement installation nut M10 (0.39)
G, g Radiator upper support installation nut M6 (0.24) — — —
 BODY DIMENSIONS DI-5

BODY OPENING AREAS (Side View: Front)

(Three-Dimensional Distance)

1,139
(44.84)

1,604
(63.15)

761
909 (29.96) 1,005
(35.79) (39.57)
1,532
(60.31)
856
(33.70)
826
(32.52) 1,191
(46.89)
1,141
(44.92)

1,272
(50.08)
855
(33.66) 1,116
(43.94)

Vehicle Dimensions

E-e F-f G-g H-h I-i J-j K-k

1,345 1,493 1,491 1,491 1,176 1,288 1,491

(52.95) (58.78) (58.70) (58.70) (46.30) (50.71) (58.70)

E-f E-h E-j F-j F-k G-q H-I J-k

or or or or or or or or
e-F e-H e-J f-J f-K g-Q h-i j-K
1,579 1,640 1,520 1,881 1,720 1,795 1,663 1,579
(62.17) (64.57) (59.84) (74.06) (67.72) (70.67) (65.47) (62.17)

HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear). mm (in.)
Symbol Name Hole dia. H, h Rocker panel assemby mark —
A, a Roof panel corner — I, i Roof side rail assembly mark —
B, b Hood hinge installation nut M8 (0.31) J, i Center body pillar assembly mark —
C, c Front door hinge installation nut M8 (0.31) K, k Center body pillar assembly mark —
D, d Front door hinge installation nut M8 (0.31) L, l Front door lock striker installation nut M8 (0.31)
E, e Front body pillar assembly mark — M, m Rear door hinge installation nut M8 (0.31)
F, f Front body pillar assembly mark — N, n Rear door hinge installation nut M8 (0.31)
G, g Rocker panel assembly mark — Q, q Rocker panel assembly mark —
DI-6 BODY DIMENSIONS

BODY OPENING AREAS (Side View: Rear)

(Three-Dimensional Distance)

747
(29.41)
883
(34.76)

1,004
(39.53) 1,080
(42.52)

1,058
(41.65)
1,068 742
(42.05) (29.21)

Vehicle Dimensions

O-o P-p Q-q R-r S-s T-t U-u

1,311 1,491 1,491 1,172 1,298 1,492 1,576

(51.61) (58.70) (58.70) (46.14) (51.10) (58.74) (62.05)

I-r O-s O-t P-t Q-r S-t

or or or or or or
i-R o-S o-T P-T q-R s-T
1,362 1,503 1,654 1,666 1,584 1,516
(53.62) (59.17) (65.12) (65.59) (62.36) (59.69)

HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear). mm (in.)
Symbol Name Hole dia. Q, q Rocker panel assembly mark —
I, i Roof side rail assembly mark — R, r Roof side rail assembly mark —
M, m Rear door hinge installation nut M8 (0.31) S, s Quarter panel assembly mark —
N, n Rear door hinge installation nut M8 (0.31) T, t Quarter panel assembly mark —
O, o Center body pillar assembly mark — U, u Rear door lock striker installation nut M8 (0.31)
P, p Center body pillar assembly mark — — — —
 BODY DIMENSIONS DI-7

BODY OPENING AREAS (Rear View)

(Three-Dimensional Distance)

1,020
(40.16)
724
1,659 (28.50)
(65.31) 1,320
(51.97)
1,124
(44.25)

1,196
(47.09)
1,291
(50.83)
1,232 587
(48.50) (23.11)
1,033 1,485
(40.67) (58.46)

439 1,123
(17.28) (44.21) 710
(27.95)

Vehicle Dimensions

G-g

1,137
(44.76)

HINT: For symbols, capital letters indicate right side of vehicle,

small letters indicate left side of vehicle (seen from rear). mm (in.)
Symbol Name Hole dia. D, d Luggage opening trough / Quarter panel adjoining point —
A, a Roof panel corner — E, e Quarter panel standard hole ø13 (0.51)
Upper back reinforcement / Quarter panel F, f Luggage trim installation hole ø8.5 (0.335)
B, b —
adjoining point G, g Rear spring support hole inner-front ø9.5 (0.374)
Upper back reinforcement / Quarter panel
C, c — H, h Center body pillar assembly mark —
adjoining point
DI-8 BODY DIMENSIONS

UNDER BODY

(Three-Dimensional Distance)

1,180
(46.46) 734
(28.90)

322
656 (12.68) 430 567
803 309 1,135 (25.83) (16.93) (22.32)
(12.17) (44.69)
(31.61)
1,088 1,093
RH 1,228 1,144 (42.83) (43.03) 1,203
679 (48.35) (45.04) 1,526 (47.36)
(26.73) 936 1,464 1,224
(60.08) 1,005
(36.85) (57.64) (48.19) (39.57) 1,024
1,203
1,000 (47.36) (40.31)
658 912 1,131
(25.91) 1,072
1,037 (39.37) (35.91) (44.53)
(40.83) 1,007 843 1,190 (42.20)
LH 1,103
(39.65) 1,001 (33.19) (43.43) (46.85)
(39.41) 1,170
(46.06)
922
(36.30) 410 588
(16.14) (23.15)

715
(28.15)

F-G F-g
F-f or or 1 2 3
f-g f-G
Front 1,100 158 1,027 100 100 98
(43.31) (6.22) (40.43) (3.94) (3.94) (3.86)

A, a B, b C, c D, d E, e F, f G, g H, h I, i J, j K, k L l M, m
316 94 290 180 120 63 29 31 125 159 272 284 285 259
(12.44) (3.70) (11.42) (7.09) (4.72) (2.48) (1.14) (1.22) (4.92) (6.26) (10.71) (11.18) (11.22) (10.20)

1 2 3 Imaginary
Standard
Line

mm (in.)
Symbol Name Hole dia. G, g Front side member standard hole ø18 (0.71)
A, a Front bumper reinforcement installation nut M10 (0.39) H, h Front floor under reinforcement standard hole ø15 (0.59)
B, b Front crossmember standard hole ø18 (0.71) I, i Strut bar installation hole-inner ø12 (0.47)
C, c Front side member standard hole ø18 (0.71) J, j Rear floor side member standard hole ø18 (0.71)
D, d Front suspension member installation nut-front M16 (0.63) K, k Rear suspension member installation nut M12 (0.47)
E, e Front suspension member installation nut-rear M16 (0.63) L, l Rear floor side member standard hole ø18 (0.71)
F, f Torque box front standard hole ø25 (0.98) M, m Rear floor side member standard hole ø18 (0.71)
 BODY DIMENSIONS DI-9

UNDER BODY

(Two-Dimensional Distance)

2,518 2,285 1,706 1,265 630 1,090 1,350 1,916

(99.13) (89.96) (67.17) (49.80) 0 (24.80) (42.91) (53.15) (75.43)

519 500 662

(20.43) (19.69) 665 585
(26.18) 550 (26.06) 525
456 (23.03) 513
RH (21.65) (17.95) (20.67)
(20.20)

329
504 (12.95) 468 456 503
LH (19.84) (18.43) (17.95) 544 (19.80) 511 547
(21.42) (20.12) (21.54)
340
(13.39)

2,395 2,177 1,395 1,135 0 541 920 1,330 1,916

(94.29) (85.71) (54.92) (44.69) (21.30) (36.22) (52.36) (75.43)

1 2 3
Front Wheel base 2,775 (109.25)
100 100 98
(3.94) (3.94) (3.86)

A, a B, b C, c D, d E, e F, f G, g H, h I, i J, j K, k L, l M, m N n O, o
316 94 290 180 752 120 63 1 29 2 31 3 125 159 272 779 284 285 259
(12.44) (3.70) (11.42) (7.09) (29.61) (4.72) (2.48) (1.14) (1.22) (4.92) (6.26) (10.71) (30.67) (11.18) (11.22) (10.20)

Imaginary
Standard
Line

mm (in.)
Symbol Name Hole dia. H, h Front side member standard hole ø18 (0.71)
A, a Front bumper reinforcement installation nut M10 (0.39) I, i Front floor under reinforcement standard hole ø15 (0.59)
B, b Front crossmember standard hole ø18 (0.71) J, j Strut bar installation hole-inner ø12 (0.47)
C, c Front side member standard hole ø18 (0.71) K, k Rear floor side member standard hole ø18 (0.71)
D, d Front suspension member installation nut-front M16 (0.63) L, l Rear suspension member installation nut M12 (0.47)
E, e Front spring support hole-outer ø12.5 (0.492) M, m Rear spring support hole-outer ø9.5 (0.374)
F, f Front suspension member installation nut-rear M16 (0.63) N, n Rear floor side member standard hole ø18 (0.71)
G, g Torque box front standard hole ø25 (0.98) O, o Rear floor side member standard hole ø18 (0.71)
DI-10 BODY DIMENSIONS

SUSPENSION CROSSMEMBER

(Three-Dimensional Distance)

Front

LH RH

700
(27.56)

920
(36.22)
879
(34.61)

945
(37.20) 1,029 520
(40.51) (20.47)
616 658
(24.25) (25.91)

676
(26.61)
486
(19.13)
738
(29.06)

Imaginary
Standard
80 74 89 55 72 72 55 89 74 80
Line
(3.15) (2.91) (3.50) (2.17) (2.83) (2.83) (2.17) (3.50) (2.91) (3.15)

HINT: For sysmbols, capital letters indicate right side of vehicle,

small letters indicate left side of vehicle (Seen from rear). mm (in.)
Symbol Name Hole dia. C, c Front frame standard hole ø13 (0.51)
A, a Front frame standard hole ø13 (0.51) D, d Front frame standard hole ø13 (0.51)
B, b Front frame standard hole ø13 (0.51) E, e Lower arm installation hole-lower ø15 (0.59)
 BODY DIMENSIONS DI-11

SUSPENSION CROSSMEMBER

(Two-Dimensional Distance)

Front

LH RH

350 350
635 (25.00) 635 (25.00)
(13.78) (13.78)

460 460
505 (19.88) (18.11) (18.11) 505 (19.88)

338 338
(13.31) (13.31)
0 0
14 (0.55) 243 243 14 (0.55)
(9.57) (9.57)
104 (4.09) 369 369 104 (4.09)
(14.53) (14.53)

Imaginary
Standard
80 74 89 55 72 72 55 89 74 80
Line
(3.15) (2.91) (3.50) (2.17) (2.83) (2.83) (2.17) (3.50)(2.91) (3.15)

HINT: For sysmbols, capital letters indicate right side of vehicle,

small letters indicate left side of vehicle (Seen from rear). mm (in.)
Symbol Name Hole dia. C, c Front frame standard hole ø13 (0.51)
A, a Front frame standard hole ø13 (0.51) D, d Front frame standard hole ø13 (0.51)
B, b Front frame standard hole ø13 (0.51) E, e Lower arm installation hole-lower ø15 (0.59)
DI-12 BODY DIMENSIONS

REFERENCE VALUE
ENGINE COMPARTMENT

(Three-Dimensional Distance)

1,552
1,582 (61.10)
(62.28)
1,562
633 (61.50)
(24.92) 1,595
(62.80)
1,536 237
(60.47) (9.33)
1,520
1,467 (59.84)
1,463 (57.76)
387 (57.60)
(15.24) 848
(33.39) 240
(9.45)
1,328
(52.28) 1,216
(47.87)
1,203
(47.36)
887 1,448 422
(34.92) (57.01) (16.61)

Vehicle Dimensions
B-E C-E
or or
b-e c-e
524 476
(20.63) (18.74)

HINT:
1) For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
2) These values are actual measurements made on model. Use these reference values.
3) Measure point with the Front fender to cowl side seal and Cool air intake dust seal removed. mm (in.)
Symbol Name Hole dia. C, c Front fender installation bolt —
A, a Front bumper cover installation bolt — D, d Front fender installation bolt —
B, b Headlight installation bolt — E, e Front fender installation bolt —
 BODY DIMENSIONS DI-13

UNDER BODY

(Three-Dimensional Distance)

679
(26.73)
871
(34.29)

274 1,007
(10.79) (39.65)
1,498
(58.98)
1,205
(47.44)
1,425 1,268
(56.10) (49.92)
802
(31.57)
1,002
(39.45) 1,044
(41.10)

658
(25.91)

936
(36.85)

HINT:
1) For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
2) These values are actual measurements made on model. Use these reference values.
3) Measure point with the Engine under cover removed. mm (in.)
Symbol Name Hole dia. C, c Front suspension member installation bolt —
A, a Front crossmember reinforcement No.2 standard hole ø10 (0.39) D, d Front side member standard hole —
B, b Front suspension member installation bolt — — — —
DI-14 BODY DIMENSIONS

UNDER BODY

(Two-Dimensional Distance)

Front bumper reinforcement

[RH] [LH]

12.9
12.9

12.3
12.4

3
M10 NUT 3
M10 NUT

72.9

25.4 72.9 31.4

Front spring support Rear spring support

11.6
0.6 9.5
2.9
42.3 64.9

36.6 56.5
2.7

0.6
22.6

36.1

12.5
62.0 50.4 39.5 37.9

5.8

3.1

12.3

2.2
2.3
2.5
2.4

20.2
4.9

mm