3506-1U-11L(INDEX).

fm 1 ページ ２０１２年１月２６日 木曜日 午前１０時３３分

2013-present CONTENTS

Title Section

Bodyshop GENERAL INFORMATION 00

Manual BODY STRUCTURE 80A

PANEL REPLACEMENT 80B

FOREWORD
WATER-PROOF AND RUST 80C
This bodyshop manual is intended for BODY PREVENTIVE
use by technicians of Authorized Mazda STRUCTURE
Dealers to help them service and repair DIMENSIONS 80D
Mazda vehicles. It can also be useful to
owners and operators of Mazda vehicles in PLASTIC BODY PARTS 80E
performing limited repair and maintenance
on Mazda vehicles. CONSTRUCTION 80F
STANDARD VALVES
For proper repair and maintenance, a
thorough familiarization with this manual is APPLICATION:
important, and it should always be kept in a This manual is applicable to vehicles beginning
handy place for quick and easy reference. with the Vehicle Identification Numbers (VIN),
shown on the following page.
All the contents of this manual, including
drawings and specifications, are the latest © 2012 Mazda Motor Corporation
available at the time of printing. PRINTED IN U.S.A., JANUARY 2012
As modifications affecting repair or Form No. 3506–1U–12A
maintenance occur, relevant information Part No. 9999–95–175F–13
supplementary to this volume will be made
available at Mazda dealers. This manual
should be kept up-to-date.

Mazda Motor Corporation reserves the

right to alter the specifications and contents
of this manual without obligation or ad-
vance notice.

All rights reserved. No part of this book may

be reproduced or used in any form or
by any means, electronic or mechanical
including photocopying and recording and
the use of any kind of information storage
and retrieval system-without permission in
writing.

Mazda Motor Corporation

HIROSHIMA, JAPAN
3506-1U-11L(INDEX).fm 2 ページ ２０１２年１月２６日 木曜日 午前１０時３３分

VEHICLE IDENTIFICATION NUMBERS (VIN)

JM3 KE2A7*D# 100001—

JM3 KE2AE*D# 100001—
JM3 KE2B7*D# 100001—
JM3 KE2BE*D# 100001—
JM3 KE2C7*D# 100001—
JM3 KE2CE*D# 100001—
JM3 KE2D7*D# 100001—
JM3 KE2DE*D# 100001—
JM3 KE2E7*D# 100001—
JM3 KE2EE*D# 100001—
JM3 KE2W7*D#100001—
JM3 KE2WE*D#100001—
JM3 KE4A7*D# 100001—
JM3 KE4AE*D# 100001—
JM3 KE4B7*D# 100001—
JM3 KE4BE*D# 100001—
JM3 KE4C7*D# 100001—
JM3 KE4CE*D# 100001—
JM3 KE4D7*D# 100001—
JM3 KE4DE*D# 100001—
JM3 KE4E7*D# 100001—
JM3 KE4EE*D# 100001—
JM3 KE4W7*D#100001—
JM3 KE4WE*D#100001—
3506-1U-12A.book 1 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

GENERAL INFORMATION 00
SECTION
00-00

Toc of SCT INFORMATION . . . . 00-00

GENERAL
Toc of SCT
00-00 GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER Vehicle Protection. . . . . . . . . . . . . . . . . 00-00–13
(VIN) CODE . . . . . . . . . . . . . . . . . . . . . . 00-00–2 Remove Dangerous Articles. . . . . . . . . 00-00–13
VEHICLE IDENTIFICATION NUMBERS Use of Pulling Equipment . . . . . . . . . . . 00-00–14
(VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–2 Prevent Short Circuits . . . . . . . . . . . . . 00-00–14
HOW TO USE THIS MANUAL . . . . . . . . . 00-00–3 EFFICIENT REMOVAL OF
Efficient Replacement of BODY PANELS . . . . . . . . . . . . . . . . . . . 00-00–15
Body Panels . . . . . . . . . . . . . . . . . . . . 00-00–3 Body Measurements . . . . . . . . . . . . . . 00-00–15
Symbols of Panel Replacement . . . . . . 00-00–4 Prevention of Body Deformation. . . . . . 00-00–15
Body Dimensions Selection of Cut-and-join Locations . . . 00-00–15
(Flat-plane Dimensions) . . . . . . . . . . . 00-00–4 Removal of Associated Parts . . . . . . . . 00-00–15
Body Dimensions Rough Cutting of Damaged Panel . . . . 00-00–16
(Straight-line Dimensions). . . . . . . . . . 00-00–6 EFFICIENT INSTALLATION OF
Symbols of Body Dimensions . . . . . . . . 00-00–7 BODY PANELS . . . . . . . . . . . . . . . . . . . 00-00–16
AIR BAG SYSTEM SERVICE WARNINGS Checking Preweld Measurements And
[STANDARD DEPLOYMENT CONTROL Watching . . . . . . . . . . . . . . . . . . . . . . 00-00–16
SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 00-00–8 Welding Notes . . . . . . . . . . . . . . . . . . . 00-00–16
Air Bag Module Inspection . . . . . . . . . . 00-00–8 Spot Welding Notes . . . . . . . . . . . . . . . 00-00–17
Air Bag Module Handling . . . . . . . . . . . 00-00–8 Checking Weld Strength. . . . . . . . . . . . 00-00–18
Side Air Bag Module Handling . . . . . . . 00-00–8 INSTALLATION PREPARATIONS. . . . . . 00-00–19
SAS Control Module Handling . . . . . . . 00-00–9 Rough Cutting of New Parts. . . . . . . . . 00-00–19
Crash Zone Sensor Handling . . . . . . . . 00-00–9 Determination of Welding Method . . . . 00-00–19
Side Air Bag Sensor Handling. . . . . . . . 00-00–9 Making Holes for Arc Welding . . . . . . . 00-00–19
Pre-tensioner Seat Belt Inspection . . . . 00-00–10 Application of Weld-through Primer . . . 00-00–20
AIR BAG SYSTEM SERVICE WARNINGS ANTICORROSION, SOUND INSULATION,
[TWO-STEP DEPLOYMENT CONTROL AND VIBRATION INSULATION . . . . . . 00-00–20
SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . . 00-00–10 Body Sealing . . . . . . . . . . . . . . . . . . . . 00-00–20
Air Bag Module Inspection . . . . . . . . . . 00-00–10 Application of Undercoating . . . . . . . . . 00-00–20
Air Bag Module Handling . . . . . . . . . . . 00-00–10 Application of Rust Inhibitor . . . . . . . . . 00-00–21
Side Air Bag Module Handling . . . . . . . 00-00–11 Application of Dumping Sheet . . . . . . . 00-00–21
SAS Control Module Handling . . . . . . . 00-00–11 ABBREVIATION . . . . . . . . . . . . . . . . . . . 00-00–21
Crash Zone Sensor Handling . . . . . . . . 00-00–11 BODY COLORS. . . . . . . . . . . . . . . . . . . . 00-00–21
Side Air Bag Sensor Handling. . . . . . . . 00-00–12 Color Code and Color Name . . . . . . . . 00-00–21
Pressure Sensor Handling . . . . . . . . . . 00-00–12 Verification of Primary Color Mixture for
Pre-tensioner Seat Belt Inspection . . . . 00-00–12 Body Color . . . . . . . . . . . . . . . . . . . . . 00-00–21
Lap Pre-tensioner Seat Belt IDENTIFICATION NUMBER
Inspection . . . . . . . . . . . . . . . . . . . . . . 00-00–12 LOCATIONS . . . . . . . . . . . . . . . . . . . . . 00-00–22
SERVICE PRECAUTIONS . . . . . . . . . . . . 00-00–13 Vehicle Identification Number (VIN) . . . 00-00–22
Arrangement of Workshop . . . . . . . . . . 00-00–13 Engine Identification Type/Number. . . . 00-00–22
Safety Precautions . . . . . . . . . . . . . . . . 00-00–13

End of Toc
BM: GENERAL INFORMATION

00-00–1
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GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN) CODE
id000000600800

J M 3 K E 2W 7 X D 1 1 2 3 4 5 6
Serial No.

0= Hiroshima
Plant 1= Hofu

Model year D= 2013

Check digit 0 to 9, X

7= 2.0 L (SKYACTIV-G 2.0) Mexico

Engine E= 2.0 L (SKYACTIV-G 2.0) USA/Canada

Body style A, B, C, D, E, W= Wagon

2= 2WD/GVW-light/with Side Air bags

Restraint system and Axle configuration, GVW class 4= 4WD/GVW-Heavy/with Side Air bags

Carline and Series KE= CX-5

World manufacturer identification JM3= Mazda M.P.V. category

ac5uuw00000002

End Of Sie
VEHICLE IDENTIFICATION NUMBERS (VIN)
id000000600100
JM3 KE2A7*D# 100001—
JM3 KE2AE*D# 100001—
JM3 KE2B7*D# 100001—
JM3 KE2BE*D# 100001—
JM3 KE2C7*D# 100001—
JM3 KE2CE*D# 100001—
JM3 KE2D7*D# 100001—
JM3 KE2DE*D# 100001—
JM3 KE2E7*D# 100001—
JM3 KE2EE*D# 100001—
JM3 KE2W7*D# 100001—
JM3 KE2WE*D# 100001—
JM3 KE4A7*D# 100001—
JM3 KE4AE*D# 100001—
JM3 KE4B7*D# 100001—
JM3 KE4BE*D# 100001—
JM3 KE4C7*D# 100001—
JM3 KE4CE*D# 100001—
JM3 KE4D7*D# 100001—
JM3 KE4DE*D# 100001—
JM3 KE4E7*D# 100001—
JM3 KE4EE*D# 100001—
JM3 KE4W7*D# 100001—
JM3 KE4WE*D# 100001—
End Of Sie

00-00–2
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GENERAL INFORMATION
HOW TO USE THIS MANUAL
id000000600900
Efficient Replacement of Body Panels
• This section contains information on the body panels in regard to the welding types, number of spot welds, and
cut-and-join locations that are necessary for panel removal and installation.
• The type of weld and position are indicated by symbols. 00-00
• Some sections have notes concerning the operation being performed. Thoroughly read and understand the
notes before carrying out any procedures.
Example

REAR FENDER PANEL REMOVAL

Shows operation section
Shows procedure, caution and note

Caution
Avoid cutting with a flame as the insulator (shaded) is flammable.
1.The rear fender panel and wheel house are joined with glue at the wheel arch line.
NOTE
Drill the 17 weld locations indicated by (A), from the room side.

Shows a cross location

Shows a dimensions BRAZE WELDING
A A

250mm
{9.84in} Shows a insulator

CUT-AND-JOINT LOCATION

ROUGH CUT LOCATION 17

(A)17

4
30mm
{1.18in} 5
5

Shows welding region

Shows number of weld
7 1 A-A

Shows a cross
acxuub00000031

00-00–3
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GENERAL INFORMATION
Symbols of Panel Replacement
• The following 6 symbols are used to indicate the type of weld that is used when replacing body panels.

SYMBOL MEANING SYMBOL MEANING

Spot welding Continuous arc welding (Cut-and-join location)
Arc welding (plug welding) Brazing welding (oxyacetylene welding)
Arc welding (spot welding) Rough cut location

ac5wzb00000204

Body Dimensions (Flat-plane Dimensions)

• Flat-plane dimensions are the dimensions measured by projecting certain reference points onto a plane
surface.
FRONT FENDER INSTALLATION NUT

810 {31.89}

FLAT-PLANE DIMENSIONS

acxuub00000033

00-00–4
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GENERAL INFORMATION
• When there are no specific indications, the standard points and dimensions are symmetrical in regard to the
center of the vehicle.
• The hypothetical lines may differ according to the vehicle model.
• The schematic diagram shows the vehicle as it is projected from the underbody.
Example
00-00
Shows vehicle section

UNDERBODY FLAT-PLANE DIMENSIONS

The dimensions on the left
and right in regard to the center Shows outline drawing
of the vehicle are different.

{19.05}
484
{17.91}

478
455

1,106 {43.54}

1,073 {37.91}
1,164 {45.83}
650 {25.59}

650 {25.59}
605 {23.82}
760 {29.92}

650 {25.59}
RH LH

{40.00}
1,016

{18.46}

{21.37}
469

485
543
Shows dimension

A B C D E F G H I J K L

Shows point
symbol
1,084 {42.84}

{25.98}

{41.06}

{26.22}

Shows hypothetical
{27.05}

{25.75}

{22.80}

{18.86}

{17.17}

{17.17}

{17.52}

{20.16}

1,043
660

666
687

654

579

479

436

436

445

512

standard line

182 93 144 120 140 68

420 1,030 760 379
{16.54} {7.17} {3.66} {5.67} {4.72} {40.55} {5.51} {29.92} {2.68} {14.92}

When there are no specific indications, all of

units are in millimeters (mm). mm {in}

Hole diameter Hole diameter

Point Point
Designation or bolt or nut Designation or bolt or nut
symbol symbol
size mm {in} size mm {in}
Crossmember No,1 standard F Front frame rear standard hole φ 18 {0.62} Shows
A φ 16 {0.62}
hole G Rear side frame standard hole φ 16 {0.62} slot
B Front side frame standard hole φ 16 {0.62} 17 × 29.5
H Link bracket
Front suspension mounting {0.66×1.16}
C φ 80 {3.14}
block surface hole center I Rear suspension housing φ 12 {0.47}
Front suspension mounting J Rear side frame standard hole φ 16 {0.62}
D M14 {0.55}
bolt K Rear suspension housing φ 31 {1.22}
E Front frame rear standard hole φ 16 {0.62} L Rear side frame standard hole φ 12 {0.47}

Shows bolt size Shows hole diameter

ac9uub00000034

00-00–5
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GENERAL INFORMATION
Body Dimensions (Straight-line Dimensions)
• Straight-line dimensions are the actual dimensions between two standard points.
FRONT FENDER INSTALLATION NUT

817 {32.17}
STRAIGHT-LINE DIMENSIONS

acxuub00000035

• When there are no specific indications, the standard points and dimensions are symmetrical in regard to the
center of the vehicle.

00-00–6
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GENERAL INFORMATION
Example

ROOM STRAIGHT-LINE DIMENSIONS (1)

Shows vehicle section Shows point 00-00

symbol Shows outline drawing
A

Shows dimension
B

1,128
{44.41} F

1,263
1,067 {49.72}
{42.01} H
Shows dimension location
No indication are shown 1,048
{41.26} I
within the outline drawing. 1,398
{55.04}
C
1,406
799 {55.35}
{31.46} G
851
{33.50}

D
When there are no specific indications, all of
units are in millimeters (mm).

mm {in}
Shows point indication
Shows details of the standard Without apostrophe:RH
Shows position and shape of the points With apostrophe:LH
point location
A B C D E,E'

Fr

Fr
Fr Fr Fr
F G H I
Fr

Fr Fr Fr

Hole diameter Hole diameter

Point Point
Designation or bolt or nut Designation or bolt or nut
symbol
size mm {in}
symbol
size mm {in}
Shows hole diameter
A Front pillar inner designation φ 16 {0.62} F Trim installation hole φ 18 {0.71}
G Harness installation hole φ 16 {0.62}
B Front pillar inner designation φ 17 {0.67} 17 × 29.5
H Chaker bracket installation hole Shows
{0.66×1.16}
C Harness installation hole φ 31 {1.22} slot
I Chaker bracket installation hole φ 12 {0.47}
D Front floor pan designation M14 {0.55}
Shows bolt size
E Adjuster installation hole φ 16 {0.62}

am3uub0000007

Symbols of Body Dimensions

• The following 8 symbols are used to indicate the standard points.

SYMBOL MEANING SYMBOL MEANING

Center of circular hole (arrow only) Bolt tip
Center elliptical hole Center of rectangular-shaped hole

Notch Edge of rectangular-shaped hole

Panel seam, bead, etc.
acxuub00000037

End Of Sie

00-00–7
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GENERAL INFORMATION
AIR BAG SYSTEM SERVICE WARNINGS [STANDARD DEPLOYMENT CONTROL SYSTEM]
id0000009200d8
Air Bag Module Inspection
• Inspecting an air bag module using a tester can operate (deploy) the air bag module, which may cause
serious injury. Do not use a tester to inspect an air bag module. Always use the on-board diagnostic
function to diagnose the air bag module for malfunctions.
NO GOOD

ac5uuw00002161

Air Bag Module Handling

• Before removing the air bag module or disconnecting the air bag module connector, always switch the
ignition to off, disconnect the negative battery cable, and then wait for 1 min or more to allow the
backup power supply of the SAS control module to deplete its stored power.
• Handling a live (undeployed) air bag module
that is pointed toward your body could result
in serious injury if the air bag module were to
accidentally operate (deploy). When carrying
a live (undeployed) air bag module, point the
deployment surface away from your body to
lessen the chance of injury in case it operates
(deploys).

GOOD NO GOOD

ac5uuw00002162

• A live (undeployed) air bag module placed

with its deployment surface to ground is GOOD NO GOOD
dangerous. If the air bag module were to
accidentally operate (deploy), it could cause
serious injury. Always place a live
(undeployed) air bag module with its
deployment surface up.

ac5uuw00002163

Side Air Bag Module Handling

• Before removing the side air bag module or disconnecting the side air bag module connector, always
switch the ignition to off, disconnect the negative battery cable, and then wait for 1 min or more to
allow the backup power supply of the SAS control module to deplete its stored power.
• When a side air bag module operates (deploys) due to a collision, the interior of the seat back (pad,
frame, trim) may become damaged. If a side air bag does not operate (deploy) normally from a seat
back that has been reused, a serious accident may result. After a side air bag has operated (deployed),
always replace both the side air bag module and the seat back (pad, frame, trim) with new parts. After
servicing, verify that the seat operates normally and that the wiring harness is not caught.

00-00–8
3506-1U-12A.book 9 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

GENERAL INFORMATION
SAS Control Module Handling
• When connecting or disconnecting the SAS control module connector, a person charged with static
electricity could accidentally operate (deploy) each air bag module. Before connecting or
disconnecting the SAS control module connector, discharge any charged static electricity from your
body.
• Removing the SAS control module or disconnecting the SAS control module connector with the 00-00
ignition ON can activate the sensor in the SAS control module and operate (deploy) the air bags and
pre-tensioner seat belts, which may cause serious injury. Before removing the SAS control module or
disconnecting the SAS control module connector, always switch the ignition to off, disconnect the
negative battery cable, and then wait for 1 min or more to allow the backup power supply of the SAS
control module to deplete its stored power.
• Connecting the SAS control module connector with the SAS control module not securely fixed to the
vehicle is dangerous. The sensor in the SAS control module could send an electrical signal to the air
bag modules and pre-tensioner seat belts. This will operate (deploy) the air bags and pre-tensioner
seat belts, which may result in serious injury. Therefore, before connecting the connector, securely fix
the SAS control module to the vehicle.
• Because a sensor is built into the SAS control module, once the air bags and pre-tensioner seat belts
have operated (deployed) due to a collision or other causes, the SAS control module must be replaced
with a new one even if the used one does not have any visible external damage or deformation. The
used SAS control module may have been damaged internally, which may cause improper operation. If
the SAS control module is reused, the air bags and pre-tensioner seat belts may not operate (deploy)
normally, which could result in a serious accident. Always replace the SAS control module with a new
one. The SAS control module cannot be bench-checked or self-checked.

Crash Zone Sensor Handling

• Removing the crash zone sensor or disconnecting the crash zone sensor connector with the ignition
ON can activate the crash zone sensor and operate (deploy) the air bags and pre-tensioner seat belts,
which may cause serious injury. Before removing the crash zone sensor or disconnecting the crash
zone sensor connector, always switch the ignition to off, disconnect the negative battery cable, and
then wait for 1 min or more to allow the backup power supply of the SAS control module to deplete its
stored power.
• If the crash zone sensor is subjected to shock or the sensor is disassembled, the air bags and pre-
tensioner seat belts may accidentally operate (deploy) and cause injury, or the system may fail to
operate normally and cause a serious accident. Do not subject the crash zone sensor to shock or
disassemble the sensor.
• Because a sensor is built into the crash zone sensor, once the air bags and pre-tensioner seat belts
have operated (deployed) due to a collision or other causes, the crash zone sensor must be replaced
with a new one even if the used one does not have any visible external damage or deformation. If the
crash zone sensor is reused, the air bags and pre-tensioner seat belts may not operate (deploy)
normally, which could result in a serious accident. Always replace the crash zone sensor with a new
one. The crash zone sensor cannot be bench-checked or self-checked.

Side Air Bag Sensor Handling

• Removing the side air bag sensor or disconnecting the side air bag sensor connector with the ignition
ON can activate the side air bag sensor and operate (deploy) the side air bag, which may cause serious
injury. Before removing the side air bag sensor or disconnecting the side air bag sensor connector,
always switch the ignition to off, disconnect the negative battery cable, and then wait for 1 min or more
to allow the backup power supply of the SAS control module to deplete its stored power.
• If the side air bag sensor is subjected to shock or the sensor is disassembled, the side air bag may
accidentally operate (deploy) and cause injury, or the system may fail to operate normally and cause a
serious accident. Do not subject the side air bag sensor to shock or disassemble the sensor.
• Because a sensor is built into the side air bag sensor, once the air bag has operated (deployed) due to
a collision or other causes, the side air bag sensor must be replaced with a new one even if the used
one does not have any visible external damage or deformation. If the side air bag sensor is reused, the
side air bag may not operate (deploy) normally, which could result in a serious accident. Always
replace the side air bag sensor with a new one. The side air bag sensor cannot be bench-checked or
self-checked.

00-00–9
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GENERAL INFORMATION
Pre-tensioner Seat Belt Inspection
• Inspecting a pre-tensioner seat belt using a
tester can operate (deploy) the pre-tensioner
seat belt, which may cause serious injury. Do
not use a tester to inspect a pre-tensioner
seat belt. Always use the on-board diagnostic
function to diagnose the pre-tensioner seat
belt for malfunctions.
End Of Sie

NO GOOD
ac5uuw00001455

AIR BAG SYSTEM SERVICE WARNINGS [TWO-STEP DEPLOYMENT CONTROL SYSTEM]

id0000009200d9
Air Bag Module Inspection
• Inspecting an air bag module using a tester can operate (deploy) the air bag module, which may cause
serious injury. Do not use a tester to inspect an air bag module. Always use the on-board diagnostic
function to diagnose the air bag module for malfunctions.
NO GOOD

ac5uuw00001452

Air Bag Module Handling

• Before removing the air bag module or disconnecting the air bag module connector, always switch the
ignition to off, disconnect the negative battery cable, and then wait for 1 min or more to allow the
backup power supply of the SAS control module to deplete its stored power.
• Handling a live (undeployed) air bag module
that is pointed toward your body could result
in serious injury if the air bag module were to
accidentally operate (deploy). When carrying
a live (undeployed) air bag module, point the
deployment surface away from your body to
lessen the chance of injury in case it operates
(deploys).

GOOD NO GOOD

ac5uuw00001453

• A live (undeployed) air bag module placed

with its deployment surface to ground is GOOD NO GOOD
dangerous. If the air bag module were to
accidentally operate (deploy), it could cause
serious injury. Always place a live
(undeployed) air bag module with its
deployment surface up.

ac5uuw00001454

00-00–10
3506-1U-12A.book 11 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

GENERAL INFORMATION
Side Air Bag Module Handling
• Before removing the side air bag module or disconnecting the side air bag module connector, always
switch the ignition to off, disconnect the negative battery cable, and then wait for 1 min or more to
allow the backup power supply of the SAS control module to deplete its stored power.
• When a side air bag module operates (deploys) due to a collision, the interior of the seat back (pad,
frame, trim) may become damaged. If a side air bag does not operate (deploy) normally from a seat 00-00
back that has been reused, a serious accident may result. After a side air bag has operated (deployed),
always replace both the side air bag module and the seat back (pad, frame, trim) with new parts. After
servicing, verify that the seat operates normally and that the wiring harness is not caught.

SAS Control Module Handling

• When connecting or disconnecting the SAS control module connector, a person charged with static
electricity could accidentally operate (deploy) each air bag module and pre-tensioner seat belt. Before
connecting or disconnecting the SAS control module connector, discharge any charged static
electricity from your body.
• Removing the SAS control module or disconnecting the SAS control module connector with the
ignition ON can activate the sensor in the SAS control module and operate (deploy) the air bags, pre-
tensioner seat belts and lap pre-tensioner seat belts, which may cause serious injury. Before removing
the SAS control module or disconnecting the SAS control module connector, always switch the ignition
to off, disconnect the negative battery cable, and then wait for 1 min or more to allow the backup power
supply of the SAS control module to deplete its stored power.
• Connecting the SAS control module connector with the SAS control module not securely fixed to the
vehicle is dangerous. The sensor in the SAS control module could send an electrical signal to the air
bag modules, pre-tensioner seat belts and lap pre-tensioner seat belts. This will operate (deploy) the air
bags, pre-tensioner seat belts and lap pre-tensioner seat belts, which may result in serious injury.
Therefore, before connecting the connector, securely fix the SAS control module to the vehicle.
• Because a sensor is built into the SAS control module, once the air bags, pre-tensioner seat belts and
lap pre-tensioner seat belts have operated (deployed) due to a collision or other causes, the SAS
control module must be replaced with a new one even if the used one does not have any visible
external damage or deformation. The used SAS control module may have been damaged internally,
which may cause improper operation. If the SAS control module is reused, the air bags, pre-tensioner
seat belts and lap pre-tensioner seat belts may not operate (deploy) normally, which could result in a
serious accident. Always replace the SAS control module with a new one. The SAS control module
cannot be bench-checked or self-checked.

Crash Zone Sensor Handling

• Removing the crash zone sensor or disconnecting the crash zone sensor connector with the ignition
ON can activate the crash zone sensor and operate (deploy) the air bags and pre-tensioner seat belts,
which may cause serious injury. Before removing the crash zone sensor or disconnecting the crash
zone sensor connector, always switch the ignition to off, disconnect the negative battery cable, and
then wait for 1 min or more to allow the backup power supply of the SAS control module to deplete its
stored power.
• If the crash zone sensor is subjected to shock or the sensor is disassembled, the air bags and pre-
tensioner seat belts may accidentally operate (deploy) and cause injury, or the system may fail to
operate normally and cause a serious accident. Do not subject the crash zone sensor to shock or
disassemble the sensor.
• Because a sensor is built into the crash zone sensor, once the air bags and pre-tensioner seat belts
have operated (deployed) due to a collision or other causes, the crash zone sensor must be replaced
with a new one even if the used one does not have any visible external damage or deformation. If the
crash zone sensor is reused, the air bags and pre-tensioner seat belts may not operate (deploy)
normally, which could result in a serious accident. Always replace the crash zone sensor with a new
one. The crash zone sensor cannot be bench-checked or self-checked.

00-00–11
3506-1U-12A.book 12 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

GENERAL INFORMATION
Side Air Bag Sensor Handling
• Removing the side air bag sensor or disconnecting the side air bag sensor connector with the ignition
ON can activate the side air bag sensor and operate (deploy) the side air bag, which may cause serious
injury. Before removing the side air bag sensor or disconnecting the side air bag sensor connector,
always switch the ignition to off, disconnect the negative battery cable, and then wait for 1 min or more
to allow the backup power supply of the SAS control module to deplete its stored power.
• If the side air bag sensor is subjected to shock or the sensor is disassembled, the side air bag may
accidentally operate (deploy) and cause injury, or the system may fail to operate normally and cause a
serious accident. Do not subject the side air bag sensor to shock or disassemble the sensor.
• Because a sensor is built into the side air bag sensor, once the air bag has operated (deployed) due to
a collision or other causes, the side air bag sensor must be replaced with a new one even if the used
one does not have any visible external damage or deformation. If the side air bag sensor is reused, the
side air bag may not operate (deploy) normally, which could result in a serious accident. Always
replace the side air bag sensor with a new one. The side air bag sensor cannot be bench-checked or
self-checked.

Pressure Sensor Handling

• Removing the pressure sensor or disconnecting the pressure sensor connector with the ignition ON
can activate the pressure sensor and operate (deploy) the side air bag, which may cause serious injury.
Before removing the pressure sensor or disconnecting the pressure sensor connector, always switch
the ignition to off, disconnect the negative battery cable, and then wait for 1 min or more to allow the
backup power supply of the SAS control module to deplete its stored power.
• If the pressure sensor is subjected to shock or the sensor is disassembled, the side air bag may
accidentally operate (deploy) and cause injury, or the system may fail to operate normally and cause a
serious accident. Do not subject the pressure sensor to shock or disassemble the sensor.
• Because a sensor is built into the pressure sensor, once the air bag has operated (deployed) due to a
collision or other causes, the pressure sensor must be replaced with a new one even if the used one
does not have any visible external damage or deformation. If the pressure sensor is reused, the side air
bag may not operate (deploy) normally, which could result in a serious accident. Always replace the
pressure sensor with a new one. The pressure sensor cannot be bench-checked or self-checked.

Pre-tensioner Seat Belt Inspection

• Inspecting a pre-tensioner seat belt using a
tester can operate (deploy) the pre-tensioner
seat belt, which may cause serious injury. Do
not use a tester to inspect a pre-tensioner
seat belt. Always use the on-board diagnostic
function to diagnose the pre-tensioner seat
belt for malfunctions.

NO GOOD
ac5uuw00001455

Lap Pre-tensioner Seat Belt Inspection

• Inspecting a lap pre-tensioner seat belt using
a tester can operate (deploy) the lap pre-
tensioner seat belt, which may cause serious
injury. Do not use a tester to inspect a lap pre-
tensioner seat belt. Always use the on-board
diagnostic function to diagnose the lap pre-
tensioner seat belt for malfunctions.
End Of Sie NO GOOD

ac5uuw00001456

00-00–12
3506-1U-12A.book 13 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

GENERAL INFORMATION
SERVICE PRECAUTIONS
id000000600200
Arrangement of Workshop
• Arrangement of the workshop is important for safe and efficient work.

Safety Precautions 00-00

• Protective head covering and safety shoes should
always be worn. Depending upon the nature of
the work, gloves, safety glasses, ear protectors,
face shield, etc., should also be used. WELDING COTTON
WELDING EAR
GLASSES PROTECTORS GLOVES GLOVES

DUST SAFETY SAFETY

MASK GLASSES SHOES
FACE SHIELD
am3uub0000007

Vehicle Protection
• Use seat covers and floor covers.
• Use heat-resistant protective covers to protect glass areas and seats from heat or sparks during welding.
• Protect items such as moldings, garnishes, and
ornaments with tape when welding.

acxuub00000063

Remove Dangerous Articles

• Remove the fuel tank before using an open flame
in that area. Plug connection piping to prevent
fuel leakage.

acxuub00000064

00-00–13
3506-1U-12A.book 14 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

GENERAL INFORMATION
Use of Pulling Equipment
• When using pulling equipment, keep away from
the pulling area and use safety wires to prevent
accidents.

SAFETY WIRES

am3uub0000007

Prevent Short Circuits

• Switch the ignition to off.
• Disconnect the battery cables. Battery cable

acxuub00000042

• Securely connect the welding machine ground

near the welding area.
End Of Sie

GROUND

am3uub0000007

00-00–14
3506-1U-12A.book 15 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

GENERAL INFORMATION
EFFICIENT REMOVAL OF BODY PANELS
id000000600300
Body Measurements
• Before removal or rough-cutting, first measure the
body at and around the damaged area against
the standard reference dimension specifications. 00-00
If there is deformation, use frame repair
equipment to make a rough correction.

acxuub00000065

Prevention of Body Deformation

• Use a clamp or a jack for removal and reinforce at
and around the rough-cutting location to prevent
deforming of the body.

acxuub00000066

Selection of Cut-and-join Locations

• For parts where complete replacement is not
feasible, careful cutting and joining operations
should be followed. If the location to be cut is a
flat area where there is no reinforcement, the
selected cutting location should be where the
welding distortion will be minimal.

acxuub00000067

Removal of Associated Parts

• Protect moldings, garnishes, and ornaments with tape when removing associated parts.

00-00–15
3506-1U-12A.book 16 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

GENERAL INFORMATION
Rough Cutting of Damaged Panel
• Verify that there are no parts (such as pipes, hoses, and wiring harness) nearby or on the opposite side of a
panel which could be damaged by heat.
• For cut-and-join areas, allow for an overlap of
30—50 mm {1.2—1.9 in} and then rough-cut the
damaged panel.
End Of Sie Wiring harness

Rough cut location Cut-and-join location

acxuub00000047

EFFICIENT INSTALLATION OF BODY PANELS

id000000600500
Checking Preweld Measurements And Watching
• Align to the standard reference dimensions,
based upon the body dimensions illustration, so
that new parts are installed in the correct position.

acxuub00000069

Welding Notes
• For the number of weld points, welding should be
performed in accordance with the following
reference standards. SPOT WELDING
ORIGINAL WELD REPAIR WELD
ORIGINAL NUMBER OF
WELDS x 1.3 OR MORE

CO2 ARC WELDING

ORIGINAL SPOT WELD
IF 3 mm REPAIR WELD
{0.12 in} OR MORE

ORIGINAL NUMBER OF
WELDS OR MORE

am3uub0000007

00-00–16
3506-1U-12A.book 17 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

GENERAL INFORMATION
Spot Welding Notes
• The shape of the spot welder tip is D=(2×t)+3. If
the upper panel thickness is different from that of
70—120°
the under panel, adjust to the thinner one.

D t 00-00

ac9uub00000041

• Because the weld strength is affected by the

shape of the spot welder tip, the optimum
condition of the tip should always be maintained.
• Spot welds should be made at points other than
the originally welded points.

acxuub00000070

• Before spot welding, make a trial weld using the

same material as the body panel to check the TEST PIECE METHOD
weld strength.

NUGGET DIAMETER
:4/5 OF TIP

am3uub0000007

00-00–17
3506-1U-12A.book 18 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

GENERAL INFORMATION
Checking Weld Strength
• Installation locations of the engine, chassis, and
seat belts are designated as important safety CHISEL DIMENSIONS
locations for weld strength. Check weld strength
by driving a chisel between the panels at every 25 mm 20°
fourth or fifth weld spot, and every tenth regular {0.98 in}
weld location.

8 mm {0.31 in}

WELD LOCATION
WITHIN 5 mm
{0.20 in}

WITHIN 5 mm
{0.20 in}

am3uub0000007

• Drive the chisel between the panels according to

the number of panels as shown below. TWO PANELS WELD LOCATION
• To determine weld strength, drive the chisel
between the panel and check whether the panels
come apart. If the panels come apart, make
another weld near the original weld.
ONE LOCATION
• Restore the shape of the checked area.
End Of Sie THREE PANELS
WELD LOCATION

TWO LOCATION

FOUR PANELS
WELD LOCATION

THREE LOCATION

am3uub0000008

00-00–18
3506-1U-12A.book 19 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

GENERAL INFORMATION
INSTALLATION PREPARATIONS
id000000600400
Rough Cutting of New Parts
• For cut-and-join areas, allow for an overlap of 30—50 mm {1.2—1.9 in} with the remaining area on the body
side and then rough-cut the new parts.
00-00

30—50 mm{1.2—1.9 in} 30—50 mm{1.2—1.9 in}

OVER LAP OVER LAP

BODY SIDE ROUGH CUT LOCATION

NEW PART ROUGH CUT LOCATION

am3uub0000008

Determination of Welding Method

• If the total thickness at the area to be welded is 3 mm {0.12 in} or more, use a gas shielded-arc welder to make
the plug welds.

3 mm
{0.1 in} OR MORE

am3uub0000008

Making Holes for Arc Welding

• For places that cannot be spot welded, make a hole for arc welding using a punch or drill as follows.

(mm {in})
Panel thickness (φ) Hole diameter (φ)
0.60—0.90 {0.024—0.035} 5.0 {0.20}
0.91—1.20 {0.036—0.047} 6.0 {0.24}
1.21—1.80 {0.0477—
8.0 {0.31}
0.0708}
1.81—4.50 {0.072—0.177} 10.0 {0.394}

• Grind the shaded section indicated in the diagram below and create a hole in the part where the 3—4 plates
are put together. Also, weld the plates together tightly so that gaps do not develop.

φ10.0 mm {0.394 in}

30° 30°

OUTER PANEL
MIDDLE PANEL
INNER PANEL

am3uub0000008

00-00–19
3506-1U-12A.book 20 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

GENERAL INFORMATION
Application of Weld-through Primer
• For treatment against corrosion, remove the paint grease, and other material from the portion of new part and
body to be welded, and apply weld-through primer.
End Of Sie

acxuub00000068

ANTICORROSION, SOUND INSULATION, AND VIBRATION INSULATION

id000000600600
Body Sealing
• Apply body sealer where necessary.
• For locations where application of body sealer is difficult after installation, apply it before installation.

acxuub00000059

Application of Undercoating
• Apply an undercoat to the required location of the body.

acxuub00000060

00-00–20
3506-1U-12A.book 21 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

GENERAL INFORMATION
Application of Rust Inhibitor
• Apply rust inhibitor (wax, oil, etc.) to the back of the welded areas.

00-00

acxuub00000061

Application of Dumping Sheet

• Apply dumping sheet by heating with an infrared ray lamp.
End Of Sie

acxuub00000062

ABBREVIATION
id000000600700

Fr Front
LH Left Hand
RH Right Hand
Rr Rear

End Of Sie
BODY COLORS
WM: GENERAL INFORMATION

id000000788800
Color Code and Color Name
Color Code Color Name
A4D Arctic white CLE
16W Black MC
27A Velocity red MC
34K Crystal white pearl MC
35J Stormy blue MC
36C Metropolitan gray MC
38P Aluminum M
41B Sky blue MC
41G Zeal red MC

Verification of Primary Color Mixture for Body Color

Confirm the primary color mixture for the body color at the paint manufacturer URL.
End Of Sie

00-00–21
3506-1U-12A.book 22 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

GENERAL INFORMATION
IDENTIFICATION NUMBER LOCATIONS
id000000800800
Vehicle Identification Number (VIN)
• The VIN marking position is located on the floor
on the front passenger-side.

ac5wzw0000118

• If the VIN plate is adhered to the dashboard, it is

located in the position shown in the figure.

am6zzw0000387

Engine Identification Type/Number

SKYACTIV-G 2.0

FRONT

ac5wzw0000118

End Of Sie

00-00–22
3506-1U-12A.book 1 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY & ACCESSORIES 09SECTION

09-80A
Toc
BODYof SCT
STRUCTURE BODY STRUCTURE
[CONSTRUCTION] . . . . . . . . . 09-80A [DIMENSIONS] . . . . . . . . . . . 09-80D
BODY STRUCTURE BODY STRUCTURE
[PANEL REPLACEMENT] . . . 09-80B [PLASTIC BODY PARTS] . . . 09-80E
BODY STRUCTURE BODY STRUCTURE
[WATER-PROOF AND RUST [CONSTRUCTION STANDARD
PREVENTIVE]. . . . . . . . . . . . . 09-80C VALUES] . . . . . . . . . . . . . . . . 09-80F
Toc of SCT
09-80A BODY STRUCTURE [CONSTRUCTION]
BODY COMPONENTS CONSTRUCTION Characteristics of Ultra High-Tensile
[CONSTRUCTION] . . . . . . . . . . . . . . . . . 09-80A–2 Steel Plates . . . . . . . . . . . . . . . . . . . . 09-80A–6
ULTRA HIGH-TENSION STEEL Range of Use and Cautions for
[CONSTRUCTION] . . . . . . . . . . . . . . . . . 09-80A–6 Service . . . . . . . . . . . . . . . . . . . . . . . . 09-80A–7

End of Toc
BM: CONSTRUCTION

09-80A–1
3506-1U-12A.book 2 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [CONSTRUCTION]

BODY COMPONENTS CONSTRUCTION [CONSTRUCTION]
id098007739700

51
44

34
58 30 37
57
56
55 19 31 39
54
45 53 36
18 35 38
52 15
1 46 40

47 28
19 20 32
49 26
16 29 33
48 21

17 27
50

6 5 8 7 10 22
25
23
9 24
2
11
41 43
12

42 81
80 82
3 4 68 67 69 81
13
78
14 66 77

62 74
61 70 73 75
72
62 79
61
63

71
76

63
64 60

65

59
ac5jjb00000011

09-80A–2
3506-1U-12A.book 3 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [CONSTRUCTION]

x:Applied
-:Not applied
High- Thicknes
Ultra high- Rust proof
No. Part Name tension s (mm)
tension steel steel
steel {in}
0.65
1 Hood - X X
{0.026}
2.90 09-80A
2 Suspension mounting reinforcement - X X
{0.114}
2.60
3 Bumper bracket X - X
{0.102}
2.00
4 Outer frame reinforcement - X X
{0.0787}
0.90
5 Shroud upper reinforcement - - X
{0.035}
Apron
0.80
reinforcement - X X
{0.031}
(lower)
6 Shroud side member component 1.20
Side stay - - X
{0.0472}
Shroud side 0.90
- X X
panel {0.035}
1.40
Front - X X
{0.0551}
7 Front side frame (outer)
1.60
Rear X - X
{0.0630}
1.40
Front - X X
{0.0551}
8 Front side frame (inner)
1.60
Rear X - X
{0.0630}
Apron upper 1.00
- - X
reinforcement {0.0394}
Apron
1.20
reinforcement X - X
{0.0472}
No.3
9 Wheel apron component
Cowl side
1.00
Reinforcement - X X
{0.0394}
inner
Suspension 0.80
- - X
housing (lower) {0.031}
0.80
10 Front fender junction - - X
{0.031}
1.60
11 Side member - - X
{0.0630}
2.00
12 Front frame (rear) X - X
{0.0787}
1.40
13 Torque box - X X
{0.0551}
0.70
14 Front fender panel - - X
{0.028}
0.70
15 Front pillar upper reinforcement - X -
{0.028}
1.40
16 Inner front pillar X - -
{0.0551}
1.20
17 Inner hinge pillar X - X
{0.0472}
1.20
18 Roof rail (inner) X - -
{0.0472}
1.20
19 Nut plate - - -
{0.0472}
1.20
20 Roof rail reinforcement X - -
{0.0472}

09-80A–3
3506-1U-12A.book 4 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [CONSTRUCTION]

High- Thicknes
Ultra high- Rust proof
No. Part Name tension s (mm)
tension steel steel
steel {in}
1.60
21 Front pillar reinforcement X - -
{0.0630}
1.60
22 Front pillar reinforcement X - -
{0.0630}
1.20
Upper X - -
{0.0472}
23 Hinge reinforcement
1.60
Lower X - -
{0.0630}
1.60
24 Upper cowl side reinforcement - X X
{0.0630}
1.40
25 Side sill reinforcement X - X
{0.0551}
1.20
26 Inner center pillar - X X
{0.0472}
2.30
27 Center pillar inner reinforcement X - -
{0.0906}
2.00
Upper X - -
{0.0787}
28 Center pillar reinforcement
2.00
Lower X - -
{0.0787}
1.80
29 Side sill reinforcement rear X - X
{0.0709}
0.70
30 Inner rear pillar - - X
{0.028}
0.65
31 Wheel housing (outer) - - X
{0.026}
0.70
32 Wheel housing (inner) - - X
{0.028}
1.20
Upper X - -
{0.0472}
0.65
33 Suspension housing reinforcement Center - - -
{0.026}
1.80
Lower - - -
{0.0709}
0.65
34 Rear side panel - - X
{0.026}
1.00
35 Corner junction - - -
{0.0394}
0.70
36 D-pillar reinforcement (upper) - - -
{0.028}
0.70
37 Rear pillar outer - - X
{0.028}
0.70
38 D-pillar reinforcement (lower) - - -
{0.028}
0.70
39 Corner plate - - X
{0.028}
0.70
40 Rear fender lower panel - - X
{0.028}
0.70
41 Cabin side outer frame - - X
{0.028}
0.70
Outer panel - X X
{0.028}
42 Front door
0.65
Inner panel - - X
{0.026}
0.70
Outer panel - X X
{0.028}
43 Rear door
0.65
Inner panel - - X
{0.026}

09-80A–4
3506-1U-12A.book 5 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [CONSTRUCTION]

High- Thicknes
Ultra high- Rust proof
No. Part Name tension s (mm)
tension steel steel
steel {in}
0.70
Outer panel - - X
{0.028}
44 Liftgate
0.65
Inner panel - - X
{0.026}
0.65 09-80A
Cowl panel - - X
{0.026}
45 Dash and cowl component
Dash upper 0.90
- - X
panel {0.035}
1.40
46 Wiper bracket - X X
{0.0551}
1.40
47 Cowl upper plate - X X
{0.0551}
0.80
Front - X X
{0.031}
48 Cowl side reinforcement lower
1.20
Rear X - X
{0.0472}
1.20
49 Wiper bracket - - X
{0.0472}
Dash lower 0.80
- - X
panel {0.031}
50 Dash lower component
Tunnel junction 0.90
- - X
No.1 {0.035}
0.75
51 Roof panel - - -
{0.030}
0.65
52 Front header - X -
{0.026}
0.55
53 Roof reinforcement No.1 - - -
{0.022}
1.00
54 Roof reinforcement No.2 X - -
{0.0394}
0.55
55 Roof reinforcement No.3 - - -
{0.022}
0.55
56 Roof reinforcement No.4 - - -
{0.022}
0.55
57 Roof reinforcement No.5 - - -
{0.022}
0.65
Upper - - -
{0.026}
58 Rear header
0.70
Lower - - X
{0.028}
1.40
Front X - X
{0.0551}
59 Front B frame
1.00
Rear X - X
{0.0394}
1.20
60 Floor reinforcement X - -
{0.0472}
1.00
61 Crossmember No.2 X - -
{0.0394}
1.20
62 Crossmember No.2.5 X - -
{0.0472}
0.60
63 Front floor side panel - - X
{0.024}
0.90
64 Tunnel reinforcement X - X
{0.035}
1.40
Front X - X
{0.0551}
65 Side sill (inner)
1.60
Rear X - X
{0.0630}

09-80A–5
3506-1U-12A.book 6 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [CONSTRUCTION]

High- Thicknes
Ultra high- Rust proof
No. Part Name tension s (mm)
tension steel steel
steel {in}
0.60
66 Center floor panel - - X
{0.024}
0.60
67 Trunk floor panel - - X
{0.024}
0.90
68 Rear floor front reinforcement - X -
{0.035}
1.60
69 Brace reinforcement - - -
{0.0630}
0.60
70 Crossmember No.3 (upper) - - X
{0.024}
1.00
71 Crossmember No.3 (lower) X - X
{0.0394}
1.20
72 Anchor reinforcement - X X
{0.0472}
1.00
73 Crossmember No.4 (front) - X X
{0.0394}
0.70
Center - - X
{0.028}
74 Crossmember No.4 (rear)
1.20
Side - - X
{0.0472}
0.90
75 Rear frame reinforcement X - X
{0.035}
1.80
Front X - X
{0.0709}
1.80
76 Rear side frame Center X - X
{0.0709}
1.60
Rear X - X
{0.0630}
1.40
Front X - X
{0.0551}
77 Floor side panel No.1
2.00
Rear - X X
{0.0787}
0.70
78 Floor side panel No.2 - - X
{0.028}
2.00
79 Rear bumper bracket X - X
{0.0787}
1.00
Rear end panel - - X
{0.0394}
80 Rear end panel component
Rear end 0.70
- - -
member {0.028}
1.00
81 Rear bumper reinforcement No.1 - - X
{0.0394}
1.00
82 Rear bumper reinforcement No.2 - - X
{0.0394}

End Of Sie
ULTRA HIGH-TENSION STEEL [CONSTRUCTION]
id098007745600
Characteristics of Ultra High-Tensile Steel Plates
• Ultra high-tensile steel plates have enhanced tensile strength compared to previous high-tensile steel plates.
• Because the strength is maintained even though the plates are thin-walled, the ultra high-tensile steel plates
are used for the frames and the main frame parts which form the cabin, reducing the weight of the vehicle.
• Enhanced shock absorption has improved the safety.

09-80A–6
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BODY STRUCTURE [CONSTRUCTION]

Range of Use and Cautions for Service
• Because the ultra high-tensile steel is hard and it may be difficult to reform, when extracting the damaged part
using a frame repair machine, perform the work verifying that other parts are not affected.
• When drilling welded parts, use a well-ground drill bit.
• After welding, inspect the weld strength. If adhesion is poor, perform arc welding (plug welding).

19
9 09-80A
17 33

10 8

7
21
27
22 26 20
4

34

32

5
16 29 31
25 30
3
14
28
15
11 23 13 24
18 12

2
ac5wzb00000190

Strength Suspension housing reinforcement

NO. Part Name 17 780
(MPa) (upper)
1 Bumper bracket 590 18 Lower cowl side reinforcement (rear) 590
2 Front side frame (outer, rear) 590 19 Roof reinforcement No.2 590
3 Front side frame (inner, rear) 590 20 Front B frame front 590
4 Apron reinforcement No.3 590 21 Front B frame rear 590
5 Front frame (rear) 590 22 Floor reinforcement 780
6 Inner front pillar 780 23 Crossmember No.2 590
7 Inner hinge pillar 590 24 Crossmember No.2.5 780
8 Roof rail (inner) 590 25 Tunnel reinforcement 590
9 Roof rail reinforcement 780 26 Side sill (inner, front) 590
10 Front pillar reinforcement 590 27 Side sill (inner, rear) 780
11 Hinge reinforcement (upper) 590 28 Crossmember No.3 (lower) 590
12 Hinge reinforcement lower 590 29 Rear frame reinforcement 590
13 Side sill reinforcement 780 30 Rear side frame (front) 590
14 Center pillar reinforcement (upper) 980 31 Rear side frame (center) 590
15 Center pillar reinforcement (lower) 590 32 Rear side frame (rear) 590
16 Side sill reinforcement (rear) 590 33 Floor side panel No.1 590
34 Rear bumper bracket 590

End Of Sie

09-80A–7
3506-1U-12A.book 8 ページ ２０１２年１月２６日 木曜日 午前１０時２０分
3506-1U-12A.book 1 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

09-80B BODY STRUCTURE [PANEL REPLACEMENT]
BUMPER BRACKET REMOVAL Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–18
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–3 Installation Procedure . . . . . . . . . . . . . . 09-80B–19
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–3 FRONT FENDER JUNCTION REMOVAL
Removal Procedure . . . . . . . . . . . . . . . 09-80B–3 [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–20
BUMPER BRACKET INSTALLATION Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–20
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–5 Removal Procedure. . . . . . . . . . . . . . . . 09-80B–20
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–5 FRONT FENDER JUNCTION
Installation Procedure . . . . . . . . . . . . . 09-80B–5 INSTALLATION 09-80B
SHROUD SIDE MEMBER REMOVAL [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–21
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–6 Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–21
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–6 Installation Procedure . . . . . . . . . . . . . . 09-80B–21
Removal Procedure . . . . . . . . . . . . . . . 09-80B–6 FRONT SIDE FRAME REMOVAL
SHROUD SIDE MEMBER INSTALLATION [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–22
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–7 Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–22
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–7 Removal Procedure. . . . . . . . . . . . . . . . 09-80B–22
Installation Procedure . . . . . . . . . . . . . 09-80B–7 FRONT SIDE FRAME INSTALLATION
SHROUD UPPER [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–23
REINFORCEMENT REMOVAL Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–23
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–8 Installation Procedure . . . . . . . . . . . . . . 09-80B–23
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–8 FRONT SIDE FRAME
Removal Procedure . . . . . . . . . . . . . . . 09-80B–8 (PARTIAL CUTTING) REMOVAL
SHROUD UPPER [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–24
REINFORCEMENT INSTALLATION Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–24
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–9 Removal Procedure. . . . . . . . . . . . . . . . 09-80B–24
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–9 FRONT SIDE FRAME
Installation Procedure . . . . . . . . . . . . . 09-80B–9 (PARTIAL CUTTING) INSTALLATION
WIPER BRACKET REMOVAL [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–27
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–9 Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–27
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–9 Installation Procedure . . . . . . . . . . . . . . 09-80B–27
Removal Procedure . . . . . . . . . . . . . . . 09-80B–10 COWL UPPER PLATE REMOVAL
WIPER BRACKET REMOVAL [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–31
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–11 Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–31
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–11 Removal Procedure. . . . . . . . . . . . . . . . 09-80B–32
Installation Procedure . . . . . . . . . . . . . 09-80B–11 COWL UPPER PLATE INSTALLATION
UPPER COWL SIDE [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–33
REINFORCEMENT REMOVAL Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–33
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–13 Installation Procedure . . . . . . . . . . . . . . 09-80B–34
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–13 TORQUE BOX REMOVAL
Removal Procedure . . . . . . . . . . . . . . . 09-80B–13 [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–35
UPPER COWL SIDE Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–35
REINFORCEMENT INSTALLATION Removal Procedure. . . . . . . . . . . . . . . . 09-80B–35
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–14 TORQUE BOX INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–14 [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–37
Installation Procedure . . . . . . . . . . . . . 09-80B–14 Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–37
LOWER COWL SIDE Installation Procedure . . . . . . . . . . . . . . 09-80B–37
REINFORCEMENT REMOVAL FRONT FRAME (REAR) REMOVAL
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–15 [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–39
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–15 Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–39
Removal Procedure . . . . . . . . . . . . . . . 09-80B–15 Removal Procedure. . . . . . . . . . . . . . . . 09-80B–39
LOWER COWL SIDE FRONT FRAME (REAR) INSTALLATION
REINFORCEMENT INSTALLATION [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–40
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–16 Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–40
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–16 Installation Procedure . . . . . . . . . . . . . . 09-80B–40
Installation Procedure . . . . . . . . . . . . . 09-80B–16 SIDE MEMBER REMOVAL
WHEEL APRON [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–41
COMPONENT REMOVAL Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–41
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–17 Removal Procedure. . . . . . . . . . . . . . . . 09-80B–41
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–17 SIDE MEMBER INSTALLATION
Removal Procedure . . . . . . . . . . . . . . . 09-80B–17 [PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–42
WHEEL APRON COMPONENT Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–42
INSTALLATION Installation Procedure . . . . . . . . . . . . . . 09-80B–42
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–18

09-80B–1
3506-1U-12A.book 2 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

FRONT PILLAR REMOVAL Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–83
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–43 Installation Procedure . . . . . . . . . . . . . 09-80B–83
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–43 REAR PILLAR (OUTER) REMOVAL
Removal Procedure . . . . . . . . . . . . . . . 09-80B–43 [PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–84
FRONT PILLAR INSTALLATION Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–84
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–51 Removal Procedure . . . . . . . . . . . . . . . 09-80B–84
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–51 REAR PILLAR (OUTER) INSTALLATION
Installation Procedure . . . . . . . . . . . . . . 09-80B–51 [PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–85
CENTER PILLAR REMOVAL Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–85
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–58 Installation Procedure . . . . . . . . . . . . . 09-80B–85
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–58 D-PILLAR REINFORCEMENT
Removal Procedure . . . . . . . . . . . . . . . 09-80B–58 (LOWER) REMOVAL
CENTER PILLAR INSTALLATION [PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–86
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–62 Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–86
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–62 Removal Procedure . . . . . . . . . . . . . . . 09-80B–86
Installation Procedure . . . . . . . . . . . . . . 09-80B–62 D-PILLAR REINFORCEMENT
SIDE SILL PANEL REMOVAL (LOWER) INSTALLATION
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–65 [PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–87
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–65 Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–87
Removal Procedure . . . . . . . . . . . . . . . 09-80B–65 Installation Procedure . . . . . . . . . . . . . 09-80B–87
SIDE SILL PANEL INSTALLATION REAR SIDE PANEL REMOVAL
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–68 [PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–88
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–68 Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–88
Installation Procedure . . . . . . . . . . . . . . 09-80B–68 Removal Procedure . . . . . . . . . . . . . . . 09-80B–88
REAR FENDER PANEL REMOVAL REAR SIDE PANEL INSTALLATION
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–71 [PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–89
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–71 Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–89
Removal Procedure . . . . . . . . . . . . . . . 09-80B–71 Installation Procedure . . . . . . . . . . . . . 09-80B–89
REAR FENDER PANEL INSTALLATION FLOOR SIDE PANEL REMOVAL
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–74 [PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–90
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–74 Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–90
Installation Procedure . . . . . . . . . . . . . . 09-80B–74 Removal Procedure . . . . . . . . . . . . . . . 09-80B–90
REAR FENDER LOWER FLOOR SIDE PANEL INSTALLATION
PANEL REMOVAL [PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–92
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–76 Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–92
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–76 Installation Procedure . . . . . . . . . . . . . 09-80B–92
Removal Procedure . . . . . . . . . . . . . . . 09-80B–76 TRUNK FLOOR PANEL REMOVAL
REAR FENDER LOWER PANEL [PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–94
INSTALLATION Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–94
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–77 Removal Procedure . . . . . . . . . . . . . . . 09-80B–94
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–77 TRUNK FLOOR PANEL INSTALLATION
Installation Procedure . . . . . . . . . . . . . . 09-80B–77 [PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–95
CORNER PLATE REMOVAL Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–95
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–78 Installation Procedure . . . . . . . . . . . . . 09-80B–95
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–78 REAR SIDE FRAME REMOVAL
Removal Procedure . . . . . . . . . . . . . . . 09-80B–78 [PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–97
CORNER PLATE INSTALLATION Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–97
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–79 Removal Procedure . . . . . . . . . . . . . . . 09-80B–97
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–79 REAR SIDE FRAME INSTALLATION
Installation Procedure . . . . . . . . . . . . . . 09-80B–79 [PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–
CORNER JUNCTION REMOVAL 100
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–80 Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–80 100
Removal Procedure . . . . . . . . . . . . . . . 09-80B–80 Installation Procedure . . . . . . . . . . . . . 09-80B–
CORNER JUNCTION INSTALLATION 100
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–81 ROOF PANEL REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–81 [PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–
Installation Procedure . . . . . . . . . . . . . . 09-80B–81 103
REAR END PANEL REMOVAL Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B–
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–82 103
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B–82 Removal Procedure . . . . . . . . . . . . . . . 09-80B–
Removal Procedure . . . . . . . . . . . . . . . 09-80B–82 103
REAR END PANEL INSTALLATION ROOF PANEL INSTALLATION
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–83 [PANEL REPLACEMENT]. . . . . . . . . . 09-80B–104

09-80B–2
3506-1U-12A.book 3 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

Symbol Mark . . . . . . . . . . . . . . . . . . . 09-80B–104 Installation Procedure . . . . . . . . . . . . . 09-80B–104

End of Toc
BUMPER BRACKET REMOVAL [PANEL REPLACEMENT]
BM: BUMPER BRACKET

id098008999500
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING 09-80B

CONTINUOUS WELDING

ROUGH CUT LOCATION

ac5wzb00000012

Removal Procedure
1. Rough cut area locations indicated by (A).

(A) ROUGH CUT

20 mm {0.79 in} LOCATION

ac5wzb00000244

2. Grind the 6 locations indicated by (B) shown in the figure.

Caution
• When grinding 6 locations indicated by (B) shown in the figure and the front side frame is
damaged, there is a possibility that attachment of a bracket may become difficulty. When grinding
6 locations indicated by (B) shown in the figure, the amount removed will affect the quality of the
installation.

3. Grind the 2 locations indicated by (C) shown in the figure.

4. Drill the 2 locations indicated by (D) shown in the figure, then remove the half portion above the bumper
bracket.

09-80B–3
3506-1U-12A.book 4 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

5. Drill the 3 locations indicated by (E) shown in the figure.
(B) 3 (D) 2

(C) 1

(B) 1

(F) 1
(B) 1 (B) 1

(G) 2
(G) 2

(C) 1
BUMPER BRACKET

(E) 3

ac5wzb00000014

6. Grind the 1 location indicated by (F) shown in the figure.

7. Drill the 4 locations indicated by (G) shown in the figure.
8. Remove the half portion below the bumper bracket.
End Of Sie

09-80B–4
3506-1U-12A.book 5 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

BUMPER BRACKET INSTALLATION [PANEL REPLACEMENT]
id098008999600
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

CONTINUOUS ARC WELDING (CUT-AND-JOIN LOCATION)

ac5wzb00000206 09-80B

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding 6 locations indicated by (A) and 3 locations indicated by (C) shown in the figure,
before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 6 locations indicated by (A) shown in the figure.
(A) 2

(B) 2

(B) 1 (B) 3

(A) 2
(A) 2
(B) 3
BUMPER BRACKET

(C) 3

ac5wzb00000245

5. Continuos weld the 9 locations indicated by (B) shown in the figure from the front wheel housing and engine
room.

Note
• A flange part is fixed by a hand vise, and where a welded area is press-fitted, welding is performed so that
a clearance does not open in the part welded.

6. Plug weld the 3 locations indicated by (C) shown in the figure, then install the bumper bracket.
End Of Sie
BM: SHROUD PANEL

09-80B–5
3506-1U-12A.book 6 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

SHROUD SIDE MEMBER REMOVAL [PANEL REPLACEMENT]
id098008919000
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000017

Removal Procedure
1. Drill the 3 locations indicated by (A) shown in the figure.
2. Drill the 8 locations indicated by (B) and 2 locations indicated by (C) shown in the figure.

Note
• When drilling the 3 locations indicated by (A) and 2 locations indicated by (C) shown in the figure, do not
drill a hole all the way through or there could be a problem when installing the new part.

SHROUD SIDE MEMBER

(B) 1
(B) 6

SHROUD UPPER REINFORCEMENT

(B) 1

(C) 2
(A) 3

SHROUD SIDE MEMBER

ac5wzb00000018

3. Remove the shroud side member.

End Of Sie

09-80B–6
3506-1U-12A.book 7 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

SHROUD SIDE MEMBER INSTALLATION [PANEL REPLACEMENT]
id098008919100
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

ac5wzb00000205

Installation Procedure 09-80B

1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 8 locations indicated by (A) and 2 locations indicated by (B) shown in the figure.

SHROUD SIDE MEMBER

(A) 1
(A) 6

SHROUD UPPER REINFORCEMENT

(A) 1

(B) 2
(C) 3

SHROUD SIDE MEMBER

ac5wzb00000020

5. Plug weld the 3 locations indicated by (C) shown in the figure, then install the shroud side member.
End Of Sie

09-80B–7
3506-1U-12A.book 8 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

SHROUD UPPER REINFORCEMENT REMOVAL [PANEL REPLACEMENT]
id098008927900
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000021

Removal Procedure
1. Drill the 4 locations shown in the figure.

Note
• When drilling the 4 locations shown in the figure, do not drill a hole all the way through or there could be a
problem when installing the new part.

SHROUD UPPER REINFORCEMENT

ac5wzb00000240

2. Remove the shroud upper reinforcement.

End Of Sie

09-80B–8
3506-1U-12A.book 9 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

SHROUD UPPER REINFORCEMENT INSTALLATION [PANEL REPLACEMENT]
id098008928000
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

ac5wzb00000213

Installation Procedure 09-80B

1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 4 locations shown in the figure, then install the shroud upper reinforcement.

SHROUD UPPER REINFORCEMENT

ac5wzb00000241

End Of Sie
WIPER BRACKET REMOVAL [PANEL REPLACEMENT]
BM: WIPER BRACKET

id098008968800
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING
ac5wzb00000025

09-80B–9
3506-1U-12A.book 10 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

Removal Procedure
1. Drill the 3 locations indicated by (A) from the inside shown in the figure.
2. Drill the 9 locations indicated by (B) shown in the figure.

(A) 3

WIPER BRACKET

(B) 3

(B) 6
ac5wzb00000026

3. Remove the wiper bracket.

End Of Sie

09-80B–10
3506-1U-12A.book 11 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

WIPER BRACKET REMOVAL [PANEL REPLACEMENT]
id098008968900
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

ac5wzb00000215

Installation Procedure 09-80B

1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 9 locations indicated by (A) shown in the figure.
5. Plug weld the 3 locations indicated by (B) from the inside shown in the figure, then install the wiper bracket.

09-80B–11
3506-1U-12A.book 12 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

(B) 3

WIPER BRACKET

(A) 3

(A) 6
ac5wzb00000028

End Of Sie
BM: COWL SIDE REINFORCEMENT

09-80B–12
3506-1U-12A.book 13 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

UPPER COWL SIDE REINFORCEMENT REMOVAL [PANEL REPLACEMENT]
id098008828500
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000029

Removal Procedure 09-80B

1. Drill the 13 locations indicated by (A) shown in the figure.
2. Drill the 8 locations indicated by (B) shown in the figure.

Note
• When a drill the 8 locations indicated by (B) shown in the figure, the through hole is not made in
consideration of the workability at the installing.

3. Remove the upper cowl side reinforcement.

(A) 2 (B) 2

(A) 6
(A) 8

(A) 3

UPPER COWL SIDE REINFORCEMENT

ac5wzb00000264

End Of Sie

09-80B–13
3506-1U-12A.book 14 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

UPPER COWL SIDE REINFORCEMENT INSTALLATION [PANEL REPLACEMENT]
id098008828600
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

ac5wzb00000211

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 21 locations shown in the figure, then install the upper cowl side reinforcement.

6
8

UPPER COWL SIDE REINFORCEMENT

ac5uub00000075

End Of Sie

09-80B–14
3506-1U-12A.book 15 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

LOWER COWL SIDE REINFORCEMENT REMOVAL [PANEL REPLACEMENT]
id098008828700
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000033

Removal Procedure 09-80B

1. Drill the 41 locations shown in the figure.

16
8
LOWER COWL SIDE REINFORCEMENT

15

ac5wzb00000265

2. Remove the lower cowl side reinforcement.

End Of Sie

09-80B–15
3506-1U-12A.book 16 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

LOWER COWL SIDE REINFORCEMENT INSTALLATION [PANEL REPLACEMENT]
id098008828800
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

PLUG WELDING (ARC WELDING)

ac5wzb00000212

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Spot weld the 19 locations indicated by (A) shown in the figure.
5. Plug weld the 26 locations indicated by (B) shown in the figure, then install the lower cowl side reinforcement.

(B) 16
(B) 8
LOWER COWL SIDE REINFORCEMEN

(B) 2

(A) 19

ac5wzb00000266

End Of Sie
BM: WHEEL APRON PANEL

09-80B–16
3506-1U-12A.book 17 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

WHEEL APRON COMPONENT REMOVAL [PANEL REPLACEMENT]
id098008746000
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000037

Removal Procedure 09-80B

1. Drill the 14 locations indicated by (A) from the front wheel housing side shown in the figure.
2. Drill the 11 locations indicated by (B) shown in the figure.
3. Drill the 4 locations indicated by (C) shown in the figure.

Note
• When drilling the 14 locations indicated by (A) and 4 locations indicated by (C) shown in the figure, do not
drill a hole all the way through or there could be a problem when installing the new part.

4. Drill the 3 locations indicated by (D) shown in the figure.

(D) 3

(B) 7
WHEEL APRON COMPONENT

(B) 4

(A) 14

(C) 2
(C) 2

ac5uub00000046

09-80B–17
3506-1U-12A.book 18 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

5. Drill the 12 locations indicated by (E) from the inside shown in the figure.

(E) 3

(D) 9

ac5uub00000047

6. Remove the wheel apron component.

End Of Sie
WHEEL APRON COMPONENT INSTALLATION [PANEL REPLACEMENT]
id098008746100
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

PLUG WELDING (ARC WELDING)

ac5wzb00000209

09-80B–18
3506-1U-12A.book 19 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 14 locations indicated by (A) from the front wheel housing side shown in the figure.
5. Spot weld the 5 locations indicated by (B) shown in the figure.
6. Arc weld the 4 locations indicated by (C) shown in the figure.
7. Plug weld the 3 locations indicated by (D) shown in the figure.

09-80B

(D) 3

(B) 7
WHEEL APRON COMPONENT

(B) 5

(A) 14

(C) 2
(C) 2

ac5uub00000048

8. Plug weld the 14 locations indicated by (E) from the inside shown in the figure, then install the wheel apron
component.

09-80B–19
3506-1U-12A.book 20 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

(E) 3

(E) 9

ac5uub00000049

End Of Sie
FRONT FENDER JUNCTION REMOVAL [PANEL REPLACEMENT]
id098008828300
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000042

Removal Procedure
1. Drill the 3 locations shown in the figure.

FRONT FENDER JUNCTION

ac5wzb00000043

09-80B–20
3506-1U-12A.book 21 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

2. Remove the front fender junction.
End Of Sie
FRONT FENDER JUNCTION INSTALLATION [PANEL REPLACEMENT]
id098008828400
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

ac5wzb00000210 09-80B

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 3 locations shown in the figure.

FRONT FENDER JUNCTION

ac5wzb00000045

End Of Sie
BM: FRONT SIDE FRAME

09-80B–21
3506-1U-12A.book 22 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

FRONT SIDE FRAME REMOVAL [PANEL REPLACEMENT]
id098008605900
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000046

Removal Procedure
1. Drill the 15 locations indicated by (A) shown in the figure.
2. Drill the 4 locations indicated by (B) shown in the figure.

Note
• When drilling the 4 locations indicated by (B) shown in the figure, do not drill a hole all the way through or
there could be a problem when installing the new part.

(A) 2 (B) 4

(A) 2
(A) 4 (A) 3

(A) 4

FRONT SIDE FRAME

ac5uub00000050

3. Remove the front side frame.

End Of Sie

09-80B–22
3506-1U-12A.book 23 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

FRONT SIDE FRAME INSTALLATION [PANEL REPLACEMENT]
id098008606000
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

ac5wzb00000207

Installation Procedure 09-80B

1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 19 locations shown in the figure, then install the front side frame.

2
4

4 3
4

FRONT SIDE FRAME

ac5uub00000051

End Of Sie

09-80B–23
3506-1U-12A.book 24 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

FRONT SIDE FRAME (PARTIAL CUTTING) REMOVAL [PANEL REPLACEMENT]
id098008742100
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ROUGH CUT LOCATION

ac5jjb00000063

Removal Procedure
1. Drill the 4 locations indicated by (A) shown in the figure, then remove suspension mounting reinforcement and
outer frame reinforcement.
2. Rough cut location indicated by (B) shown in the figure.
3. Drill the 6 locations indicated by (C) shown in the figure, then remove the front side frame (inner).

09-80B–24
3506-1U-12A.book 25 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

(C) 5
FRONT SIDE FRAME (INNER)

09-80B

LH:146 mm {5.75 in}

RH:154 mm {6.06 in}

(B) ROUGH CUT LOCATION

(A) 2

(A) 2

(C) 1

SUSPENSION MOUNTING
REINFORCEMENT

OUTER FRAME REINFORCEMENT

ac5wzb00000273

4. Rough cut location indicated by (D) shown in the figure.

5. Drill the 3 locations indicated by (E) shown in the figure.

09-80B–25
3506-1U-12A.book 26 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

(E) 1 (E) 1

(E) 1
16 mm {0.63 in}

FRONT SIDE FRAME OUTER (D) ROUGH CUT LOCATION

ac5wzb00000247

6. Remove the front side frame (outer).

End Of Sie

09-80B–26
3506-1U-12A.book 27 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

FRONT SIDE FRAME (PARTIAL CUTTING) INSTALLATION [PANEL REPLACEMENT]
id098008742200
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

ROUGH CUT LOCATION

CONTINUOUS ARC WELDING (CUT-AND-JOIN LOCATION)

09-80B

ac5jjb00000066

Installation Procedure

Caution
• The cut and joint area indicates the maximum size range of the installation position.

1. Drill holes for the plug welding before installing the new parts.
2. When installing the new parts, trial-fit new and existing parts, and then measure and adjust the body to conform
with standard dimensions.
3. Cut and join location indicated by (A) shown in the figure.
4. Plug weld the 3 locations indicated by (B) shown in the figure, then install the front side frame (outer).

(B) 1 (B) 1

(B) 1
16 mm {0.63 in}

FRONT SIDE FRAME (OUTER) (A) CUT AND JOIN LOCATION

ac5wzb00000274

09-80B–27
3506-1U-12A.book 28 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

5. To cut and join the new and existing parts, rough cut the new part at the specified location shown in the figure,
and chamfer the joint surfaces of the new and existing parts.
FRONT SIDE FRAME INNER
(NEW PART)

LH:146 mm {5.75 in}

RH:154 mm {6.06 in}

ROUGH CUT LOCATION

ac5wzb00000237

09-80B–28
3506-1U-12A.book 29 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

6. Make a reinforcement panel using the material from the front side frame (inner).
7. Plug weld the 4 locations indicated by (B) shown in the figure, then install the reinforcement to the new front
side frame (inner).

REINFORCEMENT

100 mm {3.94 in}

30 mm
{1.2 in}
09-80B

t = 1.4 mm {0.055 in}

FRONT SIDE FRAME INNER (NEW PART)

REINFORCEMENT

(B) 2

REINFORCEMENT (B) 2

REINFORCEMENT

ac5wzb00000238

09-80B–29
3506-1U-12A.book 30 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

8. Plug weld the 3 locations indicated by (C) shown in the figure.

Note
• Press fit the reinforcement panel and the body side material, and then weld them.

9. Cut and location indicated by (D) shown in the figure.

10. Plug weld the 6 locations indicated by (E) shown in the figure, then install the front side frame inner.
11. Plug weld the 5 locations indicated by (F) shown in the figure, then install suspension mounting reinforcement
and outer frame reinforcement.

(D) 2 (F) 5
FRONT SIDE FRAME INNER

LH:146 mm {5.75 in}

RH:154 mm {6.06 in}

(E) ROUGH CUT LOCATION

(G) 2

(D) 1

(G) 1

(G) 2

(F) 1

SUSPENSION MOUNTING
REINFORCEMENT

OUTER FRAME REINFORCEMENT

ac5wzb00000239

End Of Sie
BM: COWL UPPER PLATE

09-80B–30
3506-1U-12A.book 31 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

COWL UPPER PLATE REMOVAL [PANEL REPLACEMENT]
id098008957100
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000050

09-80B

09-80B–31
3506-1U-12A.book 32 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

Removal Procedure
1. Drill the 9 locations indicated by (A) shown in the figure.
2. Drill the 2 locations by (B) from the front wheel housing side shown in the figure.
3. Drill the 2 locations indicated by (C) from the inside shown in the figure.

(C) 2

COWL UPPER PLATE

(A) 3

(A) 6

(B) 2

ac5wzb00000051

4. Remove the cowl upper plate.

End Of Sie

09-80B–32
3506-1U-12A.book 33 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

COWL UPPER PLATE INSTALLATION [PANEL REPLACEMENT]
id098008957200
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

ac5wzb00000214

09-80B

09-80B–33
3506-1U-12A.book 34 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 9 locations indicated by (A) shown in the figure.
5. Plug weld the 2 locations indicated by (B) from the front wheel housing side shown in the figure.
6. Plug weld the 2 locations indicated by (C) from the inside shown in the figure, then install the cowl upper plate.

(C) 2

COWL UPPER PLATE

(A) 3

(A) 6

(B) 2

ac5wzb00000053

End Of Sie
BM: TORQUE BOX

09-80B–34
3506-1U-12A.book 35 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

TORQUE BOX REMOVAL [PANEL REPLACEMENT]
id098008607100
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000054

Removal Procedure 09-80B

1. Drill the 19 locations indicated by (A) shown in the figure.

Note
• When drilling the 19 locations indicated by (A) shown in the figure, do not drill a hole all the way through or
there could be a problem when installing the new part.

(A) 2 TORQUE BOX

(A) 3
(A) 6

(A) 6

(A) 1

(A) 1

ac5wzb00000055

09-80B–35
3506-1U-12A.book 36 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

2. Drill the 8 locations indicated by (B) from the inside shown in the figure.

(B) 1

(B) 7

ac5wzb00000056

3. Remove the torque box.

End Of Sie

09-80B–36
3506-1U-12A.book 37 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

TORQUE BOX INSTALLATION [PANEL REPLACEMENT]
id098008607200
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

ac5wzb00000208

Installation Procedure 09-80B

1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 8 locations indicated by (A) from the inside shown in the figure.

(A) 1

(A) 7

ac5wzb00000058

09-80B–37
3506-1U-12A.book 38 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

5. Plug weld the 19 locations indicated by (B) shown in the figure, then install the torque box.

(B) 2 TORQUE BOX

(B) 3
(B) 6

(B) 6

(B) 1

(B) 1

ac5wzb00000059

End Of Sie
BM: FRONT FRAME REAR

09-80B–38
3506-1U-12A.book 39 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

FRONT FRAME (REAR) REMOVAL [PANEL REPLACEMENT]
id098008742500
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000060

Removal Procedure 09-80B

1. Drill the 33 locations shown in the figure.

Note
• When drilling, do not drill a hole all the way through or there could be a problem when installing the new
part.

14

FRONT FRAME
FRONT FRAME (REAR)
REAR
4

2
ac5uub00000052

2. Remove the front frame (rear).

End Of Sie

09-80B–39
3506-1U-12A.book 40 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

FRONT FRAME (REAR) INSTALLATION [PANEL REPLACEMENT]
id098008742600
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

ac5wzb00000219

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 33 locations shown in the figure, then install the front frame (rear).

14

FRONT FRAME
FRONT FRAME (REAR)
REAR
4

2
ac5uub00000053

End Of Sie

09-80B–40
3506-1U-12A.book 41 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

SIDE MEMBER REMOVAL [PANEL REPLACEMENT]
id098008928100
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000064

Removal Procedure 09-80B

1. Drill the 45 locations shown in the figure.

Note
• When drilling, do not drill a hole all the way through or there could be a problem when installing the new
part.

2
SIDE MEMBER

3
9

2
3

5 3 13

ac5uub00000054

2. Remove the side member.

End Of Sie

09-80B–41
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BODY STRUCTURE [PANEL REPLACEMENT]

SIDE MEMBER INSTALLATION [PANEL REPLACEMENT]
id098008928200
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

ac5wzb00000223

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 45 locations shown in the figure, then install the side member.

2
SIDE MEMBER

3
9

2
3

5 3 13

ac5uub00000055

End Of Sie
BM: FRONT PILLAR

09-80B–42
3506-1U-12A.book 43 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

FRONT PILLAR REMOVAL [PANEL REPLACEMENT]
id098008744700
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ROUGH CUT LOCATION

ac5wzb00000068 09-80B

Removal Procedure

Caution
• Remove the curtain air bag module to prevent damage before servicing.

Front-side

CURTAIN AIR BAG MODULE

ac5wzb00000002

09-80B–43
3506-1U-12A.book 44 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

Rear-side

CURTAIN AIR BAG

MODULE

ac5wzb00000003

Caution
• Avoid cutting with a blowtorch or similar tools as the insulator (shaded area) is flammable.

INSULATOR

INSULATOR

ac5wzb00000232

1. Rough cut the 2 locations indicated by (A) shown in the figure.

2. Drill the 82 locations indicated by (B) shown in the figure, then remove the cabin side outer frame (outer front
pillar).

09-80B–44
3506-1U-12A.book 45 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

150
{5.91 in]

09-80B
(A) ROUGH CUT LOCATION

(B) 12

CABIN SIDE OUTER FRAME

(OUTER FRONT PILLAR)

ac5uub00000056

(B) 1

(B) 1 (B) 3
(B) 2

(B) 2 CABIN SIDE OUTER FRAME

(OUTER FRONT PILLAR)

(B) 28 76 mm {3.0 in}

(B) 2
(A) ROUGH CUTLOCATION

(B) 1

(B) 30

ac5uub00000057

09-80B–45
3506-1U-12A.book 46 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

3. Rough cut area location indicated by (C) shown in the figure.
4. Drill the 7 locations indicated by (D) shown in the figure, then remove the front pillar reinforcement and front
pillar inner reinforcement as a single unit.

Note
• When removing the front pillar reinforcement and the front pillar inner reinforcement separately, drill the 11
locations indicated by (E) shown in the figure.

180 mm {7.09 in}

FRONT PILLAR REINFORCEMENT

(E) 9 (C) ROUGH CUT LOCATION

(E) 2

FRONT PILLAR INNER REINFORCEMENT

(D) 7

ac5uub00000058

5. Drill the 9 locations indicated by (F) shown in the figure, then remove the upper hinge reinforcement.

UPPER HINGE RAINFORCEMENT

(F) 1

(F) 2 (F) 2 (F) 2

(F) 2

ac5uub00000059

09-80B–46
3506-1U-12A.book 47 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

6. Drill the 4 locations indicated by (G) from the inside shown in the figure.
7. Drill the 11 locations indicated by (H) shown in the figure.

09-80B
(G) 4

LOWER HINGE REINFORCEMENT

(H) 2

(H) 1

(H) 2

(H) 6

ac5uub00000060

09-80B–47
3506-1U-12A.book 48 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

8. Drill the 1 location indicated by (I) shown in the figure, while peeling back the lower hinge reinforcement, then
remove it.

(I) 1

LOWER HINGE
REINFORCEMENT

ac5wzb00000284

09-80B–48
3506-1U-12A.book 49 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

9. Drill the 20 locations indicated by (J) shown in the figure, then remove the inner hinge pillar.

09-80B

(J) 4

INNER HINGE PILLAR

(J) 2

(J) 9

(J) 5

ac5uub00000061

09-80B–49
3506-1U-12A.book 50 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

10. Rough cut the area location indicated by (K) shown in the figure.

210 mm {8.27 in}

(K) ROUGH CUT LOCATION

INNER FRONT PILLAR

ac5wzb00000286

11. Remove the inner front pillar.

End Of Sie

09-80B–50
3506-1U-12A.book 51 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

FRONT PILLAR INSTALLATION [PANEL REPLACEMENT]
id098008744800
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

ROUGH CUT LOCATION

CONTINUOUS ARC WELDING (CUT-AND-JOIN LOCATION)

09-80B

ac5wzb00000221

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Rough cut the area location indicated by (A) shown in the figure.

Caution
• When the part with the rough cut side sill reinforcement, there is a possibility that vibration may
occur. After the rough cut, temporarily attach the lower hinge reinforcement and check that the
rough cut area does not interfere with the side sill reinforcement.

(A) ROUGH CUT LOCATION

LOWER HINGE REINFORCEMENT

ac5wzb00000287

09-80B–51
3506-1U-12A.book 52 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

5. Cut and join the area location indicated by (B) shown in the figure, then install the inner front pillar.

190 mm {7.48 in}

(B) CUT AND JOIN LOCATION

INNER FRONT PILLAR

ac5wzb00000288

09-80B–52
3506-1U-12A.book 53 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

6. Plug weld the 20 locations indicated by (C) shown in the figure, then install the inner hinge pillar.

09-80B

(C) 4

INNER HINGE PILLAR

(C) 2

(C) 9

(C) 5

ac5uub00000062

09-80B–53
3506-1U-12A.book 54 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

7. Plug weld the 4 locations indicated by (D) from the inside shown in the figure.
8. Plug weld the 11 locations indicated by (E) shown in the figure, then install the lower hinge reinforcement.

(D) 4

LOWER HINGE REINFORCEMENT

(E) 2

(E) 1

(E) 2

(E) 6

ac5uub00000063

9. Plug weld the 9 locations indicated by (F) shown in the figure, then install the upper hinge reinforcement.

UPPER HINGE RAINFORCEMENT

(F) 1

(F) 2 (F) 2 (F) 2

(F) 2

ac5uub00000064

10. Cut and join the area location indicated by (G) shown in the figure.

09-80B–54
3506-1U-12A.book 55 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

11. Plug weld the 7 locations indicated by (H) shown in the figure, then install the front pillar reinforcement and front
pillar inner reinforcement as a single unit.

Note
• When installing the front pillar reinforcement and the front pillar inner reinforcement separately, plug weld
the 11 locations indicated by (I) shown in the figure.

09-80B
160 mm {6.30 in}

FRONT PILLAR REINFORCEMENT

(I) 9 (G) CUT AND JOINLOCATION

(I) 2

FRONT PILLAR INNER REINFORCEMENT

(H) 7

ac5uub00000065

09-80B–55
3506-1U-12A.book 56 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

12. Cut and join the 2 locations indicated by (J) shown in the figure.
13. Plug weld the 86 locations indicated by (K) shown in the figure, then install the cabin side outer frame (outer
front pillar outer).

120
{4.72 in]

(J) CUT AND JOIN LOCATION

(K) 13

CABIN SIDE OUTER FRAME

(OUTER FRONT PILLAR)

ac5uub00000066

09-80B–56
3506-1U-12A.book 57 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

(K) 1

(K) 3
(K) 1
(K) 2

09-80B

(K) 2 CABIN SIDE OUTER FRAME

(OUTER FRONT PILLAR)

(K) 30
50 mm {2.0 in}

(K) 2
(J) CUT AND JOIN LOCATION

(K) 1

(K) 31
ac5uub00000067

End Of Sie
BM: CENTER PILLAR

09-80B–57
3506-1U-12A.book 58 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

CENTER PILLAR REMOVAL [PANEL REPLACEMENT]
id098008743900
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ROUGH CUT LOCATION

ac5wzb00000001

Removal Procedure

Caution
• Remove the curtain air bag module to prevent damage before servicing.
Front-side

CURTAIN AIR BAG MODULE

ac5wzb00000002

09-80B–58
3506-1U-12A.book 59 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

Rear-side

09-80B

CURTAIN AIR BAG

MODULE

ac5wzb00000003

Caution
• Avoid cutting with a blowtorch or similar tools as the insulator (shaded area) is flammable.

INSULATOR

ac5wzb00000233

09-80B–59
3506-1U-12A.book 60 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

1. Rough cut the area locations indicated by (A).
2. Drill the 84 locations indicated by (B) shown in the figure then remove the cabin side outer frame (outer center
pillar).
(A) ROUGH CUT LOCATION

ROOF RAIL REINFORCEMENT

ROUGH CUT
LOCATION

CENTER PILLAR
REINFORCEMENT
CABIN SIDE OUTER FRAME CABIN SIDE OUTER FRAME
(CENETR PILLAR OUTER) (CENETR PILLAR OUTER)

(B) 37

(B) 32

204 mm {8.03 in}

441 mm {17.4 in}

(A) ROUGH CUT LOCATION (B) 15 (A) ROUGH CUT LOCATION

ac5uub00000069

3. Drill the 34 locations indicated by (C) shown in the figure then remove the center pillar reinforcement.
(C) 8

(C) 1 (C) 1

CENETR PILLAR REINFORCEMENT

(C) 2 (C) 2

(C) 20
ac5wzb00000005

4. Rough cut the area locations indicated by (D).

5. Drill the 3 locations indicated by (E) shown in the figure.

09-80B–60
3506-1U-12A.book 61 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

6. Pull the inner center pillar in the direction of arrow shown in the figure, then remove it from between the inner
side sill and side sill reinforcement.

90 mm {3.5 in}

(D) ROUGH CUT LOCATION

09-80B

CENTER PILLAR INNER

CENTER PILLAR INNER

(E) 3
SIDE SILL INNER

CENTER PILLAR INNER

SIDE SILL
REINFORCEMENT
SIDE SILL INNER

sec. a a
ac5wzb00000254

End Of Sie

09-80B–61
3506-1U-12A.book 62 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

CENTER PILLAR INSTALLATION [PANEL REPLACEMENT]
id098008744000
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

CONTINUOUS ARC WELDING (CUT-AND-JOIN LOCATION)

ac5wzb00000220

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Insert the end of the inner center pillar locations indicated by (A) shown in the figure, between the inner side sill
and side sill reinforcement.
5. Cut and join the area locations indicated by (B) shown in the figure.
6. Plug weld the 3 locations indicated by (C) shown in the figure.

55 mm {2.2 in}

(B) CUT AND JOINT LOCATION

INNER CENTER PILLAR

INNER CENTER PILLAR

(C) 3
INNER SIDE SILL (A)

INNER CENTER PILLAR

SIDE SILL
REINFORCEMENT
INNER SIDE SILL

sec. a a
ac5wzb00000277

09-80B–62
3506-1U-12A.book 63 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

7. Plug weld the 18 locations indicated by (D) shown in the figure, then install the center pillar inner reinforcement
to the center pillar reinforcement.
(D) 3

CENTER PILLAR CENTER PILLAR REINFORCEMENT

REINFORCEMENT

09-80B

CENTER PILLAR INNER

REINFORCEMENT

(D) 5

(D) 5

(D) 5

ac5wzb00000278

8. Plug weld the 34 locations indicated by (E) shown in the figure, then install the center pillar reinforcement.
(E)8

(E)1 (E)1

CENETR PILLAR REINFORCEMENT

(E)2 (E)2

(E)20
ac5wzb00000010

09-80B–63
3506-1U-12A.book 64 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

9. Cut and join the area locations indicated by (F) shown in the figure.
10. Plug weld the 88 locations indicated by (G) shown in the figure, then install the cabin side outer frame (outer
center pillar).

(F) CUT AND JOIN LOCATION

CABIN SIDE OUTER FRAME

(OUTER CENTER PILLAR)
(G) 38

(G) 33

215 mm {8.46 in}

460 mm {18.1 in}

(F) CUT AND JOIN LOCATION (G) 17 (F) CUT AND JOIN LOCATION

ac5uub00000070

End Of Sie
BM: SIDE SILL PANEL

09-80B–64
3506-1U-12A.book 65 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

SIDE SILL PANEL REMOVAL [PANEL REPLACEMENT]
id098008615300
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ROUGH CUT LOCATION

ac5wzb00000071 09-80B

Removal Procedure
Side sill (front side)
1. Rough cut the 2 locations indicated by (A) shown in the figure.
2. Drill the 18 locations indicated by (B) shown in the figure.

(A) ROUGH CUT LOCATION

448 mm {17.6 in}
239 mm {9.41 in} (B) 10

(B) 8
(A) ROUGH CUT LOCATION
CABIN SIDE OUTER FRAME
(OUTER SIDE SILL)
ac5wzb00000270

3. Remove the cabin side outer frame (outer side sill).

09-80B–65
3506-1U-12A.book 66 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

Side sill (component)
1. Rough cut the 3 locations indicated by (A) shown in the figure.
2. Drill the 114 locations indicated by (B) shown in the figure, then remove the cabin side outer frame (outer side
sill).

94 mm {3.7 in}
75 mm {3.0 in}

(A) ROUGH CUT LOCATION

321 mm {12.6 in}

(A) ROUGH CUT LOCATION

(B) 28 (B) 21

(B) 13 (B) 2 (B) 5

(B) 1

(B) 44
CABIN SIDE OUTER FRAME
(OUTER SIDE SILL)
ac5wzb00000271

3. Drill the 2 locations indicated by (C) shown in the figure, then remove the front fender set bracket.
4. Drill the 6 locations indicated by (D) shown in the figure, then remove the upper side sill reinforcement.

(D) 2 (C) 2

FRONT FENDER
SET BRACKET
(D) 2

(D) 2

UPPER SIDE SILL REINFORCEMENT

ac5wzb00000272

09-80B–66
3506-1U-12A.book 67 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

5. Drill the 1 location indicated by (E) shown in the figure.

SIDE SILL REINFORCEMENT 09-80B

(E) 1

ac5wzb00000118

6. Drill the 35 locations indicated by (F) shown in the figure.

(F) 2

(F) 1

SIDE SILL REINFORCEMENT (F) 2

(F) 2

(F) 3

(F) 5 (F) 20
ac5uub00000068

7. Pull the side sill reinforcement from the inner side sill, hinge reinforcement and center pillar reinforcement, and
then remove it.
End Of Sie

09-80B–67
3506-1U-12A.book 68 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

SIDE SILL PANEL INSTALLATION [PANEL REPLACEMENT]
id098008615200
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

SPOT WELDING

CONTINUOUS ARC WELDING (CUT-AND-JOIN LOCATION)

ac5uub00000043

Installation Procedure
Side sill (front side)
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Cut and join the 2 locations indicated by (A) shown in the figure.
5. Plug weld the 18 locations indicated by (B) shown in the figure, then cabin side outer frame (outer side sill).

(A) CUT AND JOIN LOCATION

448 mm {17.6 in}
239 mm {9.41 in} (B) 10

(B) 8
(A) CUT AND JOIN LOCATION
CABIN SIDE OUTER FRAME
(OUTER SIDE SILL)
ac5wzb00000267

09-80B–68
3506-1U-12A.book 69 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

Side sill (component)
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Drill the 4 locations indicated by (A) shown in the figure, then remove the upper side sill reinforcement from the
new side sill reinforcement.

UPPER SIDE SILL REINFORCEMENT

(A) 2
09-80B

(A) 2

SIDE SILL REINFORCEMENT

ac5uub00000044

5. Plug weld the 32 locations indicated by (B) shown in the figure.

6. Plug weld the 3 locations indicated by (C) shown in the figure, then install the side sill reinforcement.

(B) 2
(B) 2

SIDE SILL REINFORCEMENT (B) 2

(B) 2

(C) 3

(B) 5 (B) 20
ac5wzb00000197

09-80B–69
3506-1U-12A.book 70 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

7. Plug weld the 6 locations indicated by (D) shown in the figure, then install the upper side sill reinforcement.
8. Plug weld the 2 locations indicated by (E) shown in the figure, then install the front fender set bracket.

(D) 2 (E) 2

FRONT FENDER
SET BRACKET
(D) 2

(D) 2

UPPER SIDE SILL REINFORCEMENT

ac5uub00000045

9. Cut and join the 3 locations indicated by (F) shown in the figure.
10. Plug weld the 120 locations indicated by (G) shown in the figure, then install the cabin side outer frame (outer
side sill).

64 mm {2.5 in}
45 mm {1.8 in}

(F) CUT AND JOIN LOCATION

301 mm {11.9 in}

(F) CUT AND JOIN LOCATION

(G) 30 (G) 23

(G) 14
(G) 2 (G) 6

(G) 1

(G) 44
CABIN SIDE OUTER FRAME
(OUTER SIDE SILL)
ac5wzb00000269

End Of Sie
BM: REAR FENDER PANEL

09-80B–70
3506-1U-12A.book 71 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

REAR FENDER PANEL REMOVAL [PANEL REPLACEMENT]
id098008744900
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ROUGH CUT LOCATION

ac5wzb00000074 09-80B

Removal Procedure

Caution
• Avoid cutting with a blowtorch or similar tools as the insulator (shaded area) is flammable.

INSULATOR

INSULATOR

ac5wzb00000234

09-80B–71
3506-1U-12A.book 72 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

1. Rough cut the 3 locations indicated by (A) shown in the figure.
2. Drill the 90 locations indicated by (B) shown in the figure.

65 mm {2.6 in}

(A) ROUGH CUT LOCATION

148 mm {5.83 in}

(A) ROUGH CUT LOCATION

(B) 10

CABIN SIDE OUTER FRAME

(REAR FENDER PANEL)

(B) 31

(B) 8

(B) 13

(A) ROUGH CUT LOCATION

(B) 4

(B) 3
(B) 2

(B) 7

(B) 5
60 mm {2.4 in}

ac5uub00000071

09-80B–72
3506-1U-12A.book 73 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

09-80B
(B) 4

(B) 2

ac5wzb00000123

3. Remove the cabin side outer frame (rear fender panel).

End Of Sie

09-80B–73
3506-1U-12A.book 74 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

REAR FENDER PANEL INSTALLATION [PANEL REPLACEMENT]
id098008745000
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

CONTINUOUS ARC WELDING (CUT-AND-JOIN LOCATION)

ac5wzb00000222

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Before installing new parts, apply body sealer to the wheel arch line.

BODY SEALER

ac5wzb00000124

5. Cut and join the 3 locations indicated by (A) shown in the figure.
6. Plug weld the 95 locations indicated by (B) shown in the figure, then install the cabin side outer frame (rear
fender panel).

09-80B–74
3506-1U-12A.book 75 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

35 mm {1.4 in}

(A) CUT AND JOIN LOCATION

120 mm {4.72 in}

(A) CUT AND JOIN LOCATION

(B) 12

CABIN SIDE OUTER FRAME 09-80B

(REAR FENDER PANEL)

(B) 33

(B) 8

(B) 13

(A) CUT AND JOIN LOCATION

(B) 4

(B) 3
(B) 2

(B) 8

(B) 5
30 mm {1.2 in}

ac5uub00000072

(B) 5

(B) 2

ac5wzb00000126

09-80B–75
3506-1U-12A.book 76 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

End Of Sie

REAR FENDER LOWER PANEL REMOVAL [PANEL REPLACEMENT]

id098008614100
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000072

Removal Procedure
1. Drill the 20 locations shown in the figure.

REAR FENDER LOWER PANEL

ac5uub00000073

2. Remove the rear fender lower panel.

End Of Sie

09-80B–76
3506-1U-12A.book 77 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

REAR FENDER LOWER PANEL INSTALLATION [PANEL REPLACEMENT]
id098008614200
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000073

Installation Procedure 09-80B

1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. After temporarily installing new parts, make sure the related parts fit properly.
3. Spot weld the 26 locations shown in the figure, then install the rear fender lower panel.

REAR FENDER LOWER PANEL

ac5uub00000074

End Of Sie
BM: REAR FENDER RAIN RAIL

09-80B–77
3506-1U-12A.book 78 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

CORNER PLATE REMOVAL [PANEL REPLACEMENT]
id098008610400
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000076

Removal Procedure
1. Drill the 11 location shown in the figure.

5
2

CORNER PLATE

ac5wzb00000130

2. Remove the corner plate.

End Of Sie

09-80B–78
3506-1U-12A.book 79 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

CORNER PLATE INSTALLATION [PANEL REPLACEMENT]
id098008610500
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

PLUG WELDING (ARC WELDING)

ac5wzb00000216 09-80B

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 3 locations indicated by (A) shown in the figure.
5. Spot weld the 11 locations by (B) shown in the figure, then install the corner plate.

(B) 7
(B) 2

CORNER PLATE

(B) 4 (A) 1

ac5wzb00000131

End Of Sie

09-80B–79
3506-1U-12A.book 80 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

CORNER JUNCTION REMOVAL [PANEL REPLACEMENT]
id098008611400
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING
ac5wzb00000078

Removal Procedure
1. Drill the 27 locations shown in the figure.
2
1

CORNER JUNCTION

11

ac5wzb00000132

2. Remove the corner junction.

End Of Sie

09-80B–80
3506-1U-12A.book 81 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

CORNER JUNCTION INSTALLATION [PANEL REPLACEMENT]
id098008611500
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

PLUG WELDING (ARC WELDING)

ac5wzb00000217 09-80B

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Spot weld the 15 locations indicated by (A) shown in the figure.
5. Plug weld the 15 locations indicated by (B) shown in the figure, then install the corner junction.
(B) 2
(A) 1

CORNER JUNCTION

(B) 6

(A) 14

(B) 7

ac5wzb00000259

End Of Sie
BM: REAR END PANEL

09-80B–81
3506-1U-12A.book 82 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

REAR END PANEL REMOVAL [PANEL REPLACEMENT]
id098008744500
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000080

Removal Procedure
1. Drill the 77 locations indicated by (A) shown in the figure.
2. Drill the 18 locations indicated by (B) from room side shown in the figure.

(B) 8 (B) 8

(A) 3 (A) 1 (B) 1 (B) 1 (A) 1 (A) 3

(A) 11 (A) 11

REAR END PANEL

(A) 4 (A) 4

(A) 6 (A) 6

(A) 5 (A) 5
(A) 17
ac5uub00000037

3. Remove the rear end panel.

End Of Sie

09-80B–82
3506-1U-12A.book 83 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

REAR END PANEL INSTALLATION [PANEL REPLACEMENT]
id098008744600
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

ac5wzb00000226

Installation Procedure 09-80B

1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 77 locations indicated by (A) shown in the figure.
5. Plug weld the 18 locations indicated by (B) from room side shown in the figure, then install the rear end panel.

(B) 8 (B) 8

(A) 3 (A) 1 (B) 1 (A) 1 (A) 3

(B) 1

(A) 11 (A) 11

REAR END PANEL

(A) 4 (A) 4

(A) 6 (A) 6

(A) 5 (A) 5
(A) 17
ac5uub00000036

End Of Sie
BM: REAR PILLAR OUTER

09-80B–83
3506-1U-12A.book 84 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

REAR PILLAR (OUTER) REMOVAL [PANEL REPLACEMENT]
id098008747200
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ROUGH CUT LOCATION

ac5wzb00000260

Removal Procedure
1. Rough cut area location indicated by (A) shown in the figure.
2. Drill the 10 locations indicated by (B) shown in the figure.

150 mm {5.90 in}

(A) ROUGH CUT LOCATION

(B) 1

REAR PILLAR (OUTER)

(B) 9

ac5wzb00000293

3. Remove the rear pillar (outer).

End Of Sie

09-80B–84
3506-1U-12A.book 85 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

REAR PILLAR (OUTER) INSTALLATION [PANEL REPLACEMENT]
id098008747300
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

PLUG WELDING (ARC WELDING)

09-80B
CONTINUOUS ARC WELDING (CUT-AND-JOIN LOCATION)

ac5wzb00000227

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Cut and join the area location indicated by (A) shown in the figure.
5. Plug weld the 1 location indicated by (B) shown in the figure.
6. Spot weld the 12 locations indicated by (C) shown in the figure, then install the rear pillar (outer).

150 mm {5.90 in}

(A) CUT AND JOIN LOCATION

(B) 1

REAR PILLAR (OUTER)

(C) 12

ac5wzb00000294

End Of Sie

09-80B–85
3506-1U-12A.book 86 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

D-PILLAR REINFORCEMENT (LOWER) REMOVAL [PANEL REPLACEMENT]
id098008829300
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000086

Removal Procedure
1. Drill the 8 locations shown in the figure.
2

D-PILLAR REINFORCEMENT (LOWER)

ac5wzb00000295

2. Remove the D-pillar reinforcement (lower).

End Of Sie

09-80B–86
3506-1U-12A.book 87 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

D-PILLAR REINFORCEMENT (LOWER) INSTALLATION [PANEL REPLACEMENT]
id098008829400
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

PLUG WELDING (ARC WELDING)

ac5wzb00000230 09-80B

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 2 locations indicated by (A) shown in the figure.
5. Spot weld the 8 locations indicated by (B) shown in the figure, then install the D-pillar reinforcement (lower).
(A) 2

D-PILLAR REINFORCEMENT (LOWER)

(B) 8

ac5wzb00000296

End Of Sie

09-80B–87
3506-1U-12A.book 88 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

REAR SIDE PANEL REMOVAL [PANEL REPLACEMENT]
id098008829100
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000084

Removal Procedure
1. Drill the 11 locations shown in the figure.

REAR SIDE PANEL 3

ac5wzb00000140

2. Remove the rear side panel.

End Of Sie

09-80B–88
3506-1U-12A.book 89 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

REAR SIDE PANEL INSTALLATION [PANEL REPLACEMENT]
id098008829200
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

ac5wzb00000229

Installation Procedure 09-80B

1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 11 locations shown in the figure, then install the rear side panel.

REAR SIDE PANEL 3

ac5wzb00000141

End Of Sie
BM: FLOOR SIDE PANEL

09-80B–89
3506-1U-12A.book 90 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

FLOOR SIDE PANEL REMOVAL [PANEL REPLACEMENT]
id098008618700
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ac5wzb00000088

Removal Procedure
1. Drill the 35 locations indicated by (A) shown in the figure, then remove the floor side panel No.1.

FLOOR SIDE PANEL No.1

(A) 10

(A) 2

(A) 2
(A) 15

(A) 6

ac5wzb00000144

09-80B–90
3506-1U-12A.book 91 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

2. Drill the 5 locations indicated by (B) shown in the figure.
3. Drill the 4 locations indicated by (C) from rear wheel housing shown in the figure.

09-80B

(C) 4

(B) 5

FLOOR SIDE PANEL No.2

ac5wzb00000145

4. Remove the floor side panel No.2.

End Of Sie

09-80B–91
3506-1U-12A.book 92 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

FLOOR SIDE PANEL INSTALLATION [PANEL REPLACEMENT]
id098008618800
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

PLUG WELDING (ARC WELDING)

ac5wzb00000224

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Spot weld the 7 locations indicated by (A) shown in the figure.
5. Spot weld the 5 locations indicated by (B) shown in the figure, then install the floor side panel No.2.

(B) 5

(A) 7

FLOOR SIDE PANEL No.2

ac5uub00000076

09-80B–92
3506-1U-12A.book 93 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

6. Plug weld the 35 locations indicated by (C) shown in the figure, then install the floor side panel No.1.

FLOOR SIDE PANEL No.1

09-80B

(C) 10

(C) 2

(C) 2
(C) 15

(C) 6

ac5wzb00000147

End Of Sie
BM: TRUNK FLOOR PAN

09-80B–93
3506-1U-12A.book 94 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

TRUNK FLOOR PANEL REMOVAL [PANEL REPLACEMENT]
id098008829500
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING
ac5wzb00000090

Removal Procedure
1. Drill the 96 locations shown in the figure.

Caution
• When drilling the 96 locations shown in the figure, do not drill a hole all the way through or there
could be a problem when installing the new part.

19

17
21 16

19

3 3
1

TRUNK FLOOR PANEL

ac5wzb00000142

2. Remove the trunk floor panel.

End Of Sie

09-80B–94
3506-1U-12A.book 95 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

TRUNK FLOOR PANEL INSTALLATION [PANEL REPLACEMENT]
id098008829600
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

ac5wzb00000231

Installation Procedure 09-80B

1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Slide the part of trunk floor panel in the direction of arrow shown in the figure, and then insert it.

TRUNK FLOOR PANEL

ac5wzb00000148

09-80B–95
3506-1U-12A.book 96 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

5. Plug weld the 96 locations shown in the figure, then install the trunk floor panel.

19

17
21 16

19

3 3
1

TRUNK FLOOR PANEL

ac5wzb00000143

End Of Sie
BM: REAR SIDE FRAME

09-80B–96
3506-1U-12A.book 97 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

REAR SIDE FRAME REMOVAL [PANEL REPLACEMENT]
id098008801200
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

ROUGH CUT LOCATION

ac5wzb00000092 09-80B

Removal Procedure

Note
• When drilling the 35 locations indicated by (A) and 4 locations indicated by (C) shown in the figure, do not
drill a hole all the way through or there could be a problem when installing the new part.

1. Drill the 35 locations indicated by (A) shown in the figure, then remove the floor side panel No.1.

FLOOR SIDE PANEL No.1

(A) 10

(A) 2

(A) 2
(A) 15

(A) 6

ac5wzb00000149

09-80B–97
3506-1U-12A.book 98 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

2. Rough cut area location indicated by (B) shown in the figure.

(B) ROUGH CUT

LOCATION

PART OF TRUNK FLOOR PANEL TRUNK FLOOR PANEL

ac5wzb00000150

3. Drill the 4 locations indicated by (C) shown in the figure, then remove the part of trunk floor panel.

TRUNK FLOOR PANEL

ac5wzb00000151

09-80B–98
3506-1U-12A.book 99 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

4. Drill the 8 locations indicated by (D) shown in the figure.

(D) 3

09-80B
(D) 3

(D) 2

REAR SIDE FRAME

ac5wzb00000152

5. Remove the rear side frame.

End Of Sie

09-80B–99
3506-1U-12A.book 100 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

REAR SIDE FRAME INSTALLATION [PANEL REPLACEMENT]
id098008801300
Symbol Mark

SYMBOL MARK MEANING

PLUG WELDING (ARC WELDING)

CONTINUOUS ARC WELDING (CUT-AND-JOIN LOCATION)

ac5wzb00000228

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 8 locations indicated by (A) shown in the figure, then install the rear side frame.

(A) 3

(A) 3

(A) 2

REAR SIDE FRAME

ac5wzb00000153

09-80B–100
3506-1U-12A.book 101 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

5. Cut and join the area location indicated by (B) shown in the figure.

09-80B

(B) CUT AND JOIN

LOCATION

PART OF TRUNK FLOOR PANEL TRUNK FLOOR PANEL

ac5wzb00000154

6. Plug weld the 4 locations indicated by (C) shown in the figure, then install the part of trunk floor panel.

TRUNK FLOOR PANEL

ac5wzb00000155

09-80B–101
3506-1U-12A.book 102 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

7. Plug weld the 35 locations indicated by (D) shown in the figure, then install the floor side panel No.2.

FLOOR SIDE PANEL No.1

(D) 10

(D) 2

(D) 2
(D) 15

(D) 6

ac5wzb00000156

End Of Sie
BM: ROOF PANEL

09-80B–102
3506-1U-12A.book 103 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

ROOF PANEL REMOVAL [PANEL REPLACEMENT]
id098008744300
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING
ac5wzb00000094

Removal Procedure 09-80B

1. Drill the 116 locations shown in the figure.

ROOF PANEL
28
5

19
17

28

ac5uub00000034

2. Remove the roof panel.

End Of Sie

09-80B–103
3506-1U-12A.book 104 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

ROOF PANEL INSTALLATION [PANEL REPLACEMENT]
id098008744400
Symbol Mark

SYMBOL MARK MEANING

SPOT WELDING

PLUG WELDING (ARC WELDING)

ac5wzb00000225

Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Apply the body sealer to the position shown in the figure.

: BODY SEALER
ac5wzb00000159

09-80B–104
3506-1U-12A.book 105 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PANEL REPLACEMENT]

5. Plug weld the 83 locations indicated by (A) shown in the figure.
6. Spot weld the 47 locations indicated by (B) shown in the figure, then install the roof panel.

(A) 7

ROOF PANEL
(A) 28
09-80B
(A) 5

(B) 25
(B) 22

(A) 28

(A) 7

(A) 5

ac5uub00000035

End Of Sie

09-80B–105
3506-1U-12A.book 106 ページ ２０１２年１月２６日 木曜日 午前１０時２０分
3506-1U-12A.book 1 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE]

09-80C BODY STRUCTURE [WATER-PROOF AND RUST
PREVENTIVE]
BODY SEALING RUST PREVENTIVE TREATMENT
[WATER-PROOF AND [WATER-PROOF AND
RUST PREVENTIVE] . . . . . . . . . . . . . . 09-80C–2 RUST PREVENTIVE] . . . . . . . . . . . . . . . 09-80C–6
UNDER COATING DUMPING SHEET REPLACEMENT
[WATER-PROOF AND [WATER-PROOF AND
RUST PREVENTIVE] . . . . . . . . . . . . . . 09-80C–5 RUST PREVENTIVE] . . . . . . . . . . . . . . . 09-80C–7

End of Toc
BM: WATER-PROOF AND RUST PREVENTIVE
09-80C

09-80C–1
3506-1U-12A.book 2 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE]

BODY SEALING [WATER-PROOF AND RUST PREVENTIVE]
id098009739800
Sealant is applied to the parts where the panels meet and to the hemmed parts of the door panel and hood panel
to provide water proofing and rust proofing.

ac5wzb00000185

09-80C–2
3506-1U-12A.book 3 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE]

09-80C

ac5wzb00000186

09-80C–3
3506-1U-12A.book 4 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE]

HOOD

DOOR

LIFTGATE

ac5uub00000001

End Of Sie

09-80C–4
3506-1U-12A.book 5 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE]

UNDER COATING [WATER-PROOF AND RUST PREVENTIVE]
id098009739900
• The shaded areas indicated under body locations that are undercoated to prevent noise and rusting.
LH
RH

09-80C

ac5uub00000009

End Of Sie

09-80C–5
3506-1U-12A.book 6 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE]

RUST PREVENTIVE TREATMENT [WATER-PROOF AND RUST PREVENTIVE]
id098009740100

HOOD

DOOR

LIFTGATE

ac5uub00000002

End Of Sie

09-80C–6
3506-1U-12A.book 7 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE]

DUMPING SHEET REPLACEMENT [WATER-PROOF AND RUST PREVENTIVE]
id098009745700
• After repairing the body, attach the dumping sheet to the location shown in the figure for noise insulation.

09-80C

ac5wzb00000193

End Of Sie

09-80C–7
3506-1U-12A.book 8 ページ ２０１２年１月２６日 木曜日 午前１０時２０分
3506-1U-12A.book 1 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [DIMENSIONS]

09-80D BODY STRUCTURE [DIMENSIONS]
UNDERBODY DIMENSIONS FRONT BODY STRAIGHT-LINE
[DIMENSIONS] . . . . . . . . . . . . . . . . . . . 09-80D–2 DIMENSIONS (2) [DIMENSIONS] . . . . . 09-80D–7
FRONT WHEEL ALIGNMENT CABIN SIDE FRAME STRAIGHT-LINE
[DIMENSIONS] . . . . . . . . . . . . . . . . . . . 09-80D–3 DIMENSIONS [DIMENSIONS] . . . . . . . . 09-80D–8
Steering Angle Adjustment . . . . . . . . . 09-80D–4 ROOM STRAIGHT-LINE DIMENSIONS (1)
Total Toe-in Adjustment . . . . . . . . . . . . 09-80D–4 [DIMENSIONS] . . . . . . . . . . . . . . . . . . . . 09-80D–9
REAR WHEEL ALIGNMENT ROOM STRAIGHT-LINE DIMENSIONS (2)
[DIMENSIONS] . . . . . . . . . . . . . . . . . . . 09-80D–4 [DIMENSIONS] . . . . . . . . . . . . . . . . . . . . 09-80D–11
Total Toe-in Adjustment . . . . . . . . . . . . 09-80D–5 ROOM STRAIGHT-LINE DIMENSIONS (3)
FRONT BODY STRAIGHT-LINE [DIMENSIONS] . . . . . . . . . . . . . . . . . . . . 09-80D–12
DIMENSIONS (1) [DIMENSIONS]. . . . . 09-80D–5 REAR BODY STRAIGHT-LINE
DIMENSIONS (1) [DIMENSIONS] . . . . . 09-80D–13
09-80D
End of Toc
BM: UNDERBODY

09-80D–1
3506-1U-12A.book 2 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [DIMENSIONS]

UNDERBODY DIMENSIONS [DIMENSIONS]
id098010990000

Note
• The following figure is a bottom view.

A' B' C' E' D' F' G' H' I' J'

1,465
{57.68}

1,290
994 {39.1} 1,377 1,027
LH

{50.79}
875 {54.21} {40.43}
1,030 883
{34.4} {34.8} 1,107
RH

{40.55} 1,765 1,877

{73.90} {43.58}
{69.49}
403 1,372
{15.9} {54.02} 1,201
{47.28}

204 {8.03}
356
{14.0}
1,014 {39.92}
1,148 {45.20}

956 {37.64}

970 {38.19}
988 {38.9}

844 {33.2}
LH

922 {36.3}
958 {37.7}

937 {36.9}

{24.0}
610
RH

A B C E D F G H I J
692 {27.2}

692 {27.2}
620 {24.4}

694 {27.3}
712 {28.0}

529 {20.8}

528 {20.8}
{19.3}
{18.1}
{19.6}

490
459
497

403 437 908 702 478 356

{15.9} {17.2} {35.7} {27.6} {18.8} {14.0}

182 246 112

{7.17} {9.69} {4.41}
ac5uub00000077

09-80D–2
3506-1U-12A.book 3 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [DIMENSIONS]

A, B C D E F

G H I J K

09-80D

ac5wzb00000163

Point Hole diameter Point Hole diameter

sym Designation or bolt or nut sym Designation or bolt or nut
bol size mm {in} bol size mm {in}
A Front crossmember installation hole φ24 {0.94} F Front B frame datum hole φ16 {0.63}
B Front side frame datum hole φ16 {0.63} G Front B frame datum hole φ25 {0.98}
C Front crossmember installation hole φ22.5 {0.886} H Rear crossmember mounting bolt M12
D Front crossmember installation hole φ19 {0.75} I Rear side frame datum hole φ10 {0.39}
E Front crossmember installation hole φ22 {0.87} J Rear side frame datum hole φ30 {1.2}

End Of Sie
FRONT WHEEL ALIGNMENT [DIMENSIONS]
BM: WHEEL ALIGNMENT

id098010898900

Front wheel alignment (Unloaded)*1

Fuel gauge indication
Item
Empty 1/4 1/2 3/4 Full
Maximum steering angle Inner 37°48′
[Tolerance ±3°] Outer 30°54′
Tire
2 {0.08}
[Tolerance ±4 {0.2}]
(mm {in})
Total toe-in Rim inner Vehicle equipped with 17 inch wheel: 1.0 {0.04}
[Tolerance ±3 {0.1}] Vehicle equipped with 19 inch wheel: 1.0 {0.04}
(degree) 0°10′±0°20′
Caster angle*2 (Reference value) 6°19′ 6°21′ 6°24′ 6°27′ 6°29′
[Tolerance ±1°]
Camber angle*2 (Reference value) -0°20′ -0°21′ -0°21′ -0°21′ -0°22′
[Tolerance ±1°]
Steering axis inclination (Reference value) 11°57′ 11°58′ 11°59′ 11°59′ 12°00′

*1 : Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated
position.
*2 : Difference between left and right must not exceed 1°30′.

09-80D–3
3506-1U-12A.book 4 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [DIMENSIONS]

Steering Angle Adjustment
1. Loosen the tie-rod end locknuts.
2. Remove the steering gear boot clamp.
3. Turn the tie rods.

Standard length L
10.1—23.1 mm {0.4—0.9 in}

4. Turn the tie rods equally to provide the correct A

maximum steering angle.
5. Tighten the tie-rod end locknuts.

Tightening torque
68—98 N·m {7.1—9.9 kgf·m, 51—72 ft·lbf}
am6zzw0000365
6. Verify that the boot is not twisted, and install the
boot clamp.
7. Adjust the toe-in after adjusting the steering angle.

Total Toe-in Adjustment

1. Loosen the locknut of the tie-rod end.
2. Remove the rack boot clamp.
3. Adjust the total toe-in by rotating each tie rod (left and right) in the opposite directions by the same amount
respectively.

Note
• Toe angle changes by approx. 6 mm {0.2 in} per one rotation of the tie rod for one wheel.
• Each tie rod has a right-hand thread. When increasing the toe-in angle, rotate the right tie rod toward the
front of the vehicle and rotate the left tie rod toward the rear of the vehicle by the same amount.

4. Tighten the locknut of the tie-rod end.

Tightening torque
68—98 N·m {7.1—9.9 kgf·m, 51—72 ft·lbf}

5. Verify that the rack boot does not have any twisting and install the rack boot clamp.
End Of Sie
REAR WHEEL ALIGNMENT [DIMENSIONS]
id098010899000

Rear wheel alignment (Unloaded)*1

Fuel gauge indication
Item
Empty 1/4 1/2 3/4 Full
Tire
2 {0.08}
[Tolerance ±4 {0.2}]
(mm {in})
Total toe-in Rim inner Vehicle equipped with 17 inch wheel: 1.0 {0.04}
[Tolerance ±3 {0.1}] Vehicle equipped with 19 inch wheel: 1.0 {0.04}
(degree) 0°10′±0°20′
Camber angle*2 (Reference
value) -0°51′ -0°54′ -0°56′ -0°58′ -1°01′
[Tolerance ±1°]
Thrust angle (Reference value) [Tolerance ±0°48′] 0°

*1 : Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated
position.
*2 : Difference between left and right must not exceed 1°30′.

09-80D–4
3506-1U-12A.book 5 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [DIMENSIONS]

Total Toe-in Adjustment
1. Loosen the installation nut of the adjusting cam bolt.
2. Rotate the adjusting cam bolt in either direction to
adjust the toe-in. LEFT SIDE

Left wheel Right wheel

Toe-out direction Counterclockwise Clockwise
Toe-in direction Clockwise Counterclockwise

3. Tighten the nut.

Tightening torque
ADJUSTING CAM BOLT
84—101 N·m {8.6—10 kgf·m, 62—74 ft·lbf}

End Of Sie
BM: FRONT BODY
ac5uuw00000108

FRONT BODY STRAIGHT-LINE DIMENSIONS (1) [DIMENSIONS] 09-80D

id098010740600

C B A 523 B' C'

389 {15.3} A'
373 {14.7} {20.6}
D 697 776 638
D'
{27.4} {30.6} {25.1}
E F 1,328 {52.28} F' E'

G 1,176 {46.30} G'

ac5wzb00000297

09-80D–5
3506-1U-12A.book 6 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [DIMENSIONS]

A B, C C D E F

ac5wzb00000161

Point Hole diameter Point Hole diameter

sym Designation or bolt or nut sym Designation or bolt or nut
bol size mm {in} bol size mm {in}
A Cowl panel installation hole φ5 {0.2} E Front fender panel installation hole φ7 {0.3}
B Wiper bracket datum hole φ7 {0.3} Apron reinforcement lower datum
F φ10 {0.39}
C Hood hinge installation hole φ10 {0.39} hole
Shroud upper member installation
D
Front suspension upper mounting
φ10.2 {0.402} G φ7 {0.3}
installation hole hole

End Of Sie

09-80D–6
3506-1U-12A.book 7 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [DIMENSIONS]

FRONT BODY STRAIGHT-LINE DIMENSIONS (2) [DIMENSIONS]
id098010740700

1,172 {46.14}

A'
725 {28.5}

1,566 {61.65}

B
D
09-80D
1,562 {61.50} 1,643 {64.69}
C
365 {14.4} 1,319 {51.93}

F 1,408 {55.43} D'

E B'
1,437 {56.57}
C'
G 1,374 {54.09} 257 {10.1}
1,328 {52.28}
H
E' 848 {33.4}
1,176 {46.30} 352 {13.9}
1,348 {53.07} F'
1,260 {49.61} G'
I
H'
1,021 {40.20}
J
875 {34.45}
K I'
992 {39.1}

1,100 {43.31} J'

K'

ac5wzb00000179

A B C, D D E F

G H I I' J, K

ac5wzb00000167

Point Hole diameter

sym Designation or bolt or nut
bol size mm {in}
A Roof seamless location -

09-80D–7
3506-1U-12A.book 8 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [DIMENSIONS]

Point Hole diameter Point Hole diameter
sym Designation or bolt or nut sym Designation or bolt or nut
bol size mm {in} bol size mm {in}
Cabin side outer frame (front pillar Apron reinforcement lower datum
B - G φ10 {0.39}
outer) projection location hole
C Wiper bracket datum hole φ7 {0.3} H Front fender panel installation hole φ7 {0.3}
D Hood hinge installation hole φ10 {0.39} I Side stay datum hole φ10 {0.39}
Front suspension upper mounting Front bumper reinforcement
E φ10.2 {0.402} J φ12 {0.47}
installation hole installation hole
F Front fender panel installation hole φ7 {0.3} Front bumper reinforcement
K φ12 {0.47}
installation hole

End Of Sie
CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS [DIMENSIONS]
BM: CABIN SIDE FRAME

id098010743600

G J

990 960
{39.0} {37.8}
1,262
1,432
B {49.69}
{56.38} H
1,116 1,590
{43.94} {62.60}
C L
1,140 {44.884} 582 810
1212 1,111 1,066
{22.9} {31.9}
{47.72} {43.74} {41.97}
A
I 686
D 744 {27.0}
1,008 {39.69} {29.3}
F K

E 1,090
1,278 {42.91}
{50.31}
ac5wzb00000301

A B, C D, E F G
B

E
C
H I J K L

ac5wzb00000169

Point Hole diameter Point Hole diameter

sym Designation or bolt or nut sym Designation or bolt or nut
bol size mm {in} bol size mm {in}
A Front side frame outer datum hole φ12 {0.47} F Cabin side frame (outer) notch -
B Front fender panel installation hole φ10 {0.39} G Cabin side frame (outer) notch -
C Front door hinge installation hole φ12 {0.47} H Rear door hinge installation hole φ12 {0.47}
D Front door hinge installation hole φ12 {0.47} I Rear door hinge installation hole φ12 {0.47}
E Front fender panel installation hole φ11 {0.43}

09-80D–8
3506-1U-12A.book 9 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [DIMENSIONS]

Point Hole diameter Point Hole diameter
sym Designation or bolt or nut sym Designation or bolt or nut
bol size mm {in} bol size mm {in}
Quarter window glass installation K Rear over fender installation hole φ10 {0.39}
J φ8 {0.3}
hole L Rear bumper slider installation hole φ16 {0.63}

End Of Sie
ROOM STRAIGHT-LINE DIMENSIONS (1) [DIMENSIONS]
BM: ROOM

id098010743300

A
B
F

09-80D

1,215 {47.83}
C G
1,174 {46.22}

1,230 {48.43}
1,039 {40.91}

I-I'

1,262 {49.69}
D
H
1,584 {62.36}

1,182 {46.54} 777 {30.6}

ac5wzb00000299

09-80D–9
3506-1U-12A.book 10 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [DIMENSIONS]

A B C D E

F G H I

ac5wzb00000172

Point Hole diameter Point Hole diameter

sym Designation or bolt or nut sym Designation or bolt or nut
bol size mm {in} bol size mm {in}
A Front pillar inner datum hole φ7 {0.3} Front seat belt upper anchor
F φ14 {0.55}
B Front pillar inner datum hole φ7 {0.3} installation hole
φ14 {0.55} Front seat belt upper anchor
C Dashboard installation hole G φ14 {0.55}
installation hole
D Side sill inner front datum hole φ16 {0.63}
H Center pillar inner datum hole φ7 {0.3}
E Parking brake lever installation hole φ12 {0.47}
I Front door checker installation hole φ4 {0.2}

End Of Sie

09-80D–10
3506-1U-12A.book 11 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [DIMENSIONS]

ROOM STRAIGHT-LINE DIMENSIONS (2) [DIMENSIONS]
id098010743400

1,102 {43.39}
F

A 973 {38.3}

1,318 {51.89} I-I'

B
G
1,592 {62.68}
777 {30.6} 09-80D
1,242 {48.90}

C 780 {30.7}
1,197 {47.13}

ac5wzb00000300

A B C D E

D'

F G H I

ac5wzb00000173

Point Hole diameter Point Hole diameter

sym Designation or bolt or nut sym Designation or bolt or nut
bol size mm {in} bol size mm {in}
Front seat belt upper anchor Front seat belt upper anchor
A φ14 {0.55} B φ14 {0.55}
installation installation

09-80D–11
3506-1U-12A.book 12 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [DIMENSIONS]

Point Hole diameter Point Hole diameter
sym Designation or bolt or nut sym Designation or bolt or nut
bol size mm {in} bol size mm {in}
C Center pillar inner datum hole φ7 {0.3} F C-pillar trim installation hole φ10 {0.39}
D Rear seat installation hole φ14 {0.55} G Trunk side trim installation hole φ8.6 {0.34}
E Rear pillar inner datum hole φ7 {0.3} H Rear pillar inner datum hole φ8.6 {0.34}
I Rear door striker installation hole φ13 {0.51}

End Of Sie
ROOM STRAIGHT-LINE DIMENSIONS (3) [DIMENSIONS]
id098010746200

1,013 {39.88} 1,030 {40.55}

D

1,048 {41.26}

950 {37.4}

ac5wzb00000302

A B C D E E'
A'

A
E

ac5wzb00000176

Point Hole diameter Point Hole diameter

sym Designation or bolt or nut sym Designation or bolt or nut
bol size mm {in} bol size mm {in}
A Rear seat installation hole φ14 {0.55} Liftgate stay damper installation
C φ7 {0.3}
B D-pillar trim installation hole φ8.6 {0.34} hole
D Trunk side trim installation hole φ8.6 {0.34}

09-80D–12
3506-1U-12A.book 13 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [DIMENSIONS]

Point Hole diameter
sym Designation or bolt or nut
bol size mm {in}
E Liftgate striker installation hole φ14 {0.55}

End Of Sie
REAR BODY STRAIGHT-LINE DIMENSIONS (1) [DIMENSIONS]
BM: REAR BODY

id098010746300

A' 725 {28.5} A

198 {7.80}
907 {35.7}
B' B
1,080 {42.52}
476 {18.7}
1,323 {52.09}
1,087 {42.80}
1,097 {43.19} 09-80D
C' C
1,406 {55.35}
1,415 {55.71}
338 {13.3} E' E 1,053 {41.46}
996
{39.2}
D' 1,342 {52.83} D
338 {13.3} F'
F
1,128 {44.41}
G' 864 {34.0} G
154 {6.06} 972 {38.3}
1,067 {42.01}
H' H

ac5uub00000007

A, B A C D E F F'

B F

G, H

ac5uub00000008

Point Hole diameter Point Hole diameter

sym Designation or bolt or nut sym Designation or bolt or nut
bol size mm {in} bol size mm {in}
A Liftgate hinge installation hole φ12 {0.47} E Brace bracket datum hole φ10 {0.39}
Liftgate stay damper installation F Liftgate striker installation hole φ14 {0.55}
B φ10 {0.39}
hole Rear bumper reinforcement
G M10
Rear combination light installation installation bolt
C φ10 {0.39}
slot Rear bumper reinforcement
H M10
D Rear end panel datum bolt φ12 {0.347 installation bolt

End Of Sie

09-80D–13
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3506-1U-12A.book 1 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PLASTIC BODY PARTS]

09-80E BODY STRUCTURE [PLASTIC BODY PARTS]
PLASTIC PARTS HEAT Repairable Bumpers . . . . . . . . . . . . . . . 09-80E–2
RESISTING TEMPERATURE POLYPROPYLENE BUMPER REPAIR
[PLASTIC BODY PARTS] . . . . . . . . . . . 09-80E–1 [PLASTIC BODY PARTS]. . . . . . . . . . . . 09-80E–3
REPAIRABLE RANGE OF PROCEDURE
POLYPROPYLENE BUMPERS [PLASTIC BODY PARTS]. . . . . . . . . . . . 09-80E–4
[PLASTIC BODY PARTS] . . . . . . . . . . . 09-80E–2

End of Toc
PLASTIC PARTS HEAT RESISTING TEMPERATURE [PLASTIC BODY PARTS]
BM: PLASTIC BODY PARTS

id098011740200

Heat resisting
Part Name Code Material Name
Temperature°C{°F}
Windshield molding PVC POLYVINYLCHLORIDE 95 {203}
Cowl grille PP POLYPROPYLENE 95 {203}
Lens PC POLYCARBONATE 130 {266} 09-80E
Front combination light
Housing PP POLYPROPYLENE 90 {194}
Front bumper PP POLYPROPYLENE 100 {212}
Lens PMMA ACRYLIC 75 {167}
Front side turn light
Housing PC-PBT POLYCARBONATE-PBT 80 {176}
Panel ABS ABS 100 {212}
Out side mirror Visor ABS ABS 100 {212}
Outer cover ABS ABS 100 {212}
Side step molding PP POLYPROPYLENE 75 {167}
Roof molding PVC POLYVINYLCHLORIDE 95 {203}
Rear bumper PP POLYPROPYLENE 100 {212}
Lens PMMA ACRYLIC 80 {176}
Rear combination light
Housing AAS AAS 70 {158}
Lever PC-PBT POLYCARBONATE-PBT 80 {176}
Outer handle
Base PC-PET POLYCARBONATE-PET 80 {176}
Lens PMMA ACRYLIC 80 {176}
High-mount brake light
Housing ABS ABS 100 {212}
Rear Spoiler PP POLYPROPYLENE 90 {194}
Shroud panel PP POLYPROPYLENE 100 {212}

Note
• The application of temperatures higher than heat resisting temperatures may result in part deformation.

End Of Sie
BM: BUMPER

09-80E–1
3506-1U-12A.book 2 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PLASTIC BODY PARTS]

REPAIRABLE RANGE OF POLYPROPYLENE BUMPERS [PLASTIC BODY PARTS]
id098011600100
The three types of damaged bumpers shown below are considered repairable. Although a bumper which has been
damaged greater than this could also be repaired, it should be replaced with a new one because such repair would
detract from the looks and quality of the bumper. In addition, such repair is not considered reasonable in terms of
work time.

Repairable Bumpers
1. A bumper with a hole less than 50 mm {1.97 in} in
diameter.

am8rrb00000046

2. A bumper with a crack less than 100 mm {3.94 in}

in length.

am8rrb00000047

3. A bumper with a crack less than 100 mm {3.94 in}

in length that is less than half of the width of the
(A)
bumper.
End Of Sie

LESS THAN HALF OF (A)

am8rrb00000048

09-80E–2
3506-1U-12A.book 3 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PLASTIC BODY PARTS]

POLYPROPYLENE BUMPER REPAIR [PLASTIC BODY PARTS]
id098011600200

Scratch on paint only Hole or crack through surface Crack more than 100 mm
{3.94 in} long or completely
broken

Bumper Bumper Remove paint

surface surface
not visible visible
Smooth damaged area

09-80E
Apply aluminium tape to
reverse side of bumper

Plastic weld damaged area Replace damaged

Bumper
Spray entire bumper
Rough sand damage area surface with
polypropylene primer

Degrease damaged area

Apply polypropylene primer

to damaged area

Apply repair agent to

damaged area and let dry

Sand damaged Sand damaged area

area smooth

Apply polypropylene primer to damaged

area and let dry

Spray primer surfacer on damaged area Spray primer surfacer on

and let dry bumper and let dry

Sand partial or complete surface of bumper Sand surface of bumper

Degrease bumper

Spray matching body color paint on bumper and let dry

am2uub0000000

End Of Sie

09-80E–3
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BODY STRUCTURE [PLASTIC BODY PARTS]

PROCEDURE [PLASTIC BODY PARTS]
id098011600300
Repair of polypropylene bumpers having damage that has reached the surface of the polypropylene and are too
serious to be restored by painting only.
Hole Flaw
Crack

A B C D

A B C D

SEC. A-A 1 SEC. B-B, SEC. D-D

2 SEC. C-C

3
4

1 Top coat layer 2 Primer surface layer

3 Primer layer 4 Polypropylene layer
am2uub0000001

1. Cut the rough edges around the damage with a knife to make it smooth. Sand the area with a sander to make
an angle of about 45°.

SEC. A-A, SEC. B-B, SEC. C-C SEC. D-D

Cut with knife
Cut with knife

Polypropylene surface

Sand

Sand

45

Angle necessary for deposit of polypropylene welding rog

am2uub0000001

09-80E–4
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BODY STRUCTURE [PLASTIC BODY PARTS]

2. Weld the damaged area.
• For repair of a cracked area, melt the crack together with a heat gun and a melting attachment.
Heat gun
SEC. B-B, SEC. C-C Melt together

painted surface

Attachment for
melting Polypropylene surface Section after melting

am2uub0000001

• For repair of a hole, degrease the area on

both sides of the bumper and apply aluminium
SEC. A-A
tape on the reverse side of the damage area. Degrease

09-80E

Aluminium tape

am2uub0000001

3. Melt the polypropylene welding rod with a heat gun and deposit it the cracked area.
Polypropylene welding rod
SEC. B-B, SEC. C-C, SEC. D-D

Polypropylene welding rod

Melt this area

Melted area
am2uub0000001

Note
• Heat the shaded area to melt it.
• Take care not to overly melt welding rod. If the part is welded with the welding rod melted like jelly, the
welding strength will be reduced.
• Hold the heat gun 10—20 mm {0.39—0.79 in} from the part being welded.
• Do not move the welding rod until the welded parts cool.

Polypropylene welding
Polypropylene welding rod SEC. A-A

Paint
Surface

Top view
Aluminium tape
am2uub0000001

09-80E–5
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BODY STRUCTURE [PLASTIC BODY PARTS]

4. Sand the surface of the polypropylene gradually as it is easily melted by the abrasion heat. Sand the area to
which repair agent will be applied.
Sand gradually
Sand repair area

Paint

am2uub0000001

5. Uniformly apply polypropylene primer with a brush to an area larger than the repaired area. Allow to dry about
10 minutes at 20 °C {68 °F}.
Larger than repaired area

Polypropylene primer
am2uub0000001

6. Mix the main agent and the stiffening agent in a ratio of one to one. Apply the mixed repair agent to the
damaged area.

Note
• When mixing the main and stiffening agents, take care not to allow bubbles to form.
• The repair agent hardens quickly (about 5 minutes); proceed with the work immediately after mixing the
agents.
• Allow about 30 minutes to dry (20 °C {68 °F}) before sanding.

Repair agent
Do not mix air

Weld
Polypropylene surface

am2uub0000001

The repair agent is a two part epoxy adhesive.

When the repair agent hardens, it will provide a good finish with the same flexibility as the polypropylens.
The repair agent for a urethane bumper is also a two part adhesive compound. However, this is different from
that for a polypropylene bumper. If the incorrect repair agent is used, the repair will be faulty.

09-80E–6
3506-1U-12A.book 7 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PLASTIC BODY PARTS]

7. Sand the area with #180—240 sandpaper.

Note
• If excessive force is applied to the area when sanding, the surface will be damaged.
• If fuzz remains around the repaired area, melt it with a heat gun.

09-80E
am2uub0000001

8. Degrease the painted surface.

9. Mix the primer and the hardener at a ratio of one to one. Apply the primer to the repaired area and the surface
of the bumper with a brush or spray.
polypropylene primer Primer hardener

1 1
am2uub0000002

Use the primer within 16 hours after it is mixed.

Note
• Polypropylene primer will dissolve even after drying if it is wiped with solvent. Use only water to clean
around the primer.

10. Allow the part to dry.

09-80E–7
3506-1U-12A.book 8 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [PLASTIC BODY PARTS]

11. Add the softener to the urethane primer surfacer and spray it on the repaired area.
a. Mixing method
Urethane primer surfacer + Softener ..... Mixture A
Mixture A + hardener ..... Mixture B
Dilute mixture B with thinner to spray on bumper
b. Viscosity
14—16 seconds/viscosimeter 20 °C {68 °F} Urethane primer surfacer Hardner

Note Softener
• Mix the solutions at the specified ratio.

c. Spray pressure
300—400 kPa {3—4 kg/cm2, 43—57 psi}
d. Standard film thickness
30—40 μ
e. Spray method
Spot-spray primer surfacer on bumper three
or four times Mixture A 100 30
12. Air drying 20 °C {68 °F} — 8 hours minimum.
Forced drying 60 °C {140 °F} — 1 hour
13. Lightly sand the complete surface of the bumper
with #400—#600 sandpaper. Do not expose the Mixture B 4 1
surface of the polypropylene. (Wet or dry sanding
is acceptable.) am2uub0000002
14. Wipe the complete surface of the bumper with
degreasing agent. Quickly wipe the surface with a
clean rag to degrease it.
15. Apply a matching coat of body color to the polypropylene bumper.

Note
• Be sure to use only urethane primer for a urethane bumper and polypropylene primer for a polypropylene
bumper. Other paints for repairing a polypropylene bumper are the same as those for the urethane
bumper.

16. Air drying 20 °C {68 °F} — 8 hours minimum.

Forced drying 60 °C {140 °F} — 1 hour

Note
• Let the part air dry when possible as forced drying could cause bubbles in the top coat.

End Of Sie

09-80E–8
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BODY STRUCTURE [CONSTRUCTION STANDARD VALUES]

09-80F BODY STRUCTURE [CONSTRUCTION STANDARD
VALUES]
CONSTRUCTION STANDARD VALUES Front view . . . . . . . . . . . . . . . . . . . . . . . 09-80F–1
[CONSTRUCTION STANDARD Rear view . . . . . . . . . . . . . . . . . . . . . . . 09-80F–2
VALUES] . . . . . . . . . . . . . . . . . . . . . . . . 09-80F–1

End of Toc
CONSTRUCTION STANDARD VALUES [CONSTRUCTION STANDARD VALUES]
BM: CONSTRUCTION STANDARD VALUES

id0980c0740300
Front view

E E 09-80F

H
A D H
A B D
F
B C F
C

ac5wzb00000191

A B C D E
1 2 3 6
4

F G H
12
7 9
10
13
11
8

ac5wzb00000203

Standar Maximu Minimu Side by Standar Maximu Minimu Side by

Measure Measure
d values m values m values differenc d values m values m values differenc
No. ment No. ment
(mm (mm (mm e (mm (mm (mm (mm e (mm
part part
{in}) {in}) {in}) {in}) {in}) {in}) {in}) {in})
5.0 7.0 3.0 2.0 4.5 6.4 2.6 2.5
A 1 3
{0.20} {0.27} {0.12} {0.079} {0.18} {0.25} {0.10} {0.098}
C
4.5 6.0 3.0 1.0 2.8 -0.8
B 2 - 4 -
{0.18} {0.24} {0.12} {0.039} {0.11} {-0.03}
1.8 3.2 0.4 1.4
D 5
{0.055} {0.13} {0.002} {0.055}

09-80F–1
3506-1U-12A.book 2 ページ ２０１２年１月２６日 木曜日 午前１０時２０分

BODY STRUCTURE [CONSTRUCTION STANDARD VALUES]

Standar Maximu Minimu Side by Standar Maximu Minimu Side by
Measure Measure
d values m values m values differenc d values m values m values differenc
No. ment No. ment
(mm (mm (mm e (mm (mm (mm (mm e (mm
part part
{in}) {in}) {in}) {in}) {in}) {in}) {in}) {in})
3.7 4.9 2.5 1.2 1.6 -1.6
E 6 9 0 -
{0.15} {0.19} {0.098} {0.047} {0.063} {-0.063}
0.5 1.8 1.6 -1.6
7 - - G 10 0 -
{0.02} {0.071} {0.063} {-0.063}
F
0.5 1.2 0.2 1.5 -1.5
8 - 11 0 -
{0.02} {0.047} {0.008} {0.059} {-0.059}
3.5 4.5 2.5 1.0
12
{0.14} {0.18} {0.098} {0.039}
H
1.0 -1.0
13 0 -
{0.039} {-0.039}

Rear view

A
A

B B

C
E E I I J
C J
D
D

H
G
H
G F F

ac5wzb00000192

A B C D E

1
7

2 4 5 6
3

F G H I J

10 12 14 15
9

8 11 13

ac5wzb00000235

09-80F–2
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BODY STRUCTURE [CONSTRUCTION STANDARD VALUES]

Standar Maximu Minimu Side by Standar Maximu Minimu Side by
Measure Measure
d values m values m values differenc d values m values m values differenc
No. ment No. ment
(mm (mm (mm e (mm (mm (mm (mm e (mm
part part
{in}) {in}) {in}) {in}) {in}) {in}) {in}) {in})
6.0 7.0 5.0 1.2 6.0 8.0 4.0 2.0
1 G 9
{0.24} {0.28} {0.20} {0.047} {0.24} {0.31} {0.16} {0.079}
A
-1.0 -2.0 0.5 1.8
2 0 - 10 - -
{-0.039} {-0.079} {0.02} {0.071}
H
4.3 6.8 1.8 2.5 0.5 1.5 -0.2
B 3 11 -
{0.17} {0.27} {0.071} {0.047} {0.02} {0.059} {-0.008}
1.8 3.0 0.6 3.5 4.5 2.5 1.0
C 4 - 12
{0.071} {0.12} {0.02} {0.14} {0.18} {0.098} {0.039}
I
1.8 3.3 0.3 1.0 -1.0
D 5 - 13 0 -
{0.071} {0.13} {0.01} {0.039} {-0.039}
4.5 6.5 2.5 1.5 3.5 4.5 2.5 1.0
6 14
{0.18} {0.26} {0.098} {0.059} {0.14} {0.18} {0.098} {0.039}
E J
1.8 -1.8 1.0 -1.0
7 0 - 15 0 -
{0.071} {-0.071} {0.039} {-0.039}
4.0 6.5 1.5 2.5
F 8
{0.16} {0.26} {0.059} {0.098}
09-80F

End Of Sie

09-80F–3
3506-1U-12A.book 4 ページ ２０１２年１月２６日 木曜日 午前１０時２０分