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Body Shop Manual

FOREWORD CONTENTS
This Body Shop Manual illustrates body structures and
service procedures for the CEE'D. Title Group
This manual illustrates the replacement of major body
panels, plastic parts, body dimensions, sealing treatment General Information GI
etc., in a systematic manner which is necessary for effective
and lasting body repairs. Body Construction BC
You are encouraged to become familiar with this manual
and understand each section in order to perform proper
repair procedures. Keep this manual in a convenient Body Dimensions BD
location so that it is readily available.
Body Panel Repair Procedure BP
All information in this manual including specifications,
data and illustrations is made based on the vehicles built at
the time the manual was printed. Body Sealing Locations BS

Information regarding the removal/replacement of Corrosion Protection
components not specifically covered in this manual can be
CP
found in the CEE'D Service Manual. Information regarding
electrical harness routing/ connections, etc. can be found Body Modification Tools BT
in the CEE'D Electrical Troubleshooting Manual.
Plastic Parts PP
The descriptions and specifications contained in this manual
were in effect at the time this manual was approved for
printing. Kia Motors Corporation reserves the right to
discontinue models at any time, or change specifications
or design without notice and without incurring obligation.

Kia Motors Corporation
SEOUL, KOREA

Copyright c 2006, Kia Motors Corporation
Printed in Korea, November 2006
Pub. No. : A1HB-EG6NA (English)

All rights reserved. No part of this publication may be reproduced, stored in any retrieval system or transmitted in
any form or by any means without the prior written permission of Kia Motors Corporation.

IMPORTANT SAFETY NOTICE
Proper service methods and repair procedures are essential for safe, reliable operation of all
motor vehicles as well as personal safety of the operator. The service procedures and
descriptions in this shop manual provide general directions for a service and repair.

Procedure, techniques, tools, and parts for service including the skill of the technician vary.
It is impossible to provide advice or caution as to each case in this manual.
Accordingly, anyone who intends to use a replacement part, service procedure, or tool, which is
not recommended by the vehicle manufacturer, must first assure thoroughly that neither their
personal safety nor the safe operation of the vehicle will be first jeopardized by the replacement
part, service procedure, or tool they select.

IN THIS MANUAL

WARNING : Remind you to be especially careful in those areas where carelessness can
cause personal injury.
CAUTION : To prevent you from making errors that could damage the vehicle as well as
personal injury.
NOTE : Gives you added information that will help you complete a particular procedure.

The following list contains some general WARNINGS that you should follow while working on a
vehicle.

Always wear safety glasses for eye protection.
Use safety stands whenever a procedure requires you to be under the vehicle.
Make sure that the ignition switch is always in the OFF position, unless otherwise required by
the procedure.
Set the parking brake when working on the vehicle. If you have an automatic transaxle, set in
park unless instructed otherwise for a specific operation
Place supporters against the front and rear surfaces of the tires to help prevent the vehicle
from moving
Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide
poisoning.
Keep yourself and your clothing away from moving parts when the engine is running,
especially the drive belts.
To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
Do not smoke while working on a vehicle.
To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing
before beginning to work on a vehicle.
When it is necessary to work under the hood, keep hands and other objects clear of the
radiator fan blades! Your vehicle may be equipped with a cooling fan that may turn on, even
though the ignition switch is in the OFF position. For this reason care should be taken to
ensure that the radiator fan electric motor is completely disconnected when working under the
hood and the engine is not running.

General
Information
FUNDAMENTAL PROCEDURES
VEHICLE PROTECTION .................................. GI - 2
A WORD ABOUT SAFETY ............................... GI - 2
WELDING PROCEDURES .............................. GI - 3
BODY FRAME STRAIGHTENER ..................... GI - 3
ELECTRICAL PROCEDURES ........................ GI - 3
GI
FOR BEST RESULTS
DISASSEMBLY ................................................. GI - 4
PREPARATION OF ASSEMBLY ....................... GI - 6
ASSEMBLY ....................................................... GI - 7
RUSTPROOF TREATMENT AFTER
ASSEMBLY ....................................................... GI - 8

VEHICLE LIFT (2-SUPPORT TYPE) AND
SAFETY STAND POSITIONS ................... GI - 9

JACK SUPPORT POSITIONS .................. GI - 10

Safety glasses 2. BVQGI6001 disconnect and remove the tank and fuel pipe. and cap the pipe to prevent fuel leakage. 1. Protect moldings.GI-2 GENERAL INFORMATION FUNDAMENTAL PROCEDURES A WORD ABOUT SAFETY VEHICLE PROTECTION 1. When welding or performing other procedures that require the use of an open flame near the fuel tank. Wear the appropriate safety equipment that is necessary for the procedure being performed. Cover all glasses. seats and mats with a heat resistant Mask Ear protectors cover when welding. garnishes and ornaments. Face shield Gloves Safety shoes BVQGI6002 2. Cover the seats before performing any procedure to keep them from getting dirty. 3. BVQGI6003 .

3. Do not weld.GENERAL INFORMATION GI-3 WELDING PROCEDURES Observe the following tips when welding. cleaners or solvents or in any area where they have just been used. Handle all electrical components with care. Insert the connector until it "licks" when connecting the connector. BVQGI6004 . 2. Do not pull on wires when disconnecting electrical connectors. smoke or allow open flames around volatile chemicals. Be careful to hold the connector itself when disconnecting it. 2. Disconnect the negative battery terminal. 4. BODY FRAME STRAIGHTENER When using a frame straightener. ELECTRICAL PROCEDURES 1. 3. do not enter the area where the body is being straightened by the chain. Carefully follow the manufacturers operating instructions for the welding machine you are using. Wear appropriate eye protection. 1.

Selecting cutting area Select a cutting area that is easily accessible and that is prone to the least amount of distortion when welding. BEDGI6005 .0 in (30~50 mm). Adjust dimensions with body frame adjuster if deformed.GI-4 GENERAL INFORMATION FOR BEST RESULTS DISASSEMBLY Measuring dimensions before beginning Measure the dimensions of the damaged area according to the body dimension drawings before disassembling and repairing.2~2. Protecting body from damage Secure the body with clamps and jacks to prevent damage to the body when working on it. Select an area that would allow the new part to overlap repair area by 1.

GENERAL INFORMATION GI-5 Disassembling related parts Use caution when removing body molding and trim from the area to be worked. Wire harness Repair work area Cutting area BVQGI6006 . check if pipes. Apply masking tape where needed to prevent damage to the part being removed or to the vehicle body. Before starting repairs. hoses or electrical components are present near damaged area.

welding. and apply spot sealer for rustproofing.2~2.1 in (3 mm).0 in (30~50 mm).2~0.1 in (3mm) BEDGI6007 Machining holes for plug welding Adjusting a new part Drill a hole of approximately 0. diameter in those areas which are not suitable for spot overlapping the repair area by 1. do plug welding using a carbon arc welding machine.GI-6 GENERAL INFORMATION PREPARATION OF ASSEMBLY Applying spot sealer Remove paint from the surface of new parts and body to be spot welded.24 in (5~6 mm) in The new part should be cut larger than the repair area. 1.2~2. Thicker than 0.0 in (30~50 mm) (30~50 mm) Overlap Overlap body side to modify new part to modify BVQGI6008 BVQGI6009 . Selecting a welding method If the thickness of the area to be welded with the panels overlapped is greater than 0. Protecting body from damage Secure the body with clamps and jacks to prevent damage to the body when working on it.0 in 1.2~2.

GENERAL INFORMATION GI-7

ASSEMBLY
Measuring dimensions before welding
When assembling a new part, assemble it according to the body dimensions given in Section 31, and start welding after
checking the gaps with nearby parts.

Caution when welding
The number of welding points should be determined based on the criteria below:

Spot welding Increase the number of Plug welding
Pitch: Same number of
spot welds by 30%. welds as original part.
Pitch: Pitch:
2.0 in (50 mm) 1.4 in (35 mm) Repair part
more than
0.1 in (3 mm)

Old part Repair part

BEDGI6010

Caution when spot welding
The tip of the spot welding machine should be maintained to a minimum of 0.1 in (3 mm) because it greatly affects welding
strength. When possible, spot welding should be done between the existing spot welded points.
Before and after spot welding, weld a test piece(test pin) of the same material as the body panel, and check the welding
strength.

Using a hammer and a chisel Using a test piece(test pin)
Good No good Existing welded spots
New welded spots

0.1 in
(3 mm)
0.1 in
(3 mm)
Nugget diameter
Center to be 4/5 of chip
diameter diameter

BVQGI6011

GI-8 GENERAL INFORMATION

RUSTPROOF TREATMENT AFTER ASSEMBLY
Body sealing
Apply body sealer where necessary.

Applying rustproof material
Apply rustproofing material(wax, oil, etc.) behind welded area.

BEDGI6012

Applying undercoat
Apply undercoat on the body where necessary.

GENERAL INFORMATION GI-9

VEHICLE LIFT (2-SUPPORT TYPE) AND SAFETY STAND POSITIONS
1. Place the lift blocks under the support points as shown in the illustration

2. Raise the hoist a few inches and rock the vehicle to be sure it is firmly supported.

3. Raise the hoist to full height to inspect the lift points for secure support.

Lift Block
Lift Block

[Front] [Rear]

BEDGI6013

GI-10 GENERAL INFORMATION JACK SUPPORT POSITIONS BEDGI6014 .

.......................... BC ........... BC -16 SIDE BODY ..... BC -22 .....5 DASH PANEL ... BC -15 BC ROOF PANEL ... BC -12 REAR FLOOR PANEL ....................................................... BC ................................................................ BC -20 SIDE BODY .......................... Body Construction FENDER APRON PANEL . BC ........................................................................................................2 FRONT SIDE MEMBER .......... BC -17 FRONT AND REAR BODY ................................8 CENTER FLOOR PANEL .........

BC-2 BODY CONSTRUCTION FENDER APRON PANEL 5 1 2 6 7 3 4 BEDBC6001 No. PART NAME No. PART NAME 1 Fender apron upper outer panel assembly 5 Shock absober housing cover assembly 2 Fender apron upper inner panel assembly 6 Shock absorber housing reinforcement 3 Fender apron front upper reinforcement assembly 7 Shock absorber housing panel assembly 4 Fender apron inner panel assembly .

BODY CONSTRUCTION BC-3 < Cross-Sectional Views > [ RH TOP VIEW ] A C B C B A [ RH SIDE VIEW ] BEDBC6003 .

BC-4 BODY CONSTRUCTION A-A B-B Shock absorber Fender apron upper housing cover Fender apron inner panel assembly assembly upper outer panel assembly Fender apron upper inner panel assembly Fender apron front upper reinforcement Shock absorber assembly Fender apron upper housing panel outer panel assemlby assembly Front side complete member assembly Front side complete Fender apron inner Fender apron inner member assembly panel assembly panel assembly Fender apron front upper reinforcement assembly BEDBC6004 BEDBC6005 C-C Fender apron upper inner panel assembly Shock absorber housing panel assembly Fender apron upper outer panel assembly Fender apron inner panel assembly Front side complete member assembly BEDBC6006 .

PART NAME 1 Front crash member assembly 9 Transmission mounting reinforcement assembly 2 Crash member rear bracket assembly 10 Front side member inner reinforcement 3 Crash member bracket assembly 11 Front side member rear lower extension assembly 4 Front side member outer front extension assembly 12 Side sill inner front extension 5 Engine mounting support assembly 13 Front side inner rear reinforcement assembly 6 Front side outer member assembly 14 Front side rear lower member assembly 7 Front side member inner reinforcement assembly 15 Subframe rear mounting bracket assembly 8 Front side inner member assembly . PART NAME No.BODY CONSTRUCTION BC-5 FRONT SIDE MEMBER 6 7 5 8 2 3 4 10 9 12 13 11 1 14 15 BEDBC6101 No.

BC-6 BODY CONSTRUCTION < Cross-Sectional Views > A A [ RH SIDE VIEW ] E C C D B B D E [ RH TOP VIEW ] F F [ LH SIDE VIEW ] BEDBC6104 .

BODY CONSTRUCTION BC-7 A-A B-B Front side inner Engine mounting support assembly member assembly Front side inner member asembly Front side outer member assembly Front side member outer front extension assembly Front side member inner reinforcement assembly BEDBC6105 BEDBC6106 C-C Washer assembly bolt D-D Front side rear lower member assembly Crash member bracket assembly Front crash member Crash member rear bracket assembly assembly Front side inner member assembly Front side inner rear reinforcement assembly Front side member outer front extension assembly BEDBC6107 BEDBC6109 E-E Front side inner rear reinforcement assembly Front side rear lower member assembly Side sill inner front extension Subframe rear mounting bracket assembly Front side member rear lower extension assembly BEDBC6108 F-F Front side inner member assembly Front side outer member assembly Front side member inner reinforcement assembly BEDBC6110 .

PART NAME No. PART NAME 1 Dash cross side member assembly 5 Dash panel reinforcement assembly 2 Dash cross center member assembly 6 Dash panel assembly 3 Dash lower member assembly 7 Dust cover panel 4 Foot rest bracket .BC-8 BODY CONSTRUCTION DASH PANEL 7 6 5 4 2 1 1 3 BEDBC6201 No.

BODY CONSTRUCTION BC-9 < Cross-Sectional Views > G G H H [ TOP VIEW ] E D C B A F B E A D F C [ REAR VIEW ] BEDBC6203 .

BC-10 BODY CONSTRUCTION A-A B-B Dash panel Dash cross side member assembly reinforcement assembly Dash panel assembly Dash cross center member assembly Dash panel assembly Foot rest cover Dust cover panel Foot rest bracket BUNBC6204 BUNBC6205 C-C D-D Dash panel assembly Dash panel reinforcement assembly Dash panel reinforcement assembly Dash panel assembly Dash panel center deadening sheet Dash cross center member assembly Dash panel center deadening sheet Dash lower member Dash lower member assembly assembly BUNBC6206 BUNBC6207 .

BODY CONSTRUCTION BC-11 E-E F-F Dash cross center member assembly Dash panel assembly Dash panel assembly Dash panel reinforcement assembly Dash lower member assembly BEDBC6209 Dash cross center member assembly G-G Dash cross center member assembly Dash panel assembly Dash cross center member assembly Dash lower Dash panel Dash lower member assembly member assembly assembly BEDBC6208 BEDBC6210 H-H Dash cross center member assembly Dash panel assembly Dash lower member assembly BEDBC6211 .

PART NAME No.BC-12 BODY CONSTRUCTION CENTER FLOOR PANEL 4 6 7 6 5 5 4 3 2 1 1 BEDBC6301 No. PART NAME 1 Center floor side member 5 Front seat rear mounting member assembly 2 Muffler hanger mounting bracket assembly 6 Front seat mounting member assembly 3 Center floor panel 7 Center floor reinforcement assembly 4 Side sill inner panel assembly .

BODY CONSTRUCTION BC-13 < Cross-Sectional Views > E F F E A A [ TOP VIEW ] B C D B C D [ SIDE VIEW ] BEDBC6303 .

BC-14 BODY CONSTRUCTION A-A Center floor reinforcement assembly Center floor panel Muffler hanger mounting bracket assembly BEDBC6304 B-B C-C Center floor reinforcement assembly Center floor reinforcement assembly Front seat mounting Center floor member assembly panel Center floor panel Muffler hanger mounting bracket assembly BEDBC6305 BEDBC6306 D-D Center floor reinforcement assembly Front seat rear mounting member assembly Center floor panel BEDBC6307 E-E F-F Front seat mounting Front seat rear mounting Side sill member member assembly inner panel assembly assembly Center floor panel Center floor panel Center floor side member BEDBC6308 BEDBC6309 .

BODY CONSTRUCTION BC-15 REAR FLOOR PANEL 6 5 4 6 3 3 2 1 BEDBC6401 No. PART NAME 1 Rear floor front extension assembly 4 Rear floor center cross upper member assembly 2 Rear floor front panel assembly 5 Rear floor rear panel assembly 3 Rear seat belt anchor bracket assembly 6 Rear floor side panel . PART NAME No.

PART NAME 1 Roof panel 5 Roof center No. PART NAME No.BC-16 BODY CONSTRUCTION ROOF PANEL 1 7 6 5 4 3 2 BEDBC6501 No.1 rail 6 Roof center No.2 rail assembly .3 rail 3 Sunroof reinforcement ring assembly 7 Roof center No.3A rail 2 Roof center No.4 rail 4 Roof center No.

BODY CONSTRUCTION BC-17 SIDE BODY 2 3 5 4 1 BEDBC6601 No. PART NAME No. PART NAME 1 Quarter outer rear complete extension assembly 4 Rear door striker retainer assembly 2 Side outer reinforcement assembly 5 Fender rear mounting bracket 3 Side outer panel .

BC-18 BODY CONSTRUCTION G F G L F L K K J J E E I I D D H H C A C B A B [SIDE VIEW ] BEDBC6602 A-A B-B Side outer panel Side sill Side outer inner panel reinforcement Front inner assembly lower pillar Side outer Center floor panel reinforcement Side outer panel assembly BEDBC6603 BEDBC6604 C-C D-D Fender rear mounting bracket Side outer panel Side outer Side outer panel reinforcement Side outer assembly reinforcement assembly BEDBC6605 BEDBC6606 .

BODY CONSTRUCTION BC-19 E-E F-F Side outer panel Side outer panel Side outer reinforcement Front inner assembly upper pillar Side outer reinforcement assembly BEDBC6607 BEDBC6608 G-G H-H Side outer panel Side outer panel Side outer Side outer reinforcement reinforcement assembly assembly Center inner pillar BEDBC6609 BEDBC6610 I-I J-J Side outer panel Side outer reinforcement Side outer panel assembly Side outer reinforcement assembly BEDBC6611 BEDBC6612 K-K L-L Side outer panel Side outer panel Quarter outer rear complete extension assembly Side outer reinforcement assembly Center inner pillar Quarter inner upper panel BEDBC6613 BEDBC6614 .

BC-20 BODY CONSTRUCTION FRONT AND REAR BODY < Cross-Sectional Views > C C B B A A D D [ TOP VIEW ] F F G E E G [ REAR VIEW ] BEDBC6702 .

0 + _ 0.5 mm 5.0 Head lamp BEDBC6705 BEDBC6706 E-E Tail gate panel assembly G-G 3.8 + mm _ 0.0 + Front bumper cover BEDBC6703 BEDBC6704 C-C D-D Hood panel assembly Roof panel assembly Tail gate panel assembly _ 0.5 mm 5.5 mm Side outer panel assembly 5 mm BEDBC6708 BEDBC6709 .5 mm Tail gate panel assembly Rear lamp BEDBC6707 F-F Tail gate panel assembly 4 +_ 0.5 mm 5.5 + 4.BODY CONSTRUCTION BC-21 A-A B-B Hood panel assembly Hood panel assembly _ 0.

BC-22 BODY CONSTRUCTION SIDE BODY C B B C D A H H D N A I I E E M J J N M G L F F K K G L [SIDE VIEW ] BEDBC6801 A-A Side outer panel B-B Side outer panel 5+ _0 .5 mm Rear door panel assembly Rear door panel assembly BEDBC6804 BEDBC6805 .5 mm 5+ _ 0. 5 m m 5 +_ 0.5 mm Front door Front door panel assembly panel assembly BEDBC6802 BEDBC6803 C-C Side outer panel D-D 4 +_ 0.

5 mm 3.5 mm 3.5 mm 3.5 mm 3.5 mm Rear door m .BODY CONSTRUCTION BC-23 E-E Front door panel assembly F-F Front door panel assembly _ 0.5 m panel assembly _0 5+ BEDBC6808 BEDBC6809 I-I J-J Rear door panel assembly _ 0.5 + _ 0.5 mm 3.5 + _ 0.5 + Front door Rear door panel assembly panel assembly Front door panel assembly BEDBC6810 BEDBC6811 K-K L-L Rear door Rear door panel assembly _ 0.5 + panel assembly Front door panel assembly m .5 m _0 5+ BEDBC6812 BEDBC6813 .5 + Fender panel Fender panel BEDBC6806 BEDBC6807 G-G Front door H-H Front door panel assembly panel assembly 4+ _ 0.

3.7 + _ 0.5 + 5 mm _0 .BC-24 BODY CONSTRUCTION M-M N-N Rear door panel assembly Hood panel assembly 2.5 mm Frender panel BEDBC6814 BEDBC6815 .

.....................................................................15 UNDER BODY (ACTUAL-MEASUREMENT DIMENSIONS) .... BD .................................................... BD .....11 REAR BODY .......2 MEASUREMENT METHOD .......................... BD .........8 BD INTERIOR B ... BD ..............................13 UNDER BODY (PROFECTED DIMENSIONS) . BD .................2 ACTUAL-MEASUREMENT DIMENSIONS ... BD ........4 SIDE BODY . BD ...............3 MEASUREMENT POINT ........3 FRONT BODY ......18 .......................................................... BD ..........6 INTERIOR A ............................................... BD ................ Body Dimensions GENERAL ............. BD ...................2 PROJECTED DIMENSIONS .. BD ......................................... BD ...................

twisting or bending. If the length of the tracking gauge probes are manual. make the measurement by lengthening one probe by the amount equivalent to the difference in height of the two surfaces. adjustable. When a measuring tape is used.BD-2 BODY DIMENSIONS GENERAL MEASUREMENT METHOD 1. and are the reference dimensions used for body alterations. plane. all measurements in this manual are taken PROJECTED DIMENSIONS with a tracking gauge. Basically. 1. both projected dimension and actual-measurement dimension are used in this 2. Height Projected Dimension BMCBD6001 . 3. check to be sure there measurement points are projected into the reference is no elongation. These are the dimensions measured when the 2. For measuring dimensions.

between measurement points. Measure by first adjusting both probes to the same length (A=A') CAUTION Check the probes and gauge itself to make sure there is no free play.BODY DIMENSIONS BD-3 ACTUAL-MEASUREMENT DIMENSIONS MEASUREMENT POINT 1. Hole Center BMCBD6003 A Ac tu al ly- M A' ea su re d Di m en sio n BMCBD6002 . Measurements should be taken at the hole center. and are the reference dimensions for use if a tracking gauge is used for measurement. These dimensions indicate the actual linear distance 1. 2.

9 1611.3 1150.8 .BD-4 BODY DIMENSIONS FRONT BODY F F' B E E' A D B' C J D' C' A' H I J' G I' H' G' BEBD6101 * These dimensions indicated in this figure are actual-measurement dimensions.7 1653.3 1303. Point symbol A-A' A-B A-B' A-H' B-B' B-H' C-C' D-F' Length(mm) 1432.7 987.3 Point symbol H'-J H'-J' I-I' J-J' Length(mm) 1120.0 1024.4 714.0 646.0 1446.9 Point symbol E-E' E-F E-F' F-F' G-G' H-H' H-J H-J' Length(mm) 1437.0 483.0 994.8 1455.9 1119.0 583.2 1074.9 1520.1 1181.

H' G.A' B.F' BEDBD6105 BEDBD6103E BEDBD6106 Cowl top cover mounting hole (ø7) Front pillar coroner Roof front corner I' H.G' BEDBD6107G BEDBD6107H BEDBD6108I Front end module mounting hole Tooling hole (ø9) Transmission mounting bracket hole (ø9) (ø18) J' J I BEDBD6108J BEDBD6109I BEDBD6109J Transmission mounting bracket hole Engine mounting bracket hole (ø13) Engin mounting bracket hole (ø13) (ø18) .BODY DIMENSIONS BD-5 A.E' D' D F.C' BEDBD6102 BEDBD6103B BEDBD6104 Front end module mounting hole Hood hinge mounting hole (ø12) Front suspension mounting hole (ø9) (ø11) E.B' C.

0 306.2 953.9 591.1 1154.5 246.3 719.0 1116.4 1122.4 .3 1065.1 1107.3 Point symbol G-H G-J G-K H-J H-K I-J J-K J-L Length(mm) 331.4 953.7 977.8 978.5 345.5 1014.5 511.8 335.8 661.5 Point symbol C-F D-E D-G D-H E-F E-G E-H F-H Length(mm) 839.2 869.7 Point symbol K-L Length(mm) 662.6 1175.BD-6 BODY DIMENSIONS SIDE BODY I J G D C K L A B E H F BEDBD6201 * These dimensions indicated in this figure are actual-measurement dimensions.3 616. Point symbol A-B A-C B-C B-D B-E B-F C-D C-E Length(mm) 155.

5X8.5) .BODY DIMENSIONS BD-7 A B C BEDBD6202A BEDBD6202B BEDBD6203 Tooling hole (ø10) Tooling hole (ø20) Tooling hole (ø9) D E F BEDBD6204 BEDBD6205E BEDBD6205F Front door hinge upper mounting Front door hinge lower mounting Fender mounting hole (ø12) hole (ø13) hole (ø13) G I H BEDBD6206G BEDBD6206H BEDBD6207I Rear door hinge upper mounting Rear door hinge lower mounting hole Quarter fixed glass mounting notch hole (ø13) (ø13) (ø8 notch) J K L BEDBD6207J BEDBD6208 BEDBD6209 Quarter fixed glass mounting hole Rear door switch mounting hole Rear bumper mounting hole (ø6) (ø9) (8.

0 .4 1494.4 1393.0 1031.0 1167.1 1526.2 1651.6 1219.BD-8 BODY DIMENSIONS INTERIOR A R' R S S' A' A E' I' E I M' M F' F N' N J O O' B K B' G J' K' C H L D G' Q L' C' H' P D' BEDBD6301 * These dimensions indicated in this figure are actual-measurement dimensions.4 1164.2 974.8 1441.5 1405.8 1138.2 1085. Point symbol A-A' A-P B-B' B-P C-C' D-D' D-P E-E' Length(mm) 1201.1 1422.1 1355.8 1146.9 Point symbol E-P E-Q F-F' G-G' H-H' I-I' I-Q J-J' Length(mm) 1149.9 1490.8 1353.6 1420.6 1232.9 Point symbol R-R' R-S R-S' S-S' Length(mm) 1119.0 1055.4 1128.6 1977.0 1136.4 Point symbol J-Q K-K' L-L' M-M' M-Q N-N' O-O' O-Q Length(mm) 1061.

A' C.D' E.L' BEDBD6310J BEDBD6311 BEDBD6310L Seat striker passage hole (ø10) Rear door striker mounting hole (ø13) Wheel house trim mounting hole (ø8.K' J.H' I.C' B.BODY DIMENSIONS BD-9 A.F' BEDBD6305 BEDBD6306E BEDBD6306F Cowl side trim mounting hole (ø8.4) K.B' BEDBD6302 BEDBD6303 BEDBD6304 Trim mounting passage hole (ø9) Cowl cross bar mounting hole (ø9) Front door checker mounting hole (ø13) D.4) Seat belt height adjust upper Seat belt height adjust lower mounting hole (ø16) mounting hole (ø16) H.I' G.E' F.J' L.G' BEDBD6307 BEDBD6308 BEDBD6309I Rear door checker mounting hole Center pillar trim mounting hole Pillar trim mounting hole (ø6.6) (ø13) (ø8.4) .

BD-10 BODY DIMENSIONS N.R' BEDBD6313P BEDBD6313Q BEDBD6106R Tooling and drain hole (ø10) Fuel pump wire mounting hole (ø7) Roof front corner S.4) P Q R.O' BEDBD6309M BEDBD6312N BEDBD6312O Pillar trim mounting hole (ø8.M' O.4) Side trim mounting hole (ø6.6) Luggage side trim mounting hole (ø8.S' BEDBD6402S Side outer rear corner .N' M.

BODY DIMENSIONS BD-11 INTERIOR B A' E' I' A I E M' M O O' L D H L' H' D' BEDBD6301A * These dimensions indicated in this figure are actual-measurement dimensions. Point symbol A-D A-D' E-H E-H' I-L I-L' M-O M-O' Length(mm) 1000.7 1544.9 880.6 1645.9 854.4 1219.0 621.0 1572.0 .

H' L.4) .O' BEDBD6309M BEDBD6312O Pillar trim mounting hole (ø8.D' A.A' E.BD-12 BODY DIMENSIONS D.E' BEDBD6302 BEDBD6305 BEDBD6306E Trim mounting passage hole (ø9) Cowl side trim mounting hole (ø8.I' BEDBD6308 BEDBD6309I BEDBD6310L Center pillar trim mounting hole Pillar trim mounting hole (ø6.4) M.L' I.6) Wheel house trim mounting hole (ø8.4) Seat belt height adjust upper mounting hole (ø16) H.4) Luggage side trim mounting hole (ø8.M' O.4) (ø8.

6 416. Point symbol A-A' B-B' B-E B-E' B-H C-C' C-D C-D' Length(mm) 625.9 1045.8 1367.0 1055.3 1112.4 1383.0 1068.1 1576.0 .4 484.BODY DIMENSIONS BD-13 REAR BODY B' B A' A C' C D' D E E' F' F H' H G' G BEDBD6401 * These dimensions indicated in this figure are actual-measurement dimensions.1 Point symbol G-G' Length(mm) 1110.2 Point symbol C-H D-D' E-E' E-G E-G' F-F' F-G F-G' Length(mm) 978.4 1486.3 954.0 286.1 1469.0 746.

C' B.E' BEDBD6403E BEDBD6403F Rear combination lamp mounting Side outer rear corner Rear bumper mounting hole hole (ø8) (8.5X8.G' H' H BEDBD6404 BEDBD6405 Rear bumper mounting hole Tail gate striker mounting hole (ø16) (ø13) .BD-14 BODY DIMENSIONS A.D' F.A' C.B' BEDBD6402A BEDBD6402B BEDBD6402C Tail gate hinge mounting hole Side outer rear corner Gas lifter mounting passage hole (ø12) (ø9) D.5) G.F' BEDBD6403D E.

4 156.BODY DIMENSIONS BD-15 UNDER BODY (PROJECTED DIMENSIONS) I' K' L' N' A' B C' F' G' H' J' M' E' D' D E M F G H J K N L A B' C I 0 A B C D EF G H I J KL M N BEDBD6201A * These dimensions indicated in this figure are projected dimensions.0 824.0 Point symbol K-L L-M M-N A-0 B-0 C-0 D-0 E-0 Length(mm) 115.0 832.0 173.0 4.0 0 420.0 1100.0 155.0 99.0 .2 34.0 98.0 Point symbol C-D D-E E-F F-G G-H H-I I-J J-K Length(mm) 645.0 935.0 839.0 Point symbol I-I' J-J' K-K' L-L' M-M' N-N' A-B B-C Length(mm) 1328.0 1061.0 1012.6 -79.7 -81.0 65.0 848.0 53.4 130.0 590.0 -86.8 77.0 1000.7 115.0 140.0 993.0 377.8 339.2 Point symbol N-0 Length(mm) 178.6 184.8 Point symbol F-0 G-0 H-0 I-0 J-0 K-0 L-0 M-0 Length(mm) -72.0 363. Point symbol A-A' B-B' C-C' D-D' E-E' F-F' G-G' H-H' Length(mm) 1004.0 630.0 998.

D' E.F' H.I' J.J' K.E' D.H' BEDBD6504E BEDBD6504G BEDBD6505H Passage stay mounting hole (ø15) Tooling hole (ø20) Tooling and paint drain hole (ø20) I.G' F.BD-16 BODY DIMENSIONS A B C.K' BEDBD6505I BEDBD6505J BEDBD6506K Trailing arm mounting hole (ø16) Rear suspension mounting hole (ø19) Cross member mounting hole (ø18) .D' BEDBD6504D BEDBD6503 BEDBD6504F Subframe mounting bolt Subframe mounting bolt Tooling hole (ø10) G.C' BEDBD6202A BEDBD6202B BEDBD6502C Tooling hole (ø25) Subframe mounting hole (ø25) Tooling hole (ø25) D.

M' BEDBD6506L BEDBD6506M BEDBD6506N Spring mounting hole (ø20) Cross member mounting hole (ø18) Tooling hole (ø20) .BODY DIMENSIONS BD-17 L.L' N.N' M.

9 1325.6 Point symbol F'-J G'-H H-K' H-L' H-M' H-N' H'-J J'-K Length(mm) 1941.3 1279.1 1254.7 1591.8 1128.9 2752.5 909.5 879.8 1054.2 1226.7 1219.3 .9 1592.3 1153.1 1390. Point symbol B-C' B'-D B'-G C-F' D'-G F-G' F-H' F-N' Length(mm) 1029.1 Point symbol J'-L J'-M J'-N Length(mm) 1205.9 1126.8 1557.BD-18 BODY DIMENSIONS UNDER BODY (ACTUAL-MEASUREMENT DIMENSIONS) J' L' N' B' C' G' H' K' F' M' D' D M K F G H N B C J L BEDBD6501A * These dimensions indicated in this figure are actual-measurement dimensions.

H' J.K' BEDBD6505H BEDBD6505J BEDBD6506K Tooling and paint drain hole Rear suspension mounting hole Cross member mounting hole (ø20) (ø19) (ø18) L.F' D.J' K.BODY DIMENSIONS BD-19 D.D' BEDBD6503 BEDBD6504F BEDBD6504G Subframe mounting bolt Passage stay mounting hole (ø15) Tooling hole (ø20) H.M' BEDBD6506L BEDBD6506M BEDBD6506N Spring mounting hole (ø20) Cross member mounting hole (ø18) Tooling hole (ø20) .G' F.B' C.C' BEDBD6502B BEDBD6502C BEDBD6504D Subframe mounting hole (ø25) Tooling hole (ø25) Subframe mounting bolt G.N' M.D' B.L' N.

......................................63 INSTALLING BODY PANELS ...................................... BP ..................................36 CENTER PILLAR .25 INSTALLATION ......5 DETERMINING A WELDING METHOD ..................13 INSTALLATION ................................... BP ... BP ...50 REMOVAL .....38 INSTALLATION ...................... BP ....................................22 FRONT PILLAR ...................... BP ..........46 QUARTER PANEL ..................................................................................................................................................37 REMOVAL ................................ BP ........30 SIDE SILL PANEL ............ BP ........................64 NOTES WHEN WELDING BODY REMOVING SPOT WELDED AREA ............................... BP ..2 REMOVAL ..12 REMOVAL .................................................................................................19 REMOVAL ......................................... Body Panel Repair Procedure REPLACING BODY PANELS FRONT AND REAR DOOR OUTER CODES FOR REMOVING AND PANELS .......................................................................................................................................64 INSTALLATION ................. BP .51 INSTALLATION ...15 FRONT SIDE MEMBER .....20 INSTALLATION .............................. BP ............5 SPOT WELDING ................................10 BP FENDER APRON PANEL ASSEMBLY ..................... BP ...................................7 PREPARATION FOR INSTALLATION .....53 BACK COMPLETE PANEL ASSEMBLY AND REAR FLOOR SIDE MEMBER ................... BP .. BP ... BP ............... BP ....................58 .................9 INSTALLATION .. BP ....34 INSTALLATION ............................................... BP .................24 REMOVAL ...............3 INSTALLING A NEW BODY FRAME .......55 REMOVAL .................................... BP ..... BP ............... BP ..... BP ........6 REPLACING BODY PANEL REMOVAL ................... BP ................................. BP ........................................................... BP ............56 INSTALLATION .........................5 CARBON ARC WELDING ..... BP .......... BP ........34 REMOVAL ............ BP ....... BP .... BP . BP .... BP ............... BP ....................... BP ......................

BP-2 BODY PANEL REPAIR PROCEDURE REPLACING BODY PANELS CODES FOR REMOVING AND INSTALLING BODY PANELS 0.8~1. (20~30 mm) Rough cutting location Location for cut and assembly BVQBP6001 . (20~30 mm) 0.8~1.2 in.2 in.

BODY PANEL REPAIR PROCEDURE BP-3 NOTES WHEN WELDING BODY REMOVING SPOT WELDED AREA Most body parts are spot welded. Correct Correct Not correct BVQBP6002 . Drill(taper edge) 2. it is best to remove the spot welded area from the body frame using a spot cutter or candle type edge drill bit. Drill(candle type edge) 1. 3. 1. 2. Center punch middle of spot weld to insure the entire spot weld will be removed. Do not use a drill bit with a tapered edge. Spot cutter 1. In order to remove the damaged area. 3. 3. 2.

BP-4 BODY PANEL REPAIR PROCEDURE Center punch the middle(nugget) of the spot weld. This part will not be cut. This part will be cut. Spot welded area can be removed from the body frame. BVQBP6003 . Otherwise. Spot welded area cannot be removed from the body frame.

Commercial spot welding machines do not perform as well as the machines used in the manufacturing process. shape and size of a cross section. Do not braze any body components other than the ones brazed at the factory. Try to use either spot welding or carbon arc(plug) welding. (Plug welding) Oxygen-acetylene welding Not used BVQBP6004 SPOT WELDING 2. Therefore. damage of parts. 1. When spot welding. weld in the middle of the joint. welding method. variance of joints. When spot welding.3 times the original number of welds). Good BVQBP6006 • Spot welding on the edge of the joint will reduce welding strength. and/or welding locations. Do not use an oxy-acetylene torch for welding. Welding Symbol Details The most reliable welding method Spot welding (provides high efficiency and quality of assembled part. a new part should be fitted to the body frame using the proper procedures to avoid reducing the strength of the body. DETERMINING A WELDING METHOD It is extremely important that appropriate welding methods.BODY PANEL REPAIR PROCEDURE BP-5 INSTALLING A NEW BODY FRAME The efficiency of the transmission and load distribution are determined by many complicated factors such as thickness of plate.) Carbon arc welding Use when spot welding cannot be done or spot welding is not necessary. which don't reduce the original strength and durability of the body be used when making repairs. BVQBP6005 No good BVQBP6007 . increase the number of spot welds by 30% (1.

BP-6 BODY PANEL REPAIR PROCEDURE

CARBON ARC WELDING b) Do not weld on the edge of the flange joint.

In areas where spot welding is not suitable, do plug welding
using a carbon are welding machine.

1. Clamp the parts to be welded together tightly. Do not
exceed 1 mm of space between parts. A tolerance
greater than 1 mm will reduce the strength of the
welded area.
No good

BVQBP6009

1mm
Maximum
tolerance

BVQBP6008

2. Weld in the middle of the flange joint.
a) Drill a hole 5~6 mm on one side of the flange
only, and weld within the hole.

Good

BVQBP6006

BODY PANEL REPAIR PROCEDURE BP-7

REPLACING BODY PANEL 3. Cutting rough area for replacement part
Cutting should be done according to the following steps
REMOVAL to make removal easy:
a) Use care when cutting an area close to a pipe or
1. Body measurement
wiring harness.
a) Before removing, measure the damaged area
b) Cut an area leaving 30~50 mm of tolerance.
according to the dimensions supplied in Body
Dimension, section 31. If deformation is present,
use a frame straightener to adjust.
b) When removing a panel, apply clamps to prevent
damage of each part, and support the lower end
of the frame to prevent deformation during the
procedure.

Tracking gauge

BVQBP6012

4. Removing paint from an area to be spot welded
Using a torch and wire brush, remove paint completely
before beginning welding.

BVQBP6010

2. Cut and welding point selection
Cutting, if necessary, should not be done in a
reinforcement area. Select an area which will result in
the least amount of deformation after welding.

Cut area
BVQBP6013

Reinforcement

Reinforcement

BVQBP6011

BP-8 BODY PANEL REPAIR PROCEDURE

5. Determine a cutting method
a) Cutting a spot welded area
Make a hole in the middle of spot welded area
with a punch, remove welded area using a spot
cutter and remove using a chisel.

BVQBP6014

b) Removing brazed area
Remove using a torch and wire brush, and chisel.

BVQBP6015

c) Removing arc welded area
Remove plug welded area using a disk grinder
and chisel.

BVQBP6016

Spot weld finish overlapped by the new part using a belt sander or Use a disk grinder or similar tool to finish spot weld similar tool. If the thickness of the part to be welded is greater than 3 mm. BVQBP6018 3. Drilling a hole for plug welding Repair any bent or uneven areas with a hammer to If the thickness of the part to be welded is less than 3 improve the installation process. leave a tolerance of 30~50 mm.BODY PANEL REPAIR PROCEDURE BP-9 PREPARATION FOR INSTALLATION 4. BVQBP6021 BVQBP6019 . Panel preparation 5. NOTE Do not spot weld where thickness is greater than 3 mm. drill a 5~6 mm diameter hole. mm. Do not grind more than is necessary to smooth surface. drill a hole using a 7 mm diameter drill. Preparation for spot welding Remove paint on spot welded area and on the area 1. mark. BVQBP6017 BVQBP6020 2. Cutting a rough area for a new part When rough cutting an area for a new part.

NOTE • Plug welding should be done using a carbon arc welding machine.3 times a) When installing a new part. b) Before spot welding. • Brazing should be done only on areas that were originally brazed at the factory. Initial welding Welding after repair pitch:50 mm pitch:35 mm Spot welding:initial number of welds x1. and set part to the reference dimensions. BVQBP6022 3mm Plug welding-used when b) Prior to final welding. Selecting number of welding points Spot welding : Multiply the original number of 1. check the fit of all related spot welding is not parts. feasible or material is thicker than 3 mm BVQBP6024 3. Caution when spot welding a) Do a test welding on a piece of material of the same type and thickness as the part to be welded and proceed if test weld is good. Using a hammer Using a test piece BVQBP6023 and a chisel Center 3 mm Nugget diameter diameter: 4/5 of tip BVQBP6025 . measure the Plug welding : Same number as original number dimensions of each part according to the body of factory welds dimensions given in Section 31. Clean or sand as necessary. oil or paint is present on the area where surfaces meet.BP-10 BODY PANEL REPAIR PROCEDURE INSTALLATION 2.3 Welding points-same number as original number of factory welds. Checking welding and fitting in advance factory welds by 1. check if welding debris.

Cutting and welding an removed area 6. This degrades the Apply anti-rust agent to inside of doors and sills by strength of the weld. apply butt welding. roof panel and then apply the new center pillar panel. Finishing after welding BVQBP6030 a) Grind any areas that were plug welded or butt welded using a disk grinder. temporarily fasten a steel flange to the body sealer where necessary. Anti-rust treatment removing too much material. Applying anti-rust agent and body sealer To align a roof panel and a center pillar together for After coating the surface with anti-rust agent. Grind carefully to avoid 7. BVQBP6028 BVQBP6031 . problems caused by excessive heat.2 in) BVQBP6029 BVQBP6026 4. Remove the flange when final welding is done. 3mm(0. spraying through access holes provided. NOTE Apply body sealer before assembly.BODY PANEL REPAIR PROCEDURE BP-11 c) The tip of the spot welding machine should be b) Finish areas that have been brazed by applying maintained to a minimum tolerance of 3 mm. BVQBP6027 5. Also body filler then smooth the area with a flexible file let area cool after 5 or 6 welds to minimize and sander.

BP-12 BODY PANEL REPAIR PROCEDURE FENDER APRON PANEL ASSEMBLY WELDING POINTS MIG plug welding MIG butt welding MIG lap welding BEDBP6102 290 mm MIG plug welding MIG butt welding MIG lap welding BEDBP6104 .

BEDBP6101 1. BEDBP6109 3 Drill out all the spotwelds(27)to separate fender apron upper outer panel from fender apron upper inner panel assembly. The body must be returned to its original dimension before begining the repair procedure. NOTE On the right side. remove paint with a rotary wire brush. Remove the fender apron inner panel assembly.BODY PANEL REPAIR PROCEDURE BP-13 REMOVAL NOTE Before repairing. Drill out all the spotwelds(29) to separate fender apron inner panel assembly from fender apron upper panel assembly and front side member assembly. NOTE When spotwelded portions are not apparent. remove engine mounting support assembly before removing the fender apron inner panel assembly. BEDBP6102 BEDBP6104A . Refer to the body dimension charts and measure the vehicle to determine straightening and alignment requirements. BEDBP6103 2. remove Engine and Suspension Components.

Prepare all surfaces to be welded. 290 mm BEDBP6106B BEDBP6106 9. panel end on the fender apron upper panel assembly as shown in the illustration. After removing. apply the welding primer. 6.BP-14 BODY PANEL REPAIR PROCEDURE 4. Measure and mark the cutline on the fender apron upper inner panel 290mm from front fender apron upper inner 8. Remove the fender apron upper outer panel. BEDBP6105 BEDBP6106A 7. Remove the fender apron upper inner panel. Cut the fender apron upper inner panel along the cutlines. 5. BEDBP6106C .

BODY PANEL REPAIR PROCEDURE BP-15 INSTALLATION 3. 2. MIG butt weld all seams. BEDBP6106F BEDBP6106D 4. cut to length and chamfer butt end to improve weld surface. BEDBP6106G BEDBP6106E . Transcribe the fender apron upper inner panel cutline to the new fender apron upper inner panel. Measure each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position. Fit and clamp the fender apron upper inner panel in place. 1.

8. BEDBP6104B BEDBP6106H 6. MIG plug weld all holes. panel for MIG plug welding. Clean and prepare all welds. 9. Drill 6mm holes in the new fender apron upper outer 10. Measure each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position. After removing. BEDBP6105A BEDBP6104C 7. apply the welding primer. and remove all residue.BP-16 BODY PANEL REPAIR PROCEDURE 5. Fit and clamp the fender apron upper outer panel in place. BEDBP6107 BEDBP6104D .

and remove all residue. 14. Drill 6mm holes in the new fender apron inner panel assembly for MIG plug welding. 13. apply the welding primer. BEDBP6104E BEDBP6108 12. BEDBP6106I BEDBP6102A . Clean and prepare all welds.BODY PANEL REPAIR PROCEDURE BP-17 11. Fit and clamp the fender apron inner panel assembly in place. After removing.

(Refer to the BODY CORROSION PROTECTION) 19. Apply the correct seam sealer to all joints carefully. Apply the two-part epoxy primer. 21. (Refer to the BODY SEALING LOCATION) BEDBP6102C BEDBP6102E .BP-18 BODY PANEL REPAIR PROCEDURE 15. Apply metal conditioner and water rinse. 20. 17. 22. MIG plug weld all holes. Apply an anti-corrosion agent as required. and remove all residue. Prepare the exterior surfaces for priming using wax and grease remover. BEDBP6102D 23. Apply the two part epoxy primer to the interior of the each panel. BEDBP6102B 16. 18. Apply conversion coating and water rinse. Clean and prepare all welds.

BODY PANEL REPAIR PROCEDURE BP-19 FRONT SIDE MEMBER WELDING POINTS m 260m MIG plug welding MIG butt welding MIG lap welding BEDBP6203 143m m MIG plug welding MIG butt welding MIG lap welding BEDBP6202F .

The procedure may also be applied to the front right side member. impossible to straighten the damaged front side member. Before cutting the front side member. remove the front damage to the front side member and when it is crash member assembly.BP-20 BODY PANEL REPAIR PROCEDURE NOTE REMOVAL This procedure is to be used only for repair of minor 1. 143m m BEDBP6202 m 260m BEDBP6203 . Measure and mark the vertical cutlines on front side BEDBP6101 member from tooling hole edge. The following procedure illustrates a repair for the front left side member. BEDBP6201 2.

Prepare all surfaces to be welded. Remove the front side member. After removing. BEDBP6203A BEDBP6204 4. BEDBP6202A BEDBP6204A BEDBP6203B . Drill out all the spotwelds to separate front side member. Cut the front side member inner and outer panel along the cutlines.BODY PANEL REPAIR PROCEDURE BP-21 3. 7. apple the welding primer. 5. 6.

and remove all residue. Measure each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position.BP-22 BODY PANEL REPAIR PROCEDURE INSTALLATION 4. MIG plug weld all holes and MIG butt weld seams. Transcribe the front side member inner and outer cutline to the new front side member. 1. Fit and clamp the front side member in place. 3. BEDBP6203C BEDBP6205 5. BEDBP6203D BEDBP6206 . 2. Clean and prepare all welds. cut to length and chamfer butt end to improve weld surface.

Apply an anti-corrosion agent as required. Install the front crash member assembly. 10. Apply conversion coating and water rinse. Prepare the exterior surfaces for priming using wax and grease remover.BODY PANEL REPAIR PROCEDURE BP-23 6. (Refer to the BODY SEALING LOCATION) BEDBP6202B . 9. 7. (Refer to the BODY CORROSION PROTECTION) 8. Apply metal conditioner and water rinse. Apply the two-part epoxy primer. BEDBP6201A BEDBP6203E 12. each panel. Apply the correct seam sealer to all joints carefully. Apply the two part epoxy primer to the interior of the 13. 11.

BP-24 BODY PANEL REPAIR PROCEDURE FRONT PILLAR WELDING POINTS A m 0m 15 m 0m 12 A B B B 100mm 90mm MIG plug welding MIG butt welding MIG lap welding BUNBP6307 .

BEDBP6303 NOTE When cutting the front pillar outer panel. Before cutting the front pillar. Cut the front pillar outer panel along the cutlines. 2. be careful 50m 1 not to damage it while removing.BODY PANEL REPAIR PROCEDURE BP-25 REMOVER 4. m 20m 1 BEDBP6305 5. NOTE m If the cowl side upper outer panel is reusable. To remove the front pillar. take care not to cut through mating flanges or front pillar outer reinforcement. 3. BEDBP6305A BEDBP6321 . Measure and mark the each cutline on the front pillar outer panel 150mm and 270mm from the roof panel corner as indicated in the illustration. 1. drill out and grind away all spotwelds(19) and plug welds(4) attaching the cowl side upper outer panel. Remove the cowl side upper outer panel. be sure to support roof panel.

Cut the front side sill outer panel along the cutlines. Measure and mark the cutlines on front side sill outer outer panel. Drill out all the spotwelds(8) attaching the front pillar 8. BEDBP6306 BEDBP6307B . 9. Remove the front pillar outer panel. panel as indicated in the illustration.BP-26 BODY PANEL REPAIR PROCEDURE 6. NOTE When cutting the front side sill outer panel. take care not to cut through mating flanges or the side sill outer reinforcement. 100mm 90mm BEDBP6305B BEDBP6307A 7.

Remove the front side sill outer panel. reinforcement as indicated in the illustration. BEDBP6308 BEDBP6308B . Cut the side sill outer reinforcement along the cutline. 13.BODY PANEL REPAIR PROCEDURE BP-27 10. Measure and mark the cutline on side sill outer sill outer panel. 130mm BEDBP6307C BEDBP6308A 11. NOTE When cutting side sill outer reinforcement. Drill out all the spotwelds(8) attaching the front side 12. take care not to cut through mating flanges.

BEDBP6313 BEDBP6309 16. BEDBP6304 BEDBP6313A . To remove the front pillar inner panel. To remove the front pillar outer panel.BP-28 BODY PANEL REPAIR PROCEDURE 14. BEDBP6311 BEDBP6306A 15. drill out all spotwelds(85) and bolt (1). Remove the front pillar outer panel. drill out and grind away all spotwelds(37) and lap welds(2).

Clean cut portions with a disc grinder. 19. After removing. Remove the front pillar inner panel. BEDBP6312B BEDBP6316A 17. apply the welding primer. BEDBP6316 BEDBP6316B .BODY PANEL REPAIR PROCEDURE BP-29 BEDBP6314 BEDBP6318 18.

and remove all residue. BEDBP6315B BEDBP6315 . 1. BEDBP6315A BEDBP6319 5. Drill 8mm holes in the front pillar inner panel for MIG plug welding. 3. Clean and prepare all welds.BP-30 BODY PANEL REPAIR PROCEDURE INSTALLATION 4. MIG plug weld all holes and MIG lap weld seams. 2. Fit and clamp the new front pillar inner panel in place for welding. Measure and each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position.

MIG plug weld all holes and MIG lap weld seams. BEDBP6315C BEDBP6309A 7. After removing. Transcribe the cutlines to the new front pillar outer panel. BEDBP6309B BEDBP6320 12. and remove all residue. Clean and prepare all welds. apply the welding primer. adding 30mm overlap to each end and cut to length. 10. Install the front pillar outer panel in place. BEDBP6309C . Drill 6mm holes along front pillar outer panel flanges for attachment to other panels. 8. 9. Measure each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position.BODY PANEL REPAIR PROCEDURE BP-31 6. 11.

then MIG plug weld all holes and MIG butt weld seams. After removing. 17. apply the welding primer. Apply the two-part epoxy primer to the interior of the front pillar. BEDBP6321A BEDBP6321C . 15.BP-32 BODY PANEL REPAIR PROCEDURE 13. Clean all welds with a disc grinder. Reattach the cut away front pillar outer panel section. 16. After removing. apply the welding primer. BEDBP6321B BEDBP6309D 14.

Apply conversion coating and water rinse. 26.BODY PANEL REPAIR PROCEDURE BP-33 18. BEDBP6303B BEDBP6312 . using wax and grease remover. Reprime over the seam sealer to complete the repair. Apply an anti-corrosion agent to the welded parts and the two part epoxy primer and anti-corrosion agent to inside of front pillar (Refer to the CORROSION the interior of the fender apron panel. remove all residue. Apply the two-part epoxy primer. BEDBP6303A 21. Clean and prepare all welds. Apply metal conditioner and water rinse. apply 22. 20. Apply the correct seam sealer to all joints carefully (Refer to the BODY SEALING LOCATIONS). 24. MIG plug weld all holes. 28. Before welding the cowl side upper outer panel. BEDBP6302 27. PROTECTION). 19. Install the cowl side upper outer panel in place. 25. 23. Prepare exterior surfaces for priming.

Measure and mark the horizontal cutline on front pillar outer panel 50mm from the door hinge mounting hole 3.BP-34 BODY PANEL REPAIR PROCEDURE SIDE SILL PANEL WELDING POINTS 70mm 50mm 50mm MIG plug welding MIG butt welding MIG lap welding BEDBP6401 REMOVAL 2. outer panel 50mm from the rear door step trim mounting hole as indicated in the illustration. 70mm 50mm 50mm BEDBP6401A BEDBP6401B . Measure and mark the vertical cutline on rear side sill as indicated in the illustration. 1. Measure and mark the horizontal cutline on center pillar outer panel 70mm from the door hinge mounting hole.

After removing. Clean cut portions with a disc grinder. BEDBP6402C . Remove the side sill outer panel. 7. BEDBP6402A 8. Cut the side sill outer panel along the cutlines. be careful not to cut mating flanges. BEDBP6401C 5.BODY PANEL REPAIR PROCEDURE BP-35 4. NOTE When cutting the side sill outer panel. BEDBP6402B BEDBP6401D 6. apply the welding primer. Drill out all spotwelds(79). attaching the side sill outer panel.

8. Clean and prepare all welds and remove all residue. 3. Apply the correct seam sealer to all joints (Refer to the BODY SEALING LOCATIONS). BEDBP6401H 7. Reprime over the seam sealer. Apply conversion coating and water rinse. and grease remover. Fit and clamp the side sill outer reinforcement in place. Transcribe the cutlines to the new side sill outer panel. Apply metal conditioner and water rinse. 14. drill 6mm holes in overlap areas and along upper and lower flanges. Prepare the exterior surfaces for priming. Measure and each measurement point (Refer to the PROTECTION). Apply body filler to the side sill outer seams. BEDBP6401I BEDBP6401F 10. Apply the two-part epoxy primer. Using service panel for replacement of side sill outer panel. 2. MIG plug weld all holes and MIG butt weld seams. 11. using wax 5. adding 30mm overlap to each end and cut to length. 12. 1. BEDBP6401G . 15. BODY DIMENSIONS) and correct the installation position.BP-36 BODY PANEL REPAIR PROCEDURE INSTALLATION 6. 13. 9. Apply an anti-corrosion agent to welded parts and interior of the side sill (Refer to the CORROSION 4. Apply the two-part epoxy primer to the interior of the BEDBP6401E side sill.

BODY PANEL REPAIR PROCEDURE BP-37 CENTER PILLAR WELDING POINTS A 100mm 100mm A B C B C 100mm 20mm 80mm 100mm MIG plug welding MIG butt welding MIG lap welding BEDBP6508 .

Cut center pillar outer panel along the cutlines. BEDBP6501 BEDBP6502A 2. 100mm 100mm BEDBP6502 BEDBP6502B . Measure and mark the horizontal cutlines on center 4. be sure to support roof panel. attaching the center pillar outer pillar outer panel as indicated in the illustration.BP-38 BODY PANEL REPAIR PROCEDURE REMOVAL 3. panel. When cutting center pillar outer panel. NOTE 1. Before cutting center pillar. Drill out all spotwelds(5). take care not to cut through mating flanges or center pillar outer reinforcement.

take care not to cut through mating flanges or rear door hinge mounting upper reinforcement. Measure and mark the horizontal cutlines on center pillar outer reinforcement as indicated in the illustration. NOTE When cutting center pillar outer reinforcement. Drill out all spotwelds(3). 40mm BEDBP6503A BEDBP6503C . BEDBP6503 6. attaching the center pillar outer 130mm reinforcement. BEDBP6503B 8. Remove the center pillar outer panel. 7.BODY PANEL REPAIR PROCEDURE BP-39 5. Cut the center pillar outer reinforcement along the cutlines.

150mm 80mm 100mm BEDBP6504A BEDBP6505 . Remove the center pillar outer reinforcement. NOTE When cutting rear door hinge mounting upper reinforcement.BP-40 BODY PANEL REPAIR PROCEDURE 9. BEDBP6504 10. Measure and mark the vertical cutlines on front side sill outer panel 80mm and 180mm from the front door step trim mounting hole. Measure and mark the horizontal cutline on rear door hinge mounting upper reinforcement as indicated in the illustration. Cut the rear door hinge mounting upper reinforcement along the cutline. take care not to cut through mating flanges. 11. BEDBP6504B 12.

Remove the front side sill outer panel. NOTE When cutting the front side sill outer panel. BEDBP6506 16. 15. Measure and mark the vertical cutlines on front side sill outer reinforcement as indicated in the illustration.BODY PANEL REPAIR PROCEDURE BP-41 13. Drill out all spotwelds (5) attaching the front side sill outer panel. Cut the front side sill outer panel along the cutlines. BEDBP6505A 14. 110mm 50mm BEDBP6506A BEDBP6505B . take care not to cut through mating flanges or side sill outer reinforcement.

BP-42 BODY PANEL REPAIR PROCEDURE

17. Cut the front side sill outer reinforcement cutlines. 19. Remove the front side sill outer reinforcement.

NOTE
When cutting front side sill reinforcement, take care
not to cut through mating flanges.

BEDBP6507

20. Measure and mark the vertical cutline on side sill inner
reinforcement as indicated in the illustration.
BEDBP6506B

18. Drill out all spotwelds(3), attaching the front side sill
outer reinforcement.

130mm

BEDBP6507A

BEDBP6506C

BODY PANEL REPAIR PROCEDURE BP-43

21. Cut the front side sill inner reinforcement along the cutline. 23. Cut the rear side sill outer panel along the cutlines.

NOTE

When cutting rear side sill outer panel, take care not
to cut through mating flanges or side sill outer
reinforcement.

BEDBP6507B

22. Measure and mark the vertical cutlines on rear side
sill outer panel 20mm and 120mm from the rear door
step trim mounting hole.
BEDBP6508B

24. Drill out all spotwelds (5) attaching the rear side sill
outer panel.

100mm 20mm

BEDBP6508A

BEDBP6508C

BP-44 BODY PANEL REPAIR PROCEDURE

25. Remove the rear side sill outer panel. 27. Cut the rear side sill outer reinforcement along the
cutline.

NOTE
When cutting rear side sill outer reinforcement, take
care not to cut through mating flanges.

BEDBP6509

26. Measure and mark the cutline on side sill outer
reinforcement as indicated in the illustration.
BEDBP6509AB

28. Drill out all spotwelds (77) attaching the center pillar
outer panel.

70mm

BEDBP6509A

BEDBP6510

BEDBP6509C

Prepare all surfaces to be welded. BEDBP6511 BEDBP6514 30. 31.BODY PANEL REPAIR PROCEDURE BP-45 29. the center pillar inner panel to side sill inner panel. Remove MIG lap welds (3) and spotwelds (13) attaching 32. Remove the center pillar inner panel. BEDBP6514A BEDBP6512 BEDBP6513 . Remove the center pillar outer panel.

BEDBP6514B BEDBP6516 2. INSTALLATION 1. After removing.BP-46 BODY PANEL REPAIR PROCEDURE 33. Measure and each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position. BEDBP6511A . Fit and clamp the new center pillar inner panel in place for welding. apply the welding primer.

Apply body filler to the outer center pillar seam. BEDBP6511B . 12. adding 30mm overlap to each end and cut to length. BEDBP6517 8. Fit and clamp the new center pillar outer panel in place for welding. MIG plug weld all holes and MIG lap weld seams. Clean and prepare all welds. Reinstall center pillar outer panel. Drill 8mm holes in overlap areas and along center pillar outer panel flanges.BODY PANEL REPAIR PROCEDURE BP-47 3. 7. BEDBP6510A 10. Transcribe the cutlines to the new side outer panel. and remove all residue. 9. Sand and finish. BEDBP6513A 4. BEDBP6513B 5. 6. Measure and each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position. Check the fit of the front and rear doors. After removing. apply the welding primer. 11.

BEDBP6510B BEDBP6501A 14. Clean all welds with a disc grinder. apply the welding primer. BEDBP6510C BEDBP6501B 15. After removing. Reattach the cut away center pillar outer panel section. then MIG plug weld all holes and MIG butt weld seams. 16. 17. BEDBP6510D . Clean and prepare all welds. MIG plug weld all holes and MIG butt weld seams.BP-48 BODY PANEL REPAIR PROCEDURE 13. and remove all residue.

BEDBP6513D . 22. 24. 21. Apply metal conditioner and water rinse. Apply conversion coating and water rinse. Apply the two-part epoxy primer. Apply the correct seam sealer to all joints carefully (Refer to the BODY SEALING LOCATIONS). using wax and grease remover.BODY PANEL REPAIR PROCEDURE BP-49 18. Prepare exterior surfaces for priming. 23. Apply the two-part epoxy primer to the interior of the center pillar. BEDBP6513C 20. 19. Apply an anti-corrosion agent to the welded parts and interior of the center pillar (Refer to the CORROSION PROTECTION).

BP-50 BODY PANEL REPAIR PROCEDURE QUARTER PANEL WELDING POINTS 80mm 80 mm 70mm MIG plug welding MIG butt welding MIG lap welding BEDBP6601 .

BODY PANEL REPAIR PROCEDURE BP-51

REMOVAL 3. Drill out all attaching spotwelds(81) on the quarter outer
panel, including the seam around the door lip opening.
1. Depending on the extent of damage, measure and mark
cutlines on the quarter outer panel as indicated in the
illustration.

80mm
80m
m

BEDBP6606

BEDBP6603

70mm

BEDBP6604

BEDBP6602

2. Cut the quarter outer panel along the cutlines and
remove the quarter outer panel as illustration.

NOTE

When cutting the quarter outer panel, be careful not to
cut quarter inner panel.

BEDBP6605

BEDBP6601A

BP-52 BODY PANEL REPAIR PROCEDURE

4. Remove the quarter outer panel. 6. After removing, apply the welding primer.

BEDBP6607 BEDBP6607B

5. Clean cut portions with a disc grinder. 7. Prepare all surfaces to be welded.

BEDBP6607A

BODY PANEL REPAIR PROCEDURE BP-53

INSTALLATION 6. MIG plug weld all holes and MIG butt weld seams.

1. Transcribe the cutlines to the new quarter outer panel,
adding 30 mm overlap each end.

2. Drill 6 mm holes in overlap areas and along upper and
lower flanges of the new quarter outer panel for MIG
plug welding.

BEDBP6601C

7. Clean and prepare all welds, remove all residue.

BEDBP6608

3. Apply body filler to the welded seam. Sand and finish.
Apply the two-part epoxy primer to the interior of the
quarter outer panel.

4. Fit and clamp the quarter outer panel in place.

5. Measure and each measurement point (Refer to the
BODY DIMENSIONS) and correct the installation
position.
BEDBP6601D

BEDBP6601B

BEDBP6601F BEDBP6601E 13. Apply metal conditioner and water rinse. if necessary.BP-54 BODY PANEL REPAIR PROCEDURE 8. Apply conversion coating and water rinse. In order to improve corrosion resistance. 12. Prepare exterior surfaces for priming. Apply the two-part epoxy primer. well (Refer to the CORROSION PROTECTION). 9. 11. interior of the quarter outer panel (Refer to the apply an under body anti-corrosion agent to the wheel CORROSION PROTECTION). using wax and grease remover. 10. 14. Apply the correct seam sealers to all joints. BEDBP6604A . Reprime over the seam sealer to complete the repair. Apply an anti-corrosion agent to the welded parts and 15.

BODY PANEL REPAIR PROCEDURE BP-55 BACK COMPLETE PANRL ASSEMBLY AND REAR FLOOR SIDE MEMBER WELDING POINTS 140mm MIG plug welding MIG butt welding MIG lap welding BEDBP6705 .

BP-56 BODY PANEL REPAIR PROCEDURE REMOVAL 2. then BEDBP6702 the procedure of rear floor side members and rear floor section should be followed. BEDBP6702A BEDBP6701 BEDBP6703 . Drill out all the spotwelds(86) attaching the back vehicle to determine straightening and alignment complete panel assembly. This repair is recommended only for moderate damage to the vehicle. The body must be returned to its original dimensions before beginning the repair procedure. If both side members are damaged and need to be replaced. then the entire side member assembly should be replaced at the factory seams without employing this sectioning procedure. If the damage is more severe. NOTE Because the rear floor side members are designed to absorb energy during a rear collision. requirements. Refer to the body dimension charts and measure the 3. The following procedure applys when only one rear floor side member needs to be replaced. where distortions do not extend forward of the trunk region. Drill out all the spotwelds(43) attaching the rear combination lamp housing panel. 1. care must be used when deciding to use this repair method. Remove the rear combination lamp housing panel.

Cut rear floor side member along the cutline. measure and mark 7. 140mm BEDBP6706 BEDBP6705A 8. BEDBP6704 BEDBP6705B 5. cutline on the rear floor side member as indicated in attaching the rear floor side member to rear floor panel. Remove the rear floor side member. 6. Remove the back complete panel assembly. Drill out all spotwelds(20) and MIG lap welds(1).BODY PANEL REPAIR PROCEDURE BP-57 4. BEDBP6707 . Depending on the extent of damage. the illustration.

Prepare all surfaces to be welded. BEDBP6705C . Clean cut portions with a disc grinder. 2. INSTALLATION 1. BEDBP6707B 11. adding 30 mm overlap to the rear end. BEDBP6708 3. BEDBP6707A 10.BP-58 BODY PANEL REPAIR PROCEDURE 9. Fit and clamp the rear floor side member in place. Measure and each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position. After removing. Transcribe the cutline to the new rear floor side member. 4. Drill 8 mm holes in the new rear floor side member for MIG plug welding. apply the welding primer.

BEDBP6706A BEDBP6706C 6. 7. apply the welding primer. Fit and clamp the new back complete panel assembly in place. After removing. MIG plug weld all holes and MIG butt weld seams. Clean and prepare all welds. remove all residue. 8. BEDBP6702B . Measure and each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position. BEDBP6706B BEDBP6709 9.BODY PANEL REPAIR PROCEDURE BP-59 5.

13. apply the welding primer. Measure and each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position. BEDBP6701A BEDBP6702E . BEDBP6702D 12. MIG plug weld all holes.BP-60 BODY PANEL REPAIR PROCEDURE 10. BEDBP6702C BEDBP6710 11. Clean and prepare all welds. Fit and clamp the new rear combination lamp housing panel assembly in place. remove all residue. 14. After removing.

remove all residue. 17. using wax and grease remover. BEDBP6701E . Apply the two-part epoxy primer. Prepare exterior surfaces for priming. Clean and prepare all welds. 22. MIG plug weld all holes. 18. 20. Apply the two-part epoxy primer to the interior of the rear floor side member.BODY PANEL REPAIR PROCEDURE BP-61 15. BEDBP6701D 23. Apply conversion coating and water rinse. Apply metal conditioner and water rinse. Apply the correct seam sealer to all joints (Refer to BEDBP6701C the BODY SEALING LOCATIONS). 21. 19. BEDBP6701B 16. Apply an anti-corrosion to the interior of the rear floor side member (Refer to the CORROSION PROTECTION).

26 In order to improve corrosion resistance. BEDBP6705E . apply an Under body anti-corrosion agent to the panel which is repaired or replaced (Refer to the CORROSION PROTECTION). if necessary. carefully apply Under coating to the Under body (Refer to the CORROSION PROTECTION).BP-62 BODY PANEL REPAIR PROCEDURE BEDBP6705D 24 Reprime over the seam sealer to complete the repair 25 After completing body repairs.

BODY PANEL REPAIR PROCEDURE BP-63 FRONT AND REAR DOOR OUTER PANELS WELDING POINTS FRONT DOOR MIG plug welding MIG butt welding MIG lap welding CON-0750 REAR DOOR MIG plug welding MIG butt welding MIG lap welding CON-0800 .

member and door reinforcement beam as shown in the figure. PRO-1860 PRO-1840 . PRO-1831 PRO-1771 3. Cut door outer panel hem with a sander. 1. remove the 2. Apply mastic sealer or equivalent to the door upper outer panel. Apply adhesive or equivalent to outer panel hem. Dress rusty part with a sander and prepare surface to be hemmed.BP-64 BODY PANEL REPAIR PROCEDURE REMOVAL INSTALLATION 1. 2. After grinding off the hemming location.

BODY PANEL REPAIR PROCEDURE BP-65 3. NOTE Hemming work should be done in three steps as 6. welds at 50 mm intervals on the inside. PRO-2000 PRO-1870 7. hem with a hammer and dolly. Apply conversion coating and water rinse. make MIG spot fasten tightly with a hemming tool. After completing the hemming work. Prepare exterior surfaces for priming. remove all residue. 9. PRO-1880 PRO-2010 PRO-1900 . Apply metal conditioner and water rinse. Apply an anti-corrosion agent to the welded parts and lower inside of the door panel (Refer to the CORROSION PROTECTION). Apply the two-part epoxy primer. 10. If a hemming tool cannot be used. 8. 11. using wax and grease remover. Apply the two-part epoxy primer to the interior of the illustration. Clean and prepare all welds. 5. door panel. then 4. Bend the flange hem with a hammer and dolly.

BP-66 BODY PANEL REPAIR PROCEDURE 12. 13. PRO-2021 . Apply the correct seam sealer to whole panel edge. Reprime over the seam sealer to complete the repair.

...... BS ........9 HOOD ..........................2 UPPER BODY AND SIDE BODY .......................................... BS ..................................................................5 UNDER BODY ....... BS ...................... BS .............Body Sealing Locations FLOOR ..............11 DOOR ...............10 TAIL GATE ..12 BS .......................................................... BS ................... BS ............

BS-2 BODY SEALING LOCATIONS FLOOR F I C K L L M M A D G B E J H BEDBS6001 A B BEDBS6301 BEDBS6302 C D BEDBS6303 BEDBS6306 .

BODY SEALING LOCATIONS BS-3 E F BEDBS6304 BEDBS6305 G H BEDBS6307 BEDBS6308 I J BEDBS6309 BEDBS6310 K BEDBS6311 .

BS-4 BODY SEALING LOCATIONS L-L Cowl top outer panel Cowl inner lower panel Dash panel Dash lower center reinforcement Center floor reinforcement Muffler hanger mounting bracket Center floor panel Dash lower center reinforcement BEDBS6003 M-M Rear floor front panel Rear floor front extension Center floor reinforcement Rear floor front Rear floor front filler cross member Center floor panel Fuel tank mounting bracket Rear floor front cross member reinforcement BEDBS6004 .

BODY SEALING LOCATIONS BS-5 UPPER BODY AND SIDE BODY M L M L B C A D E J R S R P P Q Q S K G I H F BEDBS6006 A B T T BEDBS6102 BEDBS6103 .

BS-6 BODY SEALING LOCATIONS C D BEDBS6101 BEDBS6206 E F BEDBS6205 BEDBS6204 G H BEDBS6201 BEDBS6202 I J BEDBS6203 BEDBS6402 .

BODY SEALING LOCATIONS BS-7 K L-L O N N O BEDBS6401 BEDBS6007 M-M N-N Side outer panel Side outer panel Rear bumper mounting reinforcement Side outer rear extension Rear floor side panel Back panel BEDBS6008 BEDBS6009 O-O Back panel P-P Front inner lower pillar Rear floor panel BEDBS6010 Dash panel Q-Q Front side outer member BEDBS6012 BEDBS6011 .

BS-8 BODY SEALING LOCATIONS R-R S-S Quarter inner lower panel Side outer panel Side outer panel Rear floor side panel BEDBS6013 BEDBS6014 T -T Fender apron upper inner panel Shock absorber housing cover Fender apron upper outer panel Shock absorber housing panel Front side inner member Front side outer member BEDBS6015 .

BODY SEALING LOCATIONS BS-9 UNDER BODY A B BEDBS6002 A B BEDBS6501 BEDBS6502 .

BS-10 BODY SEALING LOCATIONS HOOD A A B B BEDBS6016 A-A B-B Y X BEDBS6017 BEDBS6018 X Y 1.5 mm 5 -1 mm +2 m +2 1 m - 5 1. 5 m m BEDBS6019 BEDBS6020 .

5 mm 5mm BEDBS6023 BEDBS6024 .BODY SEALING LOCATIONS BS-11 TAIL GATE A B A B BEDBS6021 A-A B-B Z BEDBS6022 Z 2.

G2 E E C C E E C C BEDBS6025 A-A B-B V V Front door rear frame Rear door front frame Rear door rear frame BEDBS6026 BEDBS6027 V C-C 94 +_ 5 mm T BEDBS6028 BEDBS6029 . D2 A A F1. F2 G1.BS-12 BODY SEALING LOCATIONS DOOR B B H1. H2 D1.

5 m m m 5m Front door inner panel BEDBS6030 BEDBS6031 D2 E Front door frame assembly Front door outer panel BEDBS6032 BEDBS6033 F1 F2 Front door frame assembly Front door frame assembly Front door inner panel Front door outer panel Front door outer panel BEDBS6034 BEDBS6035 G1 G2 Rear door frame assembly Rear door inner panel Rrar door frame assembly Rear door outer panel BEDBS6036 BEDBS6037 .BODY SEALING LOCATIONS BS-13 T D1 Front door frame assembly 1.

BS-14 BODY SEALING LOCATIONS H1 H2 Rear door frame assembly Rear door frame assembly Rear door inner panel Rear door outer panel Rear door outer panel BEDBS6038 BEDBS6039 .

...... CP ................................................11 HOOD ................ CP ................................14 CP UNDER BODY ANTI-CORROSION AGENT .............................2 ANTIVIBRATION PADS-LOCATION & SECTION .......... CP .. CP ..12 TAIL GATE ......................... CP ...............................................................15 ...............3 ATTACHMENT OF ANTIVIBRATION PADS ..........7 CAVITY WAX INJECTION ............. CP ........ CP ...............................Corrosion protection ZINC-PHOSPHATE COAT & CATIONIC ELECTRODEPOSITION PRIMER ................... CP .................13 FRONT DOOR & REAR DOOR ..........6 UNDER BODY & SIDE BODY COAT ....... CP .

the entire body is coated with a film of Zinc-phosphate and a cationic electrodeposition primer.CP-2 CORROSION PROTECTION ZINC-PHOSPHATE COAT & CATIONIC ELECTRODEPOSITION PRIMER In order to improve the adhesion of the paint coat on the steel panel. and also to improve the corrosion resistance. Cationic electrodeposition primer Zinc-phosphate film Body steel panel BMCCP6020 .

:1.8 mm .0 mm ) BEDCP6002 .CORROSION PROTECTION CP-3 ANTIVIBRATION PADS-LOCATION & SECTION LHD C D E F I A A H H K K G G Y B B C D E F X I RHD [ 3 Door / 5 Door ] mm 14 Front 21mm J J [X] Front 17 m m [ Wagon ] 12mm [Y ] Under body coating (Thickness : 0.

CP-4 CORROSION PROTECTION A-A B-B Dash panel Dash panel BEDCP6003 BEDCP6004 C-C Center floor panel 24mm BEDCP6005 D-D 25mm Center floor panel BEDCP6006 E-E Rear seat inner mounting bracket Center floor panel Center floor side member BEDCP6007 .

CORROSION PROTECTION CP-5 F-F 82mm Center floor panel Center floor side member BEDCP6008 G-G H-H Front seat mounting member 22mm 33mm Rear floor front panel BEDBC6305 BEDBC6306 I-I Spare tire mounting bracket Rear floor side member Rear floor rear panel BEDBC6307 J-J K-K Cowl top outer panel 36mm Rear floor rear panel 9mm Cowl inner lower panel BEDBC6308 BEDBC6309 .

NOTE An infrared lamp can also be used to heat both the antivibration pad layer and the body panels(be sure to wear gloves).CP-6 CORROSION PROTECTION ATTACHMENT OF ANTIVIBRATION PADS Antivibration pads are attached to the upper surface of the floor and at the interior side of the dash panel in order to absorb vibrations and shut out exhaust gas heat. BEDCP6001 1. Align the antivibration pad layer in the position where it. cut and attach replacement material (in the shape shown in the figure). and then press it down with a roller or a block of wood so that it adheres well. Heat the "antivibration pad" with a blow drier to soften 2. If these antivibration pads are peeled off in the course of replacement or repair of a welded panel. BMCCP6041 BMCCP6042 . it is to be installed.

:1. Therefore. F A G D G Y F X A D C C B B E E Under body coating (Thickness : 0. when such panel is replaced or repaired. stone chipping and vibration resistance.8 mm .CORROSION PROTECTION CP-7 UNDER BODY & SIDE BODY COAT In order to provide corrosion. apply under body coat to that part. under body coat is applied to the under sides of the floor and wheel house.0 mm ) BEDCP6102 .

CP-8 CORROSION PROTECTION A-A B-B Fender apron upper inner panel Sub frame mounting rear support Sub frame mounting rear reinforcement Shock absorber housing cover Fender apron upper Sub frame mounting outer panel rear bracket BEDCP6104 C-C Shock absorber housing lower panel Side outer rear extension Front side Tie down front outer member reinforcement Front side inner member BEDCP6103 BEDCP6105 D-D Side sill inner panel Center floor panel Side outer panel Center floor side member BEDCP6106 E-E 20mm Rear floor rear panel Rear floor center cross member 70mm Fuel tank mounting rear bracket BEDCP6107 .

CORROSION PROTECTION CP-9 F-F G-G Side outer panel Quarter inner lower panel Side outer panel Quarter inner upper panel Wheel house inner panel Wheel house inner panel Wheel house inner panel Quarter inner lower panel Rear suspension mounting bracket Rear floor panel Rear floor side member BEDCP6108 BEDCP6109 X Y [ 3 Door / 5 Door ] BEDCP6110 BEDCP6111 Y [ Wagon ] BEDCP6112 .

CP-10 CORROSION PROTECTION H H [ Wagon ] BEDCP6113 H-H 20 mm Rear floor rear panel Rear floor center cross member 70 mm BEDCP6114 .

CORROSION PROTECTION CP-11 CAVITY WAX INJECTION In order to provide greater corrosion resistance. SIDE BODY A A BEDCP6021 A-A Side outer panel Side sill inner panel Side sill outer reinforcement 16 mm 40 mm m 25 m BEDCP6202 . When replacing these parts. the side sill and the inside of other panels which are a hollow construction. be such to apply cavity wax to the appropriate areas of the new parts. such as the sidemember. cavity wax injection has been performed for the lower areas of the vehicle.

CP-12 CORROSION PROTECTION HOOD B Wax injection holes Wax injection holes B 200mm 200mm C 250mm 250mm Wax injection holes C 300mm 300mm BEDCP6203 B-B C-C Hood hinge assembly Cowl side upper panel m m 30 m m 30 BEDCP6204 BEDCP6205 .

CORROSION PROTECTION CP-13 TAIL GATE D 150 mm D Side outer panel BEDCP6206 D-D Tail gate outer panel Tail gate inner panel 30 mm 30 m m BEDCP6207 .

CP-14 CORROSION PROTECTION FRONT DOOR & REAR DOOR F E E 80 mm 80 mm 130 mm 130 mm 100 mm E E Wax injection holes BEDCP6208 E-E F 30 mm BEDCP6209 BEDCP6210 .

when such panel is replaced or repaired. Under body coating (Thickness : 0. apply under body anti-corrosion agent to that part. muffler and exhaust pipe.8 mm . :1. Therefore. NOTE Do not apply the under body anti-corrosion agent to come in contact with tires.0 mm ) BEDCP6102A .CORROSION PROTECTION CP-15 UNDER BODY ANTI-CORROSION AGENT The undersides of the floor and wheel house are undercoated to provide greater corrosion resistance.

.........2 CUT AND DISASSEMBLY TOOLS .4 MEASUREMENT TOOLS .............5 BUFFING AND GRINDING TOOLS ......................................Body Modification Tools MODIFICATION TOOLS ............. BT ......... BT ....... BT .6 HANDHELD TOOLS .... BT .....4 WELDING MACHINE .......................................9 BT ....... BT ...3 ASSEMBLY TOOLS ........................................8 REPAIR TOOLS SET .... BT ................. BT ..................... BT .

BT-2 BODY MODIFICATION TOOLS BODY MODIFICATION TOOLS MODIFICATION TOOLS Name Used for Figure A3EB3501 Frame straightener Modify twisted or bent body A3EB3502 A3EB3503 Port power Push out. pull in damaged area A3EB3504 Body puller Stretch damaged area A3EB3505 . stretch.

to finish a hole A3EB3510 Spot cutter Cut and disassemble spot welded area A3EB3511 . cut and Air chisel disassemble spot welded area A3EB3507 Rotary cutter Cut a panel A3EB3508 Hand saw and Cut a panel metal scissors A3EB3509 Fix a spot cutter or drill to cut or Air drill disassembly spot welding area.BODY MODIFICATION TOOLS BT-3 CUT AND DISASSEMBLY TOOLS Name Used for Figure Air saw Cut a panel A3EB3506 Cut or bend a panel.

BT-4 BODY MODIFICATION TOOLS ASSEMBLY TOOLS Name Used for Figure Vice pliers Fix a panel or area to weld A3EB3512 Finish contact area of flange and finish Air bench a hole for plug welding A3EB3513 Quick bench Finish a hole for plug welding A3EB3514 Flanging tool Finish contact area of flange A3EB3515 MEASUREMENT TOOLS Name Used for Figure Centering gauge Measure distortion of body and frame A3EB3516 Tracking gauge Measure body and frame A3EB3517 .

weld a stud bolt to fix Stud welding machine front window mold clip A3EB3521 .BODY MODIFICATION TOOLS BT-5 WELDING MACHINE Name Used for Figure Gas welding machine Cut a panel A3EB3518 Spot welding machine Weld a panel A3EB3519 Carbon arc welding Weld a panel machine A3EB3520 Stretch a panel.

BT-6 BODY MODIFICATION TOOLS BUFFING AND GRINDING TOOLS Name Used for Figure Disk grinder Buff A3EB3522 Disk sander Buff A3EB3523 Belt sander Buff paints A3EB3524 Small sized grinder Buff paints or smooth finishing A3EB3525 Grind rough area of puttee assembled Double action sander area A3EB3526 Grind rough area of puttee assembled Orbital sander(short) area A3EB3527 .

uneven area of a Flexible file panel A3EB3529 Surform tool Buff rough area of puttee area A3EB3530 Hand file Grind body puttee. finish puttee A3EB3531 . pulley.BODY MODIFICATION TOOLS BT-7 Name Used for Figure Orbital sander(long) Used for puttee grinding of wide area A3EB3528 Grind touch up area.

BT-8 BODY MODIFICATION TOOLS HANDHELD TOOLS Name Used for Figure Body hammer and dolly - A3EB3532 Punch a hole in the middle of a spot Center punch welding area A3EB3533 Plane chisel Cut and disassemble a panel A3EB3534 Weight hammer Used when greater force is required A3EB3535 Bowl pin hammer Used when smaller force is required A3EB3536 Used for an area where not reached by Spoon hand A3EB3537 .

A3EB3538 Remove paints.BODY MODIFICATION TOOLS BT-9 Name Used for Figure Bend rough body line damaged or sheet Body chisel metal etc. rust. slag on welded Wire brush area which are hard to recognize A3EB3539 REPAIR TOOLS SET Name Used for Figure Window tool set Repair window collar A3EB3540 Repair tool set for Repair plastic parts plastics A3EB3541 .

.. PP ..............Plastic Parts POLYPROPYLENE(PP) BUMPER REPAIRABILITY .... PP ..2 BUMPER REPAIR PROCEDURE ................................. PP ......3 REPAIR METHOD FOR PP BUMPER ............4 PP ........

Because of cost and quality considerations.(100 mm). but replacing the bumper is encouraged. (100 mm) (less than half of the bumper height). A3EB3601 2. A3EB3602 3. Bumper height Crack on section [A] A3EB3603 . 1. bumpers with more damage may be repaired. If a crack on bumper sectionis [A] is less than 4 in.(50 mm). If a crack on a bumper is less than 4 in.PP-2 PLASTIC PARTS POLYPROPYLENE(PP) BUMPER REPAIRABILITY The three types of damaged bumpers shown below can be repaired. If a hole on a bumper is less than 2 in.

Sand damaged area with a rough sandpaper.PLASTIC PARTS PP-3 BUMPER REPAIR PROCEDURE Surface of Surface of Remove paint. Sand surface of bumper with sandpaper. Clean and degrease damaged area(use TCE de-oil material). Paint bumper with a paint of the same color and let dry. Sand damaged area smooth. Apply aluminum tape on the rear side of bumper. bumper is not bumper is visible. Wipe the surface of bumper with a tack cloth. VQPP001 . Replace damaged bumper with a new bumper. Spray primer surface over bumper and let dry. Apply solvent over damaged area. Weld damaged area. Apply primer for polypropylene over bumper surface. Clean and degrease with TCE de-oil material. visible. Apply primer for polypropylene over damaged area.

Use the repair methods shown below to repair damage that reaches the surface of the polypropylene. Rough cut the damaged area 45 using a knife and then sand the angle smooth. C-C' Surface of polypropylene Make an angle with a sander . Make an angle with a sander 45 Angle of 45 is required for accumulation of polypropylene welding rod.PP-4 PLASTIC PARTS REPAIR METHOD FOR PP BUMPER Damage to the bumper that reaches the surface of the polyporpylene cannot be fixed just by painting. Section B-B' Cut with knife. A-A' Section D-D' Cut with a knife. Hole Crack Scar B C D A A' B' C' D' Section B-B' Section A-A' 1 Section D-D' Section C-C' 2 3 4 1 Upper layer (coating) 2 Primer surface layer 3 Primer layer 4 Polypropylene layer VQPP002 1. VQPP003 .

Apply on surface Surface of polypropylene Section view after melt VQPP004 b) To repair a hole. the welding strength will deteriorate.8 in. If the welding rod over-melts like jelly. Section A-A’ Remove oil.PLASTIC PARTS PP-5 2. Section A-A’ Polypropylene welding rod Polypropylene welding rod Surface of polypropylene Tape Plane view VQPP007 . A-A’ Section B-B’ Polypropylene C-C’ welding rod Polypropylene Melt here.(10~20 mm) away from the repair area to be welded.4~0. VQPP005 3. Melt polypropylene welding rod using a heat gun and fill in the cracked area. welding rod Melt here VQPP006 NOTE • Heat and melt the area indicated. Welding rod should not move until the welded area is cooled. remove oil from the damaged area and apply aluminum tape to the rear side of the damaged area. Heat gun Melt the surface using a heat gun. melt the area using a heat gun and attachment. • Use the heat gun 0. Welding damaged area a) To repair cracked area. • Melt the welding rod carefully so that it does not over-melt. Apply aluminum tape on the rear side of the damaged area.

• Dry it at 20 C (68 F) for about 30 minutes before sanding. Mix main filler material and hardener at a ratio depending on paint specifications. Mix filler material and apply over the damaged area. Dry it at 20 C (68 F) for more than 10 minutes. • Use only filler material designed for use on polypropylene bumpers. Apply polypropylene primer evenly with a brush over an area wider than the area to be repaired. Filler material Do not allow bubbles to be created. It melts easily due to the heat generated by friction. Weld Surface of polypropylene VQPP010 • Filler material consists of two types of epoxy. Polypropylene primer VQPP009 6. Apply primer wider than the area to repair. you will have a desirable finish with flexibility like polypropylene. Grind polypropylene surface carefully. Area to apply solvent Do not grind continuously. remove that area. . • Work immediately after mixing filler material because the filler material hardens quickly(in about 5 minutes). Also. grind the area where solvent is to be applied. If melted.PP-6 PLASTIC PARTS 4. When the filler material hardens. VQPP008 5. NOTE • Mix main filler material and hardener so that no bubbles are made. Paint Grind painted area and rough surface.

(Either wet sanding or dry sanding is all right. 11. Polypropylene primer Primer hardener Use the primer within 16 hours after it is mixed. heat it a little bit with a heater gun and melt it. 8.) 12. • Therefore. Degrease the painted surface. if used. VQPP011 9. Sand the damaged area with sandpaper using #180~#240 grit paper.) NOTE Air dry if possible. Mix polypropylene primer and hardener at a ratio depending on paint specifications. Air dry at 20 C(68 F) for about 8 hours. Apply polypropylene primer. (Since drying time varies according to the type of paint used.PLASTIC PARTS PP-7 7. Forced drying may create air bubbles on the top layer. 13. . will melt the primer. VQPP012 10. Solvent. or dry in 60 C(140 F) for about 2 hours. NOTE Use only water to clean after applying polypropylene primer. Spray polypropylene primer on the surface of the damaged area and the bumper. • If there is fuzz in the damaged area. use urethane primer only on urethane bumpers and polypropylene primer on polypropylene bumpers. and wipe the finished surface of the bumper quickly with a clean cloth. Use agent(TCE(Tri Chloro Ethane) degreasing material) to remove any grease or oil. NOTE • The surface will not be even if excessive force is applied during sanding. Lightly sand the sprayed area using a primer a sandpaper(#400~#600). follow paint manufacturers directions for drying times. NOTE • The painting method for the polypropylene bumper is the same used to paint the urethane bumper. The polypropylene surface should not be exposed.