CONTENTS GENERAL INFORMATION GENERAL GUIDELINES AND PRECAUTIONS... SRS AIRBAG a ELECTRONIC PARTS... CORROSION PROTECTION AND SEALING .. SIDE BODY PANELS. : WELDING. BODY CONSTRUCTION. BODY COMPONENTS os ZINC-GALVANIZED STEEL PANELS... HIGH-STRENGTH STEEL PANELS FRONT BODY SIDE BODY... FLOOR... ROOF. HOOD& FENDER... TAILGATE. DOOR. REPLACEMENT PARTS FRONTBODY. SIDEBODY. REAR BODY DOOR . BODY AND CHASSIS FRAME DIMENSIONS GENERAL... ee SIDEBODY.| INTERIOR UPPERBODY UNDER BODY... FRONT BODY. REARBODY, CHASSISFR, BODY PANEL REPAIR PROCEDURE RADIATOR SUPPORT PANEL. FENDER APRON PANEL(ASSEMBLY). FENDER APRON PANEL(PARTIAL} FRONT PILLAR... CENTERPILLAR SIDESILL (ASSEMBLY) SIDESILL (PARTIAL) QUARTERPANEL... REARFLOOR : FRONT AND REAR DOOR OUTER PANELS wens BODY SEALING LOCATIONS oon UPPER & SIDE BODY CORROSION PROTECTION ZINC-GALVANIZED STEEL PANELS... i ANTIVIBRATION PADS-LOCATION &SECTION.... ATTACHMENT OF ANTIVIBRATION PADS.. UNDER BODY COAT... SIDE BODY orn CAVITY WAX INJECTION UNDER BODY ANTI-CORROSION AGENTGENERAL INFORMATION «GENERAL INFORMATION - General guide lines and precautions et eS SS EE SE GENERAL GUIDE LINES AND PRECAUTIONS The Hyundai TERRACAN is a completely new vehicle design. During its development, close attention has been given to safety, stability, weight and corrosion protection. Typical of unit body design, the Hyundai TERRACAN is designed so that the front and rear compartments will absorb much of the collision energy so that the passengers are better protected. During collisions, these front and rear energy absorbing systems may be severely damaged. During repair, these damaged areas must be returned to their original strength and geometry. If this is not properly done, the vehicle will not provide the intended level of protection to its occupants in the event of another collision. ‘The repairs described in this manual were performed on TERRACAN body shells. in some instances special fixtures were welded in place to support the structure. During the repair of an actual vehicle, the interior would be fully disassembled and standard jack screws or portable braces may be used for temporary support. During the repair of an accident involved vehicle, the vehicle must first be returned to pre-impact dimensions prior to beginning the sectioning repair procedures. The extent of damage that must be repaired should then be evaluated to determine the appropriate repair procedures. This manual provides locations and procedures where structural sectioning may be employed. It is the responsibilty of the repair technician, based upon the extent of damage, to determine which location and procedure is suitable for the particular damaged vehicle. During the repair of a collision damaged automobile, it is impossible to fully duplicate the methods used in the factory during the vehicle manufacture. Therefore, auto body repair techniques have been developed to provide a repair that has strength properties equivalent to those of the original design and manufacture. Certain guidelines and precaution are noted as follows.GENERAL INFORMATION - SRS Airbag SRS AIRBAG SYSTEM COMPONENT Clock spring ‘ w~ SRSCM ie Sey Pretensioner seat belt easeoror recor envsan| The Hyundai TERRACAN is equipped with a Supplemental Restraint System (AIRBAG) to provide the vehicle's driver and/or the front passenger with additional protection than that offered by the seat-belt system alone, in case of a frontal or lateral impact of sufficient severity. ‘When handiing airbag components (removal, installation or inspection, etc.), always follow the directions given in the repair manual for the relevant model to prevent the occurrence of accidents and airbag matfunction. ‘Also take the following precautions when repairing the body: 1. Work must be started after approximately 30 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery. (The airbag system is equipped with a back-up power source so that if work is started within 30 seconds of disconnecting the negative (-) terminal cable of the battery, the airbag may be deployed.) When the negative() terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by the audio memory system. Then when work is finished, reset the audio system as before and adjust the clock. When using electric welding, first disconnect the SRSCM connectors under the lower crash pad center. Store the airbag module where the ambient temperature remains below 80°C (176°F), without high humidity and away from electrical noise. 4, WARNING/CAUTION labels are attached to the periphery of the airbag components. Refer to the TERRACAN SHOP MANUAL.GENERAL INFORMATION - Electronic parts 2 i tll SS SESS ELECTRONIC PARTS Vehicles today include a great many electronic parts and components, and these are in general very susceptible to adverse effects caused by over current, reverse current, electromagnetic waves, high temperature, high humility impacts, etc In pariicular such electronic components can be damaged if there is a large current flow during welding from the body side. Therefore, take the following precautions during body repair to prevent damage to the CONTROL MODULES (ECM, TOM, ABS CM, SRS CM, ete.) 41. Before removing and inspecting the electrical parts or before starting electric welding operations, disconnect the negative (-) terminal cable from the battery. 2. Do not expose the CONTROL MODULES to ambient temperatures above 80°C (176°F} NOTE: if it is possible the ambient temperatures may reach 80°C (176°F) or more, remove the CONTROL MODULES from the vehicle before starting work. 3. Be careful not to drop the CONTROL MODULES and not to apply physical shocks to them. CORROSION PROTECTION AND SEALING Proper corrosion protection and sealing is an important part of any repair. When reviewing these repair procedures, itis important to recognize the need for corrosion restoration to provide for long term strength of the repaired member. A two part epoxy primer was applied to the metal surfaces during the latter part of the repair. For closed sections, such as front and rear rails, rocker panels and pillars, the primer is applied without applying the metal conditioner and the conversion coating. These steps are omitted to insure that no rinse water is trapped in the closed sections. The primer application is followed by an application of an oil or wax based on tust proofing material. Alter the corrosion restoration process for the closed sections are completed, then the process can be applied to all exterior sections, For exterior surfaces, both metal conditioner and conversion coating treatments are applied to the exterior surface prior to application of the epoxy primer. The procedure in applying the corrosion restoration process. is important in order to insure that moisture, due to the water rinsing of the metal conditioner and conversion coating is not inadvertently trapped inside any closed section before the epoxy primer and rust proofing materials have been applied Appropriate seam sealers are then applied to all joints. Follow manufacturer's recommendations for the appropriate type of seam sealer to be used at each seam or joint. SIDE BODY PANELS The side body panel for TERRACAN is designed and stamped as single piece of sheet metal in factory as shown in the figure. While the entire side panel is available for service, the partial panels sectioned by several damaged areas are also available. Therefore when repairing side body, select and use the appropriate part — : Service part lineGENERAL INFORMATION - Welding gS rs Se Sa SE WELDING All repairs’ in this manual require the use of a Metal-Inert Gas (MIG) welder, Gas (oxyacetylene) welding must not be used. Both high strength steel and mild steel can be welded using the MIG welder. The CAR recommendations for welding should be followed. The shielding gas should be 75% Argon and 25% CO,, The recommended welding wire size is 0.23" and the wire should salisfy the American Welding Society Standard code AWSER70S-6. During the repair process, plug welds are used to duplicate original factory spot welds. All plug welds should be done with the MIG welder. An 8 mm (5/16") hole is placed in the top (welding side) sheet metal. You then begin welding along the edges and the spiral towards the center (see illustration). This is important so that weld penetration between the two metal pieces may take place along the circumference of the circle. Weld around edges first working in towards the center (Top wiew) PLUG WELDING, BNE ‘8mm or 5/16" dia. hole Illustration-Welding in collision Repair SAFETY FACTORS Disconnect the negative(-) battery cable before performing any work on the vehicle. Protect yourself by wearing goggles, earplugs, respirators, gloves, safety shoes, caps, etc. when working on a vehicle, Safely support the vehicle before any work is done. Block the front or rear wheels if the vehisle is not lifted off of the ground. Cap or remove the fuel tank when working on the rear section of the car. Insure proper ventilation of your working area. Some paint and sealant can generate toxic gases when heated. Use an air chisel or saw to remove damaged panels instead of a gas torch, Observe all local and national safety regulations when performing any work. Cover interior with heat-resistant cover to insure safety when welding. Take care when using gas or cutting torches so as not to burn body sealer or interior. Extinguish immediately if they should catch fire.BODY CONSTRUCTIONBODY CONSTRUCTION - Body components BODY COMPONENTS Body construction will sometimes differ depending on specifications and country of destination. Therefore, please keep in mind that the information contained herein is based on vehicles for general destination.BODY CONSTRUCTION - Body components ec rns SS 1. Radiator support panel 2. Bridge panel 3. Front end cross member 4. Front end lower reinforcement assembly 5, Radiator lower(A) bracket 6. Front end side reinforcement(LH/RH) 7. Fender apron panel(LH/RH) 8. Fender shield(A) reinforcement(LH/RH) 9. Cowl top reinforcement(LH/RH) 10, Fender shield(B) reinforcement(LH/RH) 11, Dash panel 12, Dash panel reinforcement 18, Cowl top outer panel 14, Cowl top inner panel 18. Cowl cross member assembly 16, Roof front inner rail 17. Map lamp bracket 18. Roof panel 19. Roof bow(A) 20. Roof bow(B) 21. Roof bow(C) 22, Roof bow(D) 23, Roof rear inner rail 24. °A" inner pillar(LH/RH) 25. Side outer panel(LH/RH) 26. °B" inner pillar(LH/RH) 27. Roof side inner rail(LH/RH) 28, Side inner panel(LH/RH) 29, Side outer extension(LH/RH) 30. Fuel filer door 31. Shift lever reinforcement 82. Backbone reinforcement 33. Front floor panel 34, Front seat cross member(LH/RH) 35. Front seat rear bracket(LH/RH) 36. Front floor No. 1 cross member 37. Body mounting No. 2 bracket(LH/RH) 38. Front floor No. 2 cross member ‘89. Body mounting No. 3 bracket(LH/RH) 40. Side sill inner panel(LH/RH) 41. Center floor panel 42, Rear floor panel 43, 2nd seat hinge rear bracket 44, Rear floor No. 1 cross member 45. Rear floor No. 2 cross member 46. Rear floor No. 3 cross member 47. Rear floor side member(LH/RH) 48. Rear floor No. 4 cross member 49, Body mounting No. 5 bracket(LH/RH) 50. Rear end cross member 51. Rear floor side panel(LH/RH) 52. Rear floor side reinforcement(LH/RH) 53. Front door outer panel(LH/RH) 54. Front door inner panel(LH/RH) 55. Rear door outer panel(LH/RH) 56. Rear door inner panel(LH/RH) 57. Tail gate outer panel 58. Tail gate inner panel 59. Hood outer panel 60. Hood inner panel 13BODY CONSTRUCTION - Zinc-galvanized steel panels ZINC-GALVANIZED STEEL PANELS Because galvanized steel panel has excellent resistance, it is used in areas which have a high possibility of painting deficiency below. 4BODY CONSTRUCTION - Zinc-galvanized steel panels 1. Bridge panel 2. Front end cross member 8. Front end lower reinforcement assembly 4, Dash panel 5. Dash panel reinforcement 6. Cowl top outer panel 7. Cowl top inner panel 8, Side outer panel(LH/RH) 9. Side inner panel(LH/RH) 10. Side outer extension(LH/RH) 11. Fuel filler door 12. Shift lever reinforcement 13, Backbone reinforcement 14. Front floor panel 15. Front floor No. 1 cross member(LH/RH) 16. Body mounting No. 2 bracket(LH/RH) 17. Front floor No. 2 cross member 18. Body mounting No. 3 bracket(LH/RH) 19. Side sill inner panel(LH/RH) 20. Center floor panel 21. 22. 23. 24, 25. 26. 27. 28. 29, 30. 31. 32. 33. 34, 36. 36. 37. 15 Rear floor panel 2nd seat hinge rear bracket Rear floor No. 1 cross member Rear floor No. 2 cross member Rear floor No. 3 cross member Rear floor side member(LH/RH) Rear floor No. 4 cross member Body mounting No. 5 bracket(LH/RH) Rear floor side panel(LH/RH) Front door outer panel(LH/RH) Front door inner panel(LH/RH) Rear door outer panel(LH/RH) Rear door inner panel(LH/RH) Tail gate outer panel Tail gate inner panel Hood outer panel Hood inner panelBODY CONSTRUCTION - High-strength steel panels HIGH STRENGTH STEEL PANELS Because High strength steel panel has excellent resistance, it is used in areas which have a high possibility of painting deficiency below.BODY CONSTRUCTION - High-strength steel panels 1. Cow! top reinforcement(LH/RH) . Body mounting No. 2 bracket(LH/RH) Rear floor No. 4 cross member . Rear end cross member . Rear door outer panel(LH/RH) 2 3. 4. 5. Front door outer panel(LH/RH) 6 7. Tail gate outer panel 8 Hood outer panel 7BODY CONSTRUCTION - Front body ENGINE ROOM BRACKET No. | PART NAME Hood latch bracket Hood latch stay Fender mounting bracket(LH) Fender mounting bracket(FH) Bumper mounting bracket(A) Bumper mounting bracket(B) ‘Side mounting bracket(LH) ‘Side mounting bracket(RH) 18BODY CONSTRUCTION - Front body RADIATOR SUPPORT COMPLETE MEMBER ASSEMBLY No. | PART NAME No. | PART NAME 1 | Radiator support panel 8 — | Body mounting No. 1 (A) reinforcement(LH) 2 | Front end side reinforcement(LH) 9 | Body mounting No. 1 bracket(LH/RH) 3 | Front end side reinforcement(RH) 40 | Body mounting No. 1 (A) reinforcement(RH) 4 | Bridge panel 11 _ | Front end lower reinforcement 5 | Radiator mounting reinforcement 12 _ | Radiator lower bracket(B) 6 | Front end cross member 13 | Airconditioning condenser bracket 7 | Radiator lower bracket(A) 14 | Hor mounting reinforcement 19BODY CONSTRUCTION - Front body RADIATOR SUPPORT COMPLETE MEMBER ASSEMBLY Radiator support pane! SECTION A-A’ Front end side reinforeement(RH) Radiator suppor panel assembly | Frontend lower Tenforement assembly | a. asconnly SECTION B-B sspnce Bridge panel assembly SECTION C-C’ ‘Radiator support panel Frontend cross member e assembly assembly f =e reinforcement SECTION D-D" servos 20BODY CONSTRUCTION - Front body FENDER APRON COMPLETE PANEL Fender apron panel(RH) SECTION A-A Fender apron panel(RH) Battory tray bracket assgmbly Fender shisld(8) einforcament(AH) SECTION B-B’ 22BODY CONSTRUCTION - Front body DASH PANEL No. PART NAME No. PART NAME Dash pane! Dash panel reinforcement ‘Accel pedal bracket ‘Accel pedal bracket Clutch stopper bracket Dash panel deadening (A) sheet Dash panel deadening (B) sheet Dash panel deadening (C) sheet Clutch house bracket Heat protector front bracket 4 12 13 Mud guard bracket Oil chamber bracket Shift lock cable bracket 23BODY CONSTRUCTION - Front body DASH PANEL Dash pane! } z Dash pane eadenng) sheet oS deadening(©) sheet, ash wintrooment Dash pel Dash enforcement SECTION A. a SECTION B-B' sie : panel Dash pant x Dash panel C Saaz) sheet gus bracket Dash gusset(LH/RH) | ¥ SECTION C-C’ ae SECTION D-D" pentet 24BODY CONSTRUCTION - Front body COWL PANEL No. | PART NAME No. 1 | Cowl top outer panel 12 | Weld bott 2 | Wiper motor reinforcement 13 | Heater bracket 3 | Wiper pivot center reinforcement 14 | Blower(A) bracket 4 | Hood hinge reinforcement(LH) 15 | Blower (B) bracket 5 | Hood hinge reinforcement(RH) 16 | Pedal support upper bracket 6 | Intercooler(A) bracket 17 | Pedal support lower bracket 7 | Intercooler(B) bracket 18 | Cowl top extension(LH) 8 | Cow! top inner panel 19 | Cowl top extension(RH) 9 | Air quide bracket 20 | Cowl top reinforcement(LH) 10 | Crash pad upper center bracket 21 | Cowl top reinforcement(RH) 11 | Crash pad upper side bracket 22 | Cow! bulkhead 25BODY CONSTRUCTION - Front body COWL PANEL Cow top outer panel y SECTION A-A’ \ AK \ 7 Seo Cowl top outer panel (Con top inner panol SECTION B-B" cone Cowl top outer pan SECTION C-C’ 7 tess a {—~ tp extesion 1 ) Cou topinnerpanel—f 26BODY CONSTRUCTION - Side body SIDE STRUCTURE 27BODY CONSTRUCTION - Side body a’ SIDE STRUCTURE 1, Side outer panel(LH/RH) 2. Front fender bracket(A) 3, Front fender bracket(B) 4, Front door checker reinforcement 5. "A" pillar lower reinforcement(LH/RH) 6. “A” inner upper reinforcement(LH/RH) 7. *A" inner upper pillar(LH/RH) 8. "A" inner lower pillar(LH/RH) 9. Electronic controlled unit bracket 10. Deck crossmember upper bracket(LH/RH) 11, Deck crossmember lower bracket(LH/RH) 12, "B" inner pillar(LH/RH) 13. 1st seat belt lower reinforcement 14. "B" pillar reinforcement(LH/RH) 15. Side sill rear reinforcement(LH/RH) 16, Front seat belt upper reinforcement(LH/RH) 17. Front door striker retainer 18. Plate 19, Side inner panel(LH/RH) 20. Rear wheel house front panel(LH/RH) 21, Rear whee! house inner panel(LH/RH) 22. Wheel house inner front extension(LH/RH) 23, 24, 25, 26, 27, 28, 29, 30, 31. 32. 33, 34. 36. 36. 37. 38, 39, 40, 4 42, 43, 44, 28 Fuel filler protector mounting bracket(A) . Wheel house inner rear extension(LH/RH) 2nd seat belt lower front reinforcement(LH/RH) Fuel filler protector mounting bracket(B) *C* pillar reinforcement(LH/RH) Roof rail side rear reinforcement(LH/RH) 2nd seat belt lower rear reinforcement Net mounting bracket "D* pillar upper reinforcement(LH/RH) "D" pillar lower reinforcement(LH/RH) Spare tire hinge upper reinforcement Spare tire hinge lower reinforcement . Side outer upper extension(LH/RH) Side outer lower extension(LH/RH) Gas spring reinforcement . Damper reinforcement . "D" pillar lower plate(LH/RH) Fuel filler neck bracket Retainer Plate Striker reinforcement Roof side inner railBODY CONSTRUCTION - Side body SIDE OUTER PANEL "A" PILLAR a eceeeeeeee Side outer pane! “air ppt st tare connor weedeat when Gor ther +4 nop par SECTION A-A' como SECTION B-B soprwe ‘Side outer panel “A° pillar lower Side outer panel cpecorr + tar ower "Snecomen a er at voor SECTION C-C" sos SECTION D-D' sore 29BODY CONSTRUCTION - Side body SIDE OUTER PANEL : "B" PILLAR Side outer panel "8" pllar reinforcement . ‘Side outer panel Sida outer panel "5" pillar reinforcement inner pilar SECTION C-C' soni] “B" pila reinfoccement Sido outer pane! “BP inner pillar SECTION D-D' sors 30BODY CONSTRUCTION - Side body SIDE OUTER PANEL : "C" & "D" PILLAR Side inage panel eae Side cuter panel Root sidoTaner ~_ ral Side inner pane! SECTION A-AY sori SECTION B-B' ae Side outer pape Sealant ice outor a je Rear side nner pane side innar panel SECTION C-C’ ‘8061125 SECTION D-D' sopiize 31BODY CONSTRUCTION - Side body SIDE OUTER PANEL : "CO" & PILLAR a Side outer panel “@" pila tentgroament x Sido inner panel SECTION E-E" soeuz SECTION F-F" soos je outer panel 1) ‘Side inner panel \ | ‘Side outer panel Sealant Side outer = SECTION G-<' a SECTION H-H' sores 32BODY CONSTRUCTION - Side body en SS SS ESSE SIDE OUTER PANEL : SIDE SILL ‘Side outer panel Front floor pana S)de outer panel Side sit inter panel “3° pila renforce- SECTION G-G' sonst SECTION H-H' sorties 33BODY CONSTRUCTION - Front floor FRONT FLOOR COMPLETE 34BODY CONSTRUCTION - Front floor en SS SSS SSS FRONT FLOOR COMPLETE 1. Front floor panel 2. Backbone reinforcement 3, Shift lever reinforcement 4, Shift lever reinforcement 5. Automatic lever mounting bracket 6. Shift lever extension(LH) 7. Shift lever extension(RH) 8. Front seat crossmember(LH) 9. Front seat crossmember(RH) 10. Front seat rear bracket 11. Front floor No. 1 crossmember(LH/RH) 12. Body mounting No. 2 bracket(LH/RH) 13. Body mounting No. 2 reinforcement(LH/RH) 14. Front floor No. 2 crossmember 18. Body mounting No. 3 bracket(LH/RH) 16. Body mounting No. 3 reinforcement(LH/RH) 7. 18. 19. 20. at 22, 23, 24, 25, 26, 27. 28. 29, 30. 31. 32. 35 Center support bracket Side sill inner panel(LH) Splash shield bracket Side sill nner panel(RH) - Side step bracket Side sil inner reinforcement(LH) . Side sill inner reinforcement(RH) Center floor panel 2nd seat hinge front bracket Center floor reinforcement Body mounting No. 4 bracket Body mounting No. 4 reinforcement Automatic transmission cable bracket Torque on demand electronic control unit bracket Parking brake cable bracket Parking brake cable No. 1 bracketBODY CONSTRUCTION - Rear floor REAR FLOOR COMPLETE 36BODY CONSTRUCTION - Rear floor REAR FLOOR COMPLETE 1. Rear floor panel 2, Rear floor No. 1 cross member 3. 2nd seat striker bracket 4, Rear floor No. 2 cross member 5, Rear floor No. 3 cross member 6. Rear floor side member(LH) 7. Rear floor side member(RH) 8. 2nd seat hinge bracket 9. Luggage hook No. 1 bracket 10, 2nd seat hinge rear bracket 11. Tail gate striker bracket 12. Rear end outer cross member 13. Rear end lower cross member 14, Spare tire rod upper guide 18. Spare tire rod lower guide 16. 17. 18. 19. 20. 21 22. 23. 24, 25. 26. 27. 28. 29, 30, 37 Rear end inner cross member Rear end inner extension(LH) Rear end inner extension(RH) Luggage hook No. 2 bracket Rear floor No. 4 cross member Body mounting No. 5 bracket(LH) Body mounting No. 5 bracket(RH) Body mounting No. 5 reinforcement Rear floor side panel(LH) Rear floor side panel(RH) Rear floor side reinforcement(LH) Rear floor side reinforcement(RH) Oil jack support Spare tire mounting bracket Spare tire mounting reinforcementBODY CONSTRUCTION - Rear floor st ESS SSS SSSA REAR FLOOR PANEL Se oie eee ~~ NY aor pane SK eee ant set re fear backot \ SECTIONA-A’ op SECTIONE-S' — oo ee momber ) = for tor perl oa fh aor se member ~ member Far end complete panel SECTIONC-C* AFP C8 SECTION D-D' BrPri04 38BODY CONSTRUCTION - Roof ROOF PANEL No. | PARTNAME No. | PARTNAME 1 | Roofpanel 11. | Tailgatehinge reinforcement(RH) 2 | Roofbow(A) 12 | Roofrearouter rail 3 | Roofbow(B) 13 | Sunroof reinforcement ring 4 | Roofbow(C) 14 | Sunroof reinforcementextension(LH) 5 | Roofbow(D) 18 | Sunroofreinforcementextension(RH) 6 | Roof rack mounting rear bracket 16 | Roofbow(SUN ROOF) 7 | Roof front inner rail 17 | Roomlamp bracket & | Map lamp bracket 9 | Roof rearinner rail 40 | Tailgate hinge reinforcement(LH)BODY CONSTRUCTION - Hood & Fender HOOD PANEL & FENDER PANEL No. | PARTNAME 1 Hood panel assembly 2 Hood hinge assembly 3 Fenderpanelassembly 40BODY CONSTRUCTION - Tail gate TAIL GATE PANEL ail gate outer panel SECTION A-A' To1101 SECTIONB-B' sere CA | _—— Tat on trp Seatant(o16) Tall gate outer panel \ P | 1 a — SECTIONC-C' e100 | SECTION D-D" TaN104 aBODY CONSTRUCTION - Door TSE SE FRONT DOOR PANEL Front door side impact bar assambly Front door hinge reinforcement Front door infer pane! Front doer innee wT ~y SECTIONC-C' Front door inner } Front door outer panel ad | ae | SECTIONA-A' coer SECTIONB-B' sone Front door side impact bar \ asambly Front door inner et I SECTIOND-D' 42BODY CONSTRUCTION - Door REAR DOOR PANEL Rear door outer pane Fear door window Far dor inner sash assembly Fear door side impact ear door auter bar assembly panel Rear door inner panel Rear door hinge I reinforcement panel SECTIONA-A’ ine SECTIONB-B' sore Rear door fixed glass bracket Fear door outer panel Re ee Fear door latch reinforcement Fear door joner panel Fear door bett outer reinforcement } en nel Rear door belt 3 inner reinorce- ment SECTIONC-C’ ores SECTIOND-D' foal 43REPLACEMENT PARTSREPLACEMENT PARTS - Front body es Ro REST STS REPLACEMENT PARTS ‘The following section ilustrates replacement parts used in the repairs described in this manual. It is important that only Hyundai replacement parts be used in making these repairs to ensure the repairs are made with the highest possible standards for fi, safety and corrosion protection. For a more complete listing of service parts, refer to an authorized Hyundai dealership. FRONT BODY PART NAME, RADIATOR SUPPORT MEMBER ASSEMBLY FENDER APRON PANEL COMPLETE, LH/RH COWL TOP REINFORCEMENT, LH/RH COWL COMPLETE PANEL DASH PANEL COMPLETE COWL CROSS MEMBER ASSEMBLY amooo> 46REPLACEMENT PARTS - Side body SIDE BODY ne PART NAME e-ro7moom> FRONT PILLAR OUTER PANEL ASSEMBLY, "A" PILLAR LOWER REINFORCEMENT, "A" INNER PILLAR ASSEMBLY, CENTER PILLAR OUTER PANEL ASSEMBLY, PILLAR REINFORCEMENT ASSEMBLY, INNER PILLAR ASSEMBLY, ROOF SIDE INNER RAIL SIDE SILL OUTER PANEL ASSEMBLY, QUARTER OUTER PANEL ASSEMBLY, SIDE OUTER EXTENSION ASSEMBLY, LHRH LHRH LHRH LHRH LHRH LHRH LH/RH LH/RH LH/RH LH/RHREPLACEMENT PARTS - Rear body REAR BODY PART NAME —zommooo> REAR FLOOR PANEL REAR FLOOR SIDE MEMBER ASSEMBLY, LHIRH REAR FLOOR(A) CROSS MEMBER ASSEMBLY REAR FLOOR(8) CROSS MEMBER ASSEMBLY REAR FLOOR(C) CROSS MEMBER ASSEMBLY 2ND SEAT HINGE REAR BRACKET ASSEMBLY 2ND SEAT HINGE BRACKET ASSEMBLY LUGGAGE HOOK BRACKET ASSEMBLY REAR END COMPLETE CROSS MEMBER ASSEMBLYREPLACEMENT PARTS - Door ee ec DOOR PART NAME ‘A | FRONT DOOR PANEL ASSEMBLY, LH/RH B | FRONTDOOR OUTER PANEL, — LH/RH | FRONT DOOR HINGE ASSEMBLY, LH/RH D | REAR DOOR PANEL ASSEMBLY, — LH/RH E | REAR DOOR OUTER PANEL, LH/RH F | REAR DOOR HINGE ASSEMBLY, — LH/RH 49BODY AND CHASSIS FRAME DIMENSIONSGENERAL GENERAL 1. Basically, all measurements in this manual are taken with @ tracking gauge. 2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending. 3, For measuring dimensions, both projected dimension and ac- tual-measurement dimension are used in this manual. MEASUREMENT METHOD PROJECTED DIMENSIONS 4. These are the dimensions measured when the measurement points are projected into the reference plane, and are the reference dimensions used for body alterations. 2. Ifthe length of the tracking gauge probes are adjustable, make the measurement by lengthening one probe by the amount ‘equivalent to the difference in height of the two surfaces. ACTUAL-MEASUREMENT DIMENSIONS 4. These dimensions indicate the actual linear distance between measurement points, and are the reference dimensions for use ifa tracking gauge is used for measurement. 2. Measure by first adjusting both probes to the same length (Axa). NOTE Check the probes and gauge itself to make sure ther free play. MEASUREMENT POINT 4. Measurements should be taken at the hole center. 52 Hale canterBODY DIMENSIONS - Side body SIDE BODY * These dimensions indicated in this figure are actual-measurement dimensions. T_of “These dimensions indicated in this figure are projected dimensions. Point symbol ap | ac | ec | pp | pe | cp | ce | DE Length (mm) sco_| 40 | 413 | 1040 | 1130 | 1112 | 1034 | 440 Point symbol Of 0a er eo eo rn one Length (mm) eet | e739 | 1175 | 935 | soe | ove | ssa | 09 Point symbol et | wi | vz | Kz | oz | mz | oz | a Length (mm) set | 438 | 128 | 670 | -a7 | -28 | 162 | 1220 Point symbol KL] om | LN | Lo! ee Length (mm) 95 965 654 | 2805 53BODY DIMENSIONS - Side body Wiring earth mounting Front door hinge upper mount- Front door hinge lower mount- hole(26.6) ing hole(@11} ing hole(@11) = 1 D y /|| eS ) I ff =Z7 ing hole(@ 11) ing hole(2 11) G ] I) H l f/\\« —— Lo4}} \\ ears | JE [——¥ Rear door switch mounting Quarter glass mounting hole Quarter glass mounting hole hole(C1 9.2 x 9.2) (5 x 20 slot) (5 x 20 slot) L Body mounting No.1 hole(214) Hood hinge mounting hole Body mounting No. 2 hole (210) (14) 54BODY DIMENSIONS - Side body Body mounting No. 3 hole Body mounting No. 4 hole Body mounting No. 5 hole (214) (ora) (214) 55BODY DIMENSIONS - Interior INTERIOR * These dimensions indicated in this figure are actual-measurement dimensions. Point symbol aa | ee [ce | op | ee | FP | Ga | HH Length (mm) 1523 | 1260 | 1470 | 1563 | 1316 | 1114 | 1565 | 1156 Point symbol ee [ow [ae | kee | oe | oe Length (mm) y2ea | 1120 | 1476 | 1990 | 1112 | 1860 56BODY DIMENSIONS - Interior Let / OT ee Front door checker mounting Front seat mounting hole(211) Front seat belt lower mounting hole(@11) hole(211) D I\ / 3 | i ! | | / UH Front door striker lower mount- Front seat belt upper mounting Rear seat belt lower mounting ing hole(@ 11) hole(2 14.5) hole(o14) G | Wi Rear door striker lower mount- Trim mounting hole Wiring mounting hole(26.6) ing hole(a11) (84x84) : ‘— rt / an i En Rear(2nd) assist grip mounting Rear seat belt upper mounting Rear assist grip mounting hhole(26.6) hole(215) hole(2e) 87BODY DIMENSIONS - Upper body UPPER BODY = = ii * These dimensions indicated in this figure are actual-measurement dimensions. Point symbol Aa | as | BB | Bc | cc | cp | po | De Length (mm) i410 | 1446 | 1435 | 1480 | 1456 | 1462 | 1360 | 1505 Point symbol ee | er | ea | pa | oe | pc | AD | EF Length (mm) 1238 | 2817 | 1177 | 1692 | 1969 | 1462 | 973 | 2174 58BODY DIMENSIONS - Upper body Fender mounting hole(26.6) Fender mounting hole(Z6.6) Fender mounting hole(Z6.6) Uj \ erene Comer of side outer panel Front edge of side outer panel 59 Rear edge of side outer panelBODY DIMENSIONS - Under body sR te SETHE I UNDER BODY * These dimensions indicated in this figure are actual-measurement dimensions. Be | cc | co | po | ve ei0 | 1318 | 1417 | 1290 | 1805 Point symbol AA | AB! Length (mm) 884 1635 Point symbol EE EF F-D AB B-C BE cD D-E Length (mm) i224 | 626 | 1563 | 1248 | 966 | sora | 555 | 1205 60BODY DIMENSIONS - Under body B SEES SW Sow Body mounting No. 2 hole (214) (214) Body mounting No. 3 hole (or E EF oe we ARS EO SA ee : VA c VE EF | Rasy Za Body mounting No. 4 hole Body mounting No. 5 hole Location hole(216) (@14) (B14) 61BODY DIMENSIONS - Front body a FRONT BODY * These dimensions indicated in this figure are actual-measurement dimensions. Point symbol aa | ee | cc | pp | oe | or | oe | Be Length (mm) ixes_| 1520 | 700 | 1410 | 1446 | 1545 | 1692 | 1495 Point symbol FF | Fo | GG Length (mm) 1456 | 1462 | 1960 62BODY DIMENSIONS - Front body Head lamp mounting hole (26.6) 3 «ase S| Fender mounting hole(26.6) Hood hinge mounting hole (@10) 63 Fender mounting hole(6.6)REAR BODY BODY DIMENSIONS - Rear body * These dimensions indicated in this figure are actual-measurement dimensions. {_Point symbol ac | AD | AE Be | cc | co | oo Length (mm) | 775 | 796 | 883 1312 | 1500 | 1390 | 1240 Point symbol Fe | &D | EF Lar | ar [Length (mm) 1335 | 1204 | 1175 | 830 | 1119 | 1193BODY DIMENSIONS - Rear body Tall gate striker mounting hole ear bumper mounting hole Rear combination lamp mount (29) (26.6) ng hole(210) D E / ] F Iw.) S Hi} 0) \ le {It { Ye \ (CO N\\\ sows (le Lamp mounting hole(26.6) Tail gate upper hinge mounting Tail gate hinge mounting hole (28) hole(21) 65CHASSIS FRAME DIMENSION - 2.5 Engine, 2 wheel drive saat SE SSS SES 25 ENGINE, 2 WHEEL DRIVE(ACTUAL DIMENSION) 7 Bret SS ee 7| ol Pe 2 i DO NP 3 : | Bo 21% fal * These dimensions indicated in this figure are actual-measurement dimensions. | Pointsymbol | 1 | 2 | 3 | 4 | 5 | 6 | 7 | @ | 9 | 10 Length (mm) | 710 | 807 | 998 | 152 | 24 | 1008 | 464 | 1249 | 906 | 73 Pointsymbol_| 11 | 12 | 13 | 14 | 15 | 16 | 17 | 18 | 19 | 20_ Length (mm) | 1348 | 822 | 526 | 1029 | 1260 | 1610 | 1984 | 966 | 1318 | 1417 Point symbol ete ee eee Length (mm) | 555 | 1104 | 1290 | 984 | 1144 | 1210 | 1804 | 1294 | 615 | 480 Point symbol | 31 | 32 | 33 | 34 | 35 | 36 | 37 | 38 | 39 | 40 Length (mm) | 757 | 1325 | 943 | 7e2 | 1303 | 757 | 1167 | 1286 | 725 | 1224 Point symbol | 41 | 42 Length(mm) | 158 _| 1056 I 66CHASSIS FRAME DIMENSION - 2.5 Engine, 2 wheel drive 2.5 ENGINE, 2 WHEEL DRIVE(PROJECTED DIMENSION) * These dimensions indicated in this figure are projected dimensions. Pointsymbol_ | 1 | 2 | 3 | 4 | 5 | 6 | 7 | @ | 9 | 10 [Length (mm) | 710 | 807 | aaa | 1005 | 906 | 1326 | 1021 | 526 | 1260 | 1610 |__ Point symbol 1 © Loe eee ee [Length (mm) | 318 | 1417 | 1290 | 963 | 615 | 1131 | 782 | 1202 | 757 | 1303 _ Point symbol | 21 | 22 | 23 | 24 | 25 | 26 | 27 | 28 | 29 | 30 Length (mm) 1224 | 1147 | 1056 | 141 | 196 | 110 | 141 | 103 | 36 | 152 Point symbol | 31 | 32 | 33 | 34 | 35 | a6 | 37 | 38 | 30 | 40 Length(mm) | 21 | 155 9 4 181 | 92 | 139 | 92 | 153 | 105 Point symbol | 41 | 42 | 43 | 44 | 45 | 46 | 47 | 48 | 49 | 50 Length (mm) | 275 | 623 | 973 | 1230 | 1498 | 1623 | 690 | 456 | 98 | 245 Point symbol | 51 | 52 | 53 | 54 | 55 | 56 Length(mm) | 455 | 631 | 658 | 714 | 1286 | 1417 67CHASSIS FRAME DIMENSION - 2.5 Engine, 4 wheel drive stesso SEES SES ha EES 2.5 ENGINE, 4 WHEEL DRIVE(ACTUAL DIMENSION) * These dimensions indicated inthis figure are actual-measurement dimensions. 4000 Point symbol | 1 | 2 | 3 | 4] 5 | 6 | 7 | 8 | ® | 10 Length (mm) | 710 | 07 | 703 | 998 | 152 | esa | 722 | 1008 | 464 | 1249 | Point symbol_| 11 | 12 | 13 | 14 | 15 | 16 | 17 | 18 | 19 | 20 Length (mm) | 430 | 721 | 906 | 773 | 1348 | 822 | 526 | 1029 | 1260 | 1610 Point symbol_| 21 | 22 | 23 | 24 | 25 | 26 | 27 | 28 | 29 | 30 Length (mm) | 1964 | 966 | 1918 | 1417 | 855 | 1104 | 1290 | 964 | 1144 | 4210 Point symbol | 31 | 32 | 33 | 34 | 35 | 96 | 37 | 38 | 39 | 40 Length (mm) | 1804 | 1204 | 615 | 400 | 757 | 1425 | 043 | 7@2 | 1903 | 767 | | Point symbot | 41 | 42 | 43 | 44 | 45 | 46 Length (mm) | 1187 | 1286 | 725 | 1224 | 158 | 1056 68CHASSIS FRAME DIMENSION - 2.5 Engine, 4 wheel drive 2.5 ENGINE, 4 WHEEL DRIVE(PROJECTED DIMENSION) Point oymbol eat |e) aoe) 0 io [em mara) ema|nre Length (mm) | 710 | 807 | sea | 693 | 438 | 698 | 906 | 1926 | 1021 Pointsymbol_| 11 | 12 | 19 | 14 | 15 | 16 | 17 | t@ | 19 | 20 Length (mm) | 1260 | 1610 | 31a | 1417 | 1290 | oes | 615 | 1191 | 7e2 | 1202 Pointsymbol_ | 21 | 22 | 23 | 24 | 25 | 26 | 27 | 28 | 29 | 30 Length (mm) | 757 | 1303 | 1224 | 1147 | 1056 [ 141 | 136 | 110 | 141 | 103 Point symbol_| 31 | 32 | 33 | 34 | 35 | 96 | a7 | 38 | 39 | 40 Length(mm) | 26 | 182 | 21 | 185 | 9 | 4 | 181 | 62 | 199 | 92 Pointsymbo! | 41 | 42 | 43 | 44 | 45 | 46 | 47 | 48 | 49 | 50 Length(mm) | 153 | 105 | 275 | 823 | 973 | 1230 | 1498 | 1623 | 690 | 456 Point symbol | 51 | 52 | 53 | 54 | 55 | 56 | 57 | 58 Length (mm) | 98 | 245 | 455 | 631 | 658 | 714 | 1286 | 1411 69CHASSIS FRAME DIMENSION - 3.5 Engine, 2 wheel drive 3.5 ENGINE, 2 WHEEL DRIVE(ACTUAL DIMENSION) z z = ra ; B a 3 1 RO c= § 0 i C4 “=e | hy 5 . lal ¢ NEO ‘ | . ean | a - .S * These dimensions indicated in this figure are actual-measurement dimensions. Pointeymbol | 1 [2] 3]/4]s5][s8]7] 8] 9 | 1 Length (mm) | 710 | 807 | 998 | 152 | @84 | too | 464 | 1249 | 906 | 756 Point symbol | 11 | 12 | 138 | 14 | 15 | 16 | 17 | 18 | 19 | 20, Length (mm) | 1348 | 22 | 526 | 1056 | 1260 | 1610 | 1984 | 966 | 136 | 1417 Point symbol_| 21 | 22 | 23 | 24 | 25 | 26 | 27 | 28 | 29 | 30 Length (mm) | 565 | 1104 | 1200 | 984 | 1144 | 1210 | ta0 | 1294 | 615 | 480 Pointsymbo! | 31 | 92 | 93 | 34 | 35 | 36 | 37 | 98 | 39 | 40 Length (mm) | 757 | 1825 | 943 | 762 | 1200 | 767 | 1167 | 1286 | 725 | 1224 Point symbol_| 41 | 42 | | Length (mm) | 158 | 1056 | fF 70CHASSIS FRAME DIMENSION - 3.5 Engine, 2 wheel drive 3.5 ENGINE, 2 WHEEL DRIVE(PROJECTED DIMENSION) Pointsymbol_ | 1 | 2 | 3 | 4] 5 | 6 | 7 | 8 | 9 | 10 Length (mm) | 710 | a07 | e84 | 1005 | 906 | 1326 | 1048 | 526 | 1260 | 1610 Point symbol! | 11 | 12 | 13 | 14 | 15 | 16 | 17 18 | 19 | 20 Length (mm) 1318 | 1417 | 1290 | 983 | 615 | 1131 | 782 | 1202 | 757 | 1303 Pointsymbol_| 21 | 22 | 23 | 24 | 25 | 26 | 27 | 28 | 29 | 30 [Length (mm) | 1204 | 1147 | 1056 | 141 | 136 | 110 | 141 | 109 152 Point symbol | 31 | 32 | 33 | 34 | 35 | 36 | 37 | 38 40 Length(mm) | 21 | 165 | 9 | 4 | 181 | 92 | 199 | 92 105 Point symbot_ | 41 | 42 | 43 | 44 | 45 | 46 | 47 | 48 | 49 | 50 Length (mm) | 260 | 808 | 968 | 1215 | 1483 | 1608 | 705 | 456 | 98 | 245 Point symbol | 51 | 62 | 53 | 54 | 55 | 56 Length (mm) | 455 | 631 | 658 | 714 | 1286 | 1411 a nCHASSIS FRAME DIMENSION - 3.5 Engine, 4 wheel drive 2s pe SESS SS SS SEE 3.5 ENGINE, 4 WHEEL DRIVE(ACTUAL DIMENSION) "These dimensions indicated in this figure are actual-measurement dimensions. Pointeymbol | 1 [2] 3 ]4)]5]6]7] 8 |e | 10 Length(mm) | 710 | 807 | 703 | 998 | 162 | 684 | 722 | 1008 | 464 | 1249 Pointsymbol_| 11 | 12 | 13 | 14 | 15 | 16 | 17 | 18 | 19 | 20 Length (mm) | 439 | 721 | 906 | 756 | 1348 | 222 | 526 | 1056 | 1260 | 1610 | Point symbol | 21 | 22 | 23 | 24 | 25 | 26 | 27 | 28 | 29 | 30 Length(mm) | 1984 | 966 | 1318 | 1417 | 555 | 1104 | 1200 | 984 | 1144 | 1210 Point symbol | 31 | 92 | 93 | 34 | 38 | a6 | 37 | 28 | 39 | 40 Length (mm) | 1804 | 1294 | 615 | 480 | 757 | 1925 | 943 | 7e2 | 1909 | 757 Point symbol | 41 | 42 | 43 | 44 | 45 | 46 Length (mm) | 1167 | 1286 | 725 | 1224 | 158 | 1056 | 72CHASSIS FRAME DIMENSION - 3.5 Engine, 4 wheel drive 3.5 ENGINE, 4 WHEEL DRIVE(PROJECTED DIMENSION) Point symbol Length (mm) vio | eo7 | 064 | 69a | 438 | 698 | 906 | 1326 | 1048 | 526 Pointsymbol_ | 11 | 12 | 13 | 14 | 15 | 16 | 17 | 18 | 19 | 20 Length(mm) | 1260 | 1610 | 1318 | 1417 | 1290 | 983 | 615 | 1131 | 782 | 1202 Pointsymbol_| 21 | 22 | 23 | 24 | 25 | 26 | 27 | 28 | 29 | 30 Length (mm) | 787 | 1000 | 1224 | 1147 | 1056 | 141 | 196 | 110 | tat | 109 Point symbol_| 31 | 92 | 33 | 34 | 35 | 36 | 37 | 38 | 39 | 40 __Length (mm) ae [2] 21 | 5] 9 4 [ta | 92 | 139 | 92 Pointsymbol_| 41 | 42 | 43 | 44 | 45 | 46 | 47 | 48 | 49 | 50 | Length (mm) | 153 | 105 | 260 | 808 | 958 | 1215 | 1483 | 1608 | 705 | 456 Pointsymbol | 51 | 52 | 53 | 54 | 55 | 66 | 57 | 58 ene Length(mm) | 98 | 245 | 455 | 631 | 658 | 714 | 1286 | 1411 73CHASSIS FRAME DIMENSION - 2.9 Engine, 2 wheel drive AE 2.9 ENGINE, 2 WHEEL DRIVE(ACTUAL DIMENSION) These dimensions indicated in ths figure are actual-measurement dimensions. Point symbol 1 2 3 Cee ee eee Length(mm) | 710 | 807 | 998 | 152 | #84 | 1008 | 464 | 1249 | e06 | 745 Pointsymbol_ | 11 | 12 | 13 | 14 | 18 | 16 | 7 | 16 [ 19 | 20 [7 Length (mm) | 1848 022 | 826 | 1079 | 1260 | 1610 | 1984 | 966 | 1918 | 1417 Point symbol | 21 | 22 | 23 | 24 | 25 | 26 | 27 | 28 | 29 | 30 Length (mm) | 885 | 1104 | 1200 | 984 | 1144 | 1210 | 1804 | 1294 | Gis | 480 Pointaymbo! | 31 | 32 | 33 | 94 | 95 | 36 | a7 | 38 | 39 | 40 Length (mm) | 757 | 1325 | 043 | 7e2 | 1903 | 757 | 1187 | 1286 | 725 | 1224 Point symbol | 41 | 42 Length (mm) | 158 | 1056 I 74CHASSIS FRAME DIMENSION - 2.9 Engine, 2 wheel drive SE a SS SESE ESE 2.9 ENGINE, 2 WHEEL DRIVE(PROJECTED DIMENSION) * These dimensions indicated in this figure are projected dimensions. Pointsymbol | 1 | 2 | 3 | 4 | § | 6 | 7 | @ | 9 | 10 Length (mm) | 710 | 807 | 884 | 1005 | 906 | 1926 | 1071 | 526 | 1260 | 1610 Pointsymbol | 11 | 12 | 13 | 14 | 15 | t6 | 17 | 18 | 19 | 20 Length (mm) | 1318 | 1417 | 1290 | 9e3 | 615 | 1191 | 7e2 | 1202 | 757 | 1903 “Point symbol | 21 | 22 | 23 | 24 | 25 | 26 | a7 | 28 | 29 | 30 Length (mm) | 1224 | 1147 | 1056 | 141 | 196 | 110 | 141 | 103 | a6 | 152 Point symbol a2 [sa [ 34 | 35 | 36 | 37 | 38 | 90 | 40 Length (mm) 155 | 9 | 4 | 181 | 92 | 199 | 92 | 153 | 105 Point symbol | 41 | 42 | 43 | 44 | 45 | 46 [ 47 | 48 | 49 | 50 Length(mm) | 260 | 808 | 958 | 1215 | 1483 | 1608 | 705 | 456 | 98 | 245 Pointsymbol | 51 | 52 | 53 | 54 | 55 | 56 Length (mm) | 455 | 631 | 658 | 714 | 1286 | 1411 752.9 ENGINE, 4 WHEEL DRIVE(ACTUAL DIMENSION) CHASSIS FRAME DIMENSION - 2.9 Engine, 4 wheel drive 5S SESS * These dimensions indicated in this figure are actual-measurement Pointsymbol | 1 | 2 | 3 | 4] 5 | 6 | 7] 8 | 9 | 10 Length (mm) | 710 | 807 | 703 | 998 | 152 | aaa | 722 | 1008 | 46a | 1249 Pointsymbol_ | 11 | 12 | 13 | 14 | 15 | 16 | 17 | 18 | 19 | 20 Length (mm) | 439 | 721 | 906 | 745 | 1348 | 822 | s26 | 1079 | 1260 | 1610 Pointsymbol_| 21 | 22 | 23 | 24 | 25 | 26 | 27 | 28 | 29 | 30 Length (mm) | 1984 | 966 | 1918 | ta17 | 555 | 1104 | 1290 | 984 | 1144 | 1210 Point symbol | 31 | 32 | 33 | 34 | 35 | 36 | 37 | 38 | 39 | 40 Length (mm) | 1804 | 1294 | 615 | 480 | 757 | 1325 | 943 | 7e2 | 1303 | 757 Pointsymbol | 41 | 42 | 43 | 44 | 45 | 46 [ [Length (mm) | 1187 | 1286 | 725 | 1204 | 158 | 1056 I 76CHASSIS FRAME DIMENSION - 2.9 Engine, 4 wheel drive 2.9 ENGINE, 4 WHEEL DRIVE(PROJECTED DIMENSION) Pointsymbol_ | 1 | 2 | 3 | 4 | 5 | 6 | 7 , [Length (mm) | 710 | 807 | 884 | 693 | 438 | e98 | 906 | 1926 | 1071 | 526 Pointsymbol_| 11 | 12 | 13 | 14 | 15 17 | 18 | 19 | 20 [Length (mm) | 1260 | 1610 | 1918 | 1417 | 1290 | 98s | 615 | 1191 | 7e2 | 1202 Point symbol 21 | 22 | 23 | 24 | 25 | 26 | 27 | 28 | 20 | 30 Length (mm) | 757 | 1303 | 1224 | 1147 | i056 | 141 | 136 | 110 | 141 | 103 Point symbol | 31 | 32 | 33 | 34 | 35 | 36 | a7 | 38 | 39 | 40 Length(mm) | 36 | 152 | 21 | 155 | 9 | 4 | 181 | 92 | 199 | 92 Point symbol | 41 | 42 | 43 | 44 | 45 | 46 | 47 | 48 | 49 | 50 Length(mm) | 153 | 105 | 260 | eos | 958 | 1215 | 1483 | 1608 | 705 | 456 Point symbol | 51 | 52 | 53 | 54 | 55 | 56 | 57 | 58 Length(mm) | 98 | 245 | 455 | 631 | 658 | 714 | 1286 | 1411 7BODY DIMENSIONS - Interior AE. Differential mounting hole(213) Front shock absorber mounting hole(@ 15.1) Ee Upper link mounting hole(27) Spring seat mounting hole(a82) Rear shock absorber mounting hole(216.6) 78 Body mounting hole(260)BODY DIMENSIONS - Interi FA, | Pe Ne \o | \ Rear bumper mounting bolt Lower arm mounting front center Upper arm mounting hole(215) hole(212.5) 16 : 17 it S WN ~ eee Ek ~~ a. | PE Lower arm mounting rear No.2 cross member mounting hole(@ 44.6) Lower link mounting hole(@ 12) hole(214.2) 19] Co ru / N/ Lateral rod mounting front Lateral rod mounting rear hole(@14.2) hole(14.2) 79BODY PANEL REPAIR PROCEDUREBODY PANEL REPAIR PROCEDURE - Radiator support member assembly RADIATOR SUPPORT MEMBER ASSEMBLY Remciaol ues) © MIG plug welding 82BODY PANEL REPAIR PROCEDURE - Fender apron panel complete (Assembly) FENDER APRON PANEL COMPLETE © MIG plug welding 30 MIG lap welding © MIG plug welding 38 MIG lap weldingBODY PANEL REPAIR PROCEDURE - Fender apron panel complete (Assembly) NOTE Before repairing, remove Engine and Suspension Components, Refer to the body dimension charts and measure the vehicle to determine straightening and alignment requirements. The body must be returned to its original dimension before you begin the repair procedure. REMOVAL 1. Drilloutallthe spotwelds to separate radiator support panel from fender apron panel. NOTE When spotwelded portions are not apparent, remove paint with a rotary wire brush. Prong 2, Remove the radiator support panel. 3. Drill out all the spotwelds attaching the cowl top reinforcement panel. NOTE If itis possible that the cow! top reinforcement panel is reusable, be careful not to damage it while removing.BODY PANEL REPAIR PROCEDURE - Fender apron panel complete (Assembly) 4, Using a spotweld cutter, drill out all the spotwelds attaching the fender apron to the dash panel. 5, Remove the fender apron panel. 6. Grind and smooth any weld traces which might be left on the body surface by using an air grinder or similar tool, being careful not to damage any of the panels which is not to be replaced 7. Usinga hammer and dolly, correct any flanges that become bent or deformed when spotwelds are broken.BODY PANEL REPAIR PROCEDURE - Fender apron panel complete (Assembly) INSTALLATION 1. Drill 8 mm holes in the new fender apron panel for MIG plug welding, 2. Remove paint from both sides of all portions that are to be welded such as peripheries of MIG plug weld holes. 3. Temporarily install new parts in place. 4, Measure each measurement point (Refer to the BODY DIMEN- SIONS) and correst the installation position. L 2 {KX 5. MIG plug weld all holes \ 86BODY PANEL REPAIR PROCEDURE - Fender apron panel complete (Assembly) 6. Clean MIG welds with a disc grinder NOTE 1. Be careful not to grind welded portions too much. 2. The internal parts will be stronger if the weld traces are not ground. 7. Before welding the cow! top reinforcement, apply the two part epoxy primer and anti-corrosion agentto the interior ofthe fender apron panel. 8. Install the cowl top reinforcement in place. 9. MIG plug weld all holes. 10. Clean and prepare all welds, remove all residue. 11. Apply the two part epoxy primer to the interior of the each panel. 8712. 13, 14, 15. 16. 17. 18. 49. 20, BODY PANEL REPAIR PROCEDURE - Fender apron panel complete (Assembly) Apply an anti-corrosion agent as required (Refer to the CORROSION PROTECTION). Prepare the exterior surfaces for priming using wax and grease remover, 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 LOCATION). Reprime over the seam sealer to complete the repair. After completing body repairs, carefully apply under coating to the dash panel and fender apron (Refer to the CORROSION PROTECTION). In order to improve corrosion resistance, it necessary, apply an under body anti-corrosion agentto the panel which is repaired or replaced (Refer to the CORROSION PROTECTION). 88BODY PANEL REPAIR PROCEDURE - Fender apron panel (Partial) FENDER APRON PANEL (PARTIAL) Crete kaon tes UH ® MIG plug welding Prose +Hit MIG butt welding 29¢ MIG lap welding somm © MIG plug welding proose Ht MIG butt welding +e MIG lap welding 89BODY PANEL REPAIR PROCEDURE - Fender apron panel (Partial) SSS i SEES li rT tf es os REMOVAL NOTE This procedure is to be used only for repair of minor damage to the fender apron panel and when it is impossible to straighten the damaged fender apron panel. The following procedure illustrates a repair for the front left fender apron panel. ‘The proceduremay also be appliedto thefrontrightfenderapron panel. 4. Mark a vertical cut line at 20mm point from the fender mounting hole center. 2. Drilloutallthe spotwelds to separate radiator support panel from fenderapronpanel. NOTE 1. When spotwelded portions are not apparent, remove paint with a rotary wire brush. 2. Inordertoperform cuttingand separation of spotwelded points usea spot weld cutter whichis arger than the size of the nugget to make a hole only in the panels to be replaced. 90BODY PANEL REPAIR PROCEDURE - Fender apron panel (Partial) 3. Cutthrough the fender apron panel cutlines. NOTE Take carenottocutthrough fender apron shield(A) reinforce- ment. 4. Prepare all surfaces to be welded. i sno. INSTALLATION ie 2 3. 4. 5, Transeribe the fender apronpanelcutline tothenew fender apron panel, cutto length and chamfer butt endtoimprove weld surface. Drill 8mm holes in new fender apron panel for MIG plug welding, Fit and clamp the fender apron panel in place. MIG plug weld all holes and MIG butt weld all seams. Measure each measurement point (Refer to the BODY DIMEN- SIONS) and correct the installation position a1BODY PANEL REPAIR PROCEDURE - Fender apron panel (Partial) 10. 4 12 13. 14. 46. 16. Fit and clamp the radiator support panel in place. MIG plug weld all holes, Clean and prepare all welds, remove all residue. Apply the two-part epoxy primer to the interior of the front side member. Apply an anti-corrosion agent as required (Refer to the CORROSION PROTECTION), Prepere the exterior surfaces for priming using wax and grease remover. 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). Reprime over the seam sealer to complete the repair. 92BODY PANEL REPAIR PROCEDURE - Front pillar FRONT PILLAR (emanate) © MIG plug welding pros +H MIG butt welding 7 MIG lap welding 93BODY PANEL REPAIR PROCEDURE - Front pillar Se ES NCHS AAC ESSE REMOVAL 4, Measure and mark the cutline on the front pillar outer panel at 120mmfromthe roof panel endlineto remove the frontouterpillar panel. After that measure and mark the cutline on the "A" inner pillar at ‘50mm from the cutline on the pillar outer panel to remove the "A" inner pillar indicated in the illustration. 2, Measure and mark the culline on front door scuff trim mounting hole center as shown in the illustration. 8. Depending on the extend of damagedarea, it may be possible to determine the cutting range within indicated in the illustration. 4, To remove the front pillar, grind away and drill out all welds attaching the cowl top reinforcement as illustration. NOTE Ifitis possible that the cowl top reinforcement is reusable, bbe careful not to damage it while removing.BODY PANEL REPAIR PROCEDURE - Front pillar Drill out all welds attaching the front pillar to dash and cowl top outer, cow! inner lower panel 6. Remove spotwelds and lap welds attaching cowl crossmember bar mounting upper bracket to remove front pillar. 7. Before cutting front pillar, be sure to support roof panel, 8. Cutthefrontpilarthrough each cutline,takingcare nottodamage the other panel as illustration, Frontpillar outer 'A" inner*illar ei 9. Beforecutting the frontside sill outer panel, make. rough cut the front side sill outer panel only. 95BODY PANEL REPAIR PROCEDURE - Front pillar 10. Cut the side sill outer front reinforcement as illustration, 41. Cutthe front side sill outer panel vertical cutline and remove the front pillar. 42. Straighten all flanges as necessary, prepare all surfaces to be welded, INSTALLATION 4. Transcribe the cutline to the new"A” inner upper pillar, cut to length and chamfer butt end to improve weld surface. 2. Transcribe the cutline to the new front pillar outer panel, adding ‘30mm overlap to end and cut to length. 8. _ Drill mm holes along outer panel flanges in production location for attachment to other panels. 96BODY PANEL REPAIR PROCEDURE - Front pillar 10. 1" 12, 13, 14, 15. 16. Transcribe the cutline to the new overlap to end and cut to length. Drill 8mm holes in the “A" inner pillar for MIG plug welding, Fit and clamp the new “A" inner pillar in place for welding, MIG plug weld all holes and MIG butt weld the seams. "inner pillar, adding 30mm Temporarily instal place. Measure and each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position. if necessary, make temporary welds, and then check to confirm that the closing and fit for windshield glass, door and fender are correct. inner pillar and front pillar outer panel in MIG butt weld *A* inner pillar and front pillar outer panel seams. Reattach thecut away’A"inner pillar section, then MIG butt weld. MIG. plug weld allholes and MIG butt weld all seams in the front side sill outer panel. Clean and prepare all welds, removing all residue. Apply body filer to joints and sand as needed. Apply the two-part epoxy primer to the interior ofthe front pillar. 97 ‘8 nner pillarBODY PANEL REPAIR PROCEDURE - Front lar 17. Clean all welds with a disc grinder. NOTE ° 1. Be careful not to grind welded portions too much. 2. The internal parts will be stronger if the weld traces are not ground. 18, Before welding the cow top reinforcement, apply the two part ‘epoxy primer and anti-corrosion agenttothe interiorof the fender shield panel. 19. Install the cow! top reinforcement in place. 20. MIG plug weld all holes, 21. Clean and prepare all welds, removing al residue. 22. Apply an anti-corrosion agent to the welded parts and inside of front pillar (Refer to the CORROSION PROTECTION) 28. Prepare exterior surfaces for priming, using wax and grease remover. 24. Apply metal conditioner and water rinse. 25. Apply conversion coating and water rinse. 26. Apply the two-part epoxy primer. 98BODY PANEL REPAIR PROCEDURE - Front pillar 27. Apply the correct seam sealer to all joints carefully (Refer to the BODY SEALING LOCATIONS). 28. Reprime over the seam sealer to complete the repair. 99BODY PANEL REPAIR PROCEDURE - Center pillar CENTER PILLAR atcha © MIG plug welding Prose. +t MIG butt welding ~6¢ MIG lap welding 100BODY PANEL REPAIR PROCEDURE - Center pillar REMOVAL 4. Measure and mark the horizontal cutline on center outer pillaras ilustration. 2, Measure and mark the vertical cutline on side sill outer panel 80mm trom the front door scuff trim mounting hole and rear door scuff trim mounting hole. 3. Before cutting center pillar, be sure to support roof pane 4, Drilloutall spotwelds attaching the center outer pillarto the body to remove center outer pillar. 101BODY PANEL REPAIR PROCEDURE - Center pillar Cut through center outer pillar and side sill outer panel at cutlines. NOTE When cutting side sill outer pane! take care not to cut through mating flanges or side sill rear reinforcement. 6. After cutting side outer panel (center outer pillar & side sil), cut the °B" pilar reinforcement and °B* inner pillar. 7. Remove the center pillar. 8. Determine if the side sill rear reinforcement is damaged and needs to be replaced. If replacing is necessary, mark out the damaged portion of the reinforcement. Cut at cutlines and remove damaged portion 9. Straighten all anges as necessary. 10. Prepare all surfaces to be welded. 102 Fontan iat coum = — Ey Fee Ah Senter pier “8° Inner pillar 2) Side sil rear reinforcementBODY PANEL REPAIR PROCEDURE - Center pillar INSTALLATION 1. In ofder to install "B" inner pillar drill out all spotwelds attaching the roof side inner rail to center inner pillar to separate them, 2. Transcribe the center outer pillar cutlines to the new center outer pillar, adding 30mm overtap at side sill rear reinforcement, 3. Cut and chamfer butt end to improve weld surface. 4. Drill 8mm holes in overlap area and along outer panel flanges. 5. MIG buttweldall seams in"B*innerpillar and front seat belt upper and°B* pillar reinforcement and center outer panels illustration. 103BODY PANEL REPAIR PROCEDURE - Center pillar 6. Transeribe the cutline dimensions to the new side sill rear reinforcement, adding 30mm overlap to each end and cut to length, 7. Drili&mm holes in overlapareas on each end of new side sillrear reinforcement and clamp. 8. MIG plug weld all holes MIG butt weld seams. NOTE The reinforcement will be stronger if the weld traces are not ground. 9. Temporarily install new center outer panel in place. 10. Screw center pillar in place. 11. Measure and each measurement point (Refer to the BODY DIMENSIONS) and cortect the installation position. 12, Check the fit ofthe front and rear doors. 13, Reinstall center cuter pillar and screw in place. 14, MIG plug weld all holes and MIG butt weld all seams. 15. Clean and prepare all welds, and remove all residue. 16. Apply body filler to the outer center pillar seam. Sand and finish. 17. Apply the two-part epoxy primero the intarior ofthe center pillar. 18. Apply an anti-corrosion agent to the welded parts and interior of the center pilar (Refer to the CORROSION PROTECTION). 104BODY PANEL REPAIR PROCEDURE - Center pillar 19. Prepare exterior surfaces for priming, using wax and grease remover. 20. Apply metal conditioner and water rinse. 21. Apply conversion coating and water rinse. 22. Apply the two-part epoxy primer. 23. Apply the correct seam sealer to all joints carefully (Refer to the BODY SEALING LOCATIONS). 24, Reprime over the seam sealer to complete the repair. 105BODY PANEL REPAIR PROCEDURE - Side sill (Assembly) SIDE SILL (ASSEMBLY) Ramen) © MIG plug welding +H MIG butt welding e+ MIG lap welding REMOVAL 1. Measure and mark vertical cutine from the rear door scuff trim ‘mounting hole on the side sill outer panel. 2. At the front and center pillar, measure and mark horizontal cutlines from the door hinge mounting hole on the side outer panel as illustration. 106BODY PANEL REPAIR PROCEDURE - Side sill (Assembly) 3 Cutthe side sill outer panel along cutlines. Be careful not to cut mating flanges. 4, Dill out all spotwelds, attaching the side sill outer panel. 5. Remove the side sill outer panel. 6. Determine if the side sill rear reinforcement is damaged and needs to be replaced, measure cutline on reinforcement as illustration. ‘Cut side sill rear reinforcement along the cutlin. 8. Dilloutspotweldsattaching the side sillrearreinforcementto the body and remove side sill rear reinforcement. 9, Prepare all surfaces to be welded. INSTALLATION 1. Transcribe cutline dimension to side sill rear reinforcement, adding 30mm overlap to rear end and cut to length. 2. Drill mm holes in overlap area on rear end and along front flange. 3. Fit and clamp the side sill rear reinforcement in place, 4, MIG plug weld all holes and MIG butt weld seams. 5. Before welding the side sill outer panel, apply the two-part epoxy primer and anti-corrosion agent to the welded parts. NOTE The reinforcement will be stronger if the weld traces are not ground. 107BODY PANEL REPAIR PROCEDURE - ide sill (Assembly) 6 10. "1 42. 13, 14, 16, 16. 17. 18, 49. Using service panel for replacement of side sill outer panel, drill &8mmholes in overlap areas and along upper and lower flanges. Crimp flanges on the remaining portion of the side sill outer panel at all joint for overlap, Fit and clamp the side sill outer panel in place. MIG plug weld all holes and MIG butt weld seams. Clean and prepare all welds and remove all residue. Apply body filler to the side sill outer seams. Apply the two-part epoxy primer to the interior of the side sill. Apply an anti-corrosion agent to welded parts and interior of the side sill (Refer to the CORROSION PROTECTION). Prepare the exterior surfaces for priming, using wax and grease remover. 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 (Refer to the BODY SEALING LOCATIONS). Reprime over the seam sealer. 108BODY PANEL REPAIR PROCEDURE - Side sill (Assembly) 20. Apply the anti-corrosion primer to the side sill outer panel to complete the repair (Refer to the CORROSION PROTECTION). 109BODY PANEL REPAIR PROCEDURI ide il (pal SIDE SILL (PARTIAL) SSX © MIG plug welding ‘Hit MIG butt welding 29¢ MIG lap welding REMOVAL 1. Depending on the extent of damage, mark out the damaged portion of the side sil. 2. Dill out the spotwelds in upper and lower flanges of side sill between cutlines to remove side sill outer panel and cut the damaged portion of the side sill at the cutlines. 110BODY PANEL REPAIR PROCEDURE - Side sill (parti 10. " 12, 13, 14, 15, Transcribe the side sill outer panel cutline to the new side sill, adding 30 mm overlap to each end, cut and chamfer butt end to improve weld surface. Drill 8 mm holes in overlap areas on each end and along upper and lower flanges of the new side sill outer panel for MIG plug welding Fit and clamp the side sil in place MIG plug weld all holes and MIG butt weld seams Clean and prepare all welds, removing all residue, Apply body filler to the side sill outer seams. Apply the two-part epoxy primer to the interior of the side sil. Apply an anti-corrosion agent to the welded parts and interior of the side sill (Refer to the CORROSION PROTECTION). Prepare the exterior surfaces for priming, using wax and grease remover. Apply metal conditioner and water rinse. ‘Apply conversion coating and water rinse. Apply the two-part epoxy primer. ‘Apply the anti-corrosion primer to the side sill outer panel to complete the repair (Refer tothe CORROSION PROTECTION). a1BODY PANEL REPAIR PROCEDURE - Quarter panel QUARTER PANEL Rae cnaon te! @ MIG plug welding +t MIG butt welding 26+ MIG lap welding 112BODY PANEL REPAIR PROCEDURE - Quarter panel REMOVAL 1. Depending on the extent of damage, measure and mark cutlines on the quarter outer panel as illustration. 2. Drill out all attaching spotwelds on the quarter outer panel, including the seam around the door lip opening. 8. Cut the quarter outer panel at cutlines and remove the quarter outer panel as illustration, NOTE When cutting the quarter outer panel, be careful not to cut quarter inner panel. 4. Prepare all surfaces to be welded. prosz70| INSTALLATION 4. Transcribe the cutline to the new quarter outer panel, adding 30 mm for overiap at the old joint. 2. Drill 8 mm holes in overlap areas and along upper and lower flanges of the new quarter outer panel for MIG plug welding Fitand clamp the quarter outer panel in place. 4, MIG plug weld all holes and MIG butt weld seams. Atthe wheel well the edge must be crimped over the wheel housing, This joint may be welded after crimping or may be made by applying a bead of adhesive may be applied to the joint before or after crimping. 5. Clean and prepare all welds, removing all residue. 113BODY PANEL REPAIR PROCEDURE - Quarter panel 6. Apply body filler to the welded seam. Sand and finish. Apply the two-part epoxy primer to the interior of the quarter outer panel. 7. Apply an anti-corrosion agent to the welded parts and interior of, the quarter outer panel (Refer to the CORROSION PROTEC- TION). 8. Prepare exterior surfaces for priming, using wax and grease remover. 9. Apply metal conditioner and water rinse. 10. Apply conversion coating and water rinse. 14. Apply the two-part epoxy primer. 12. Apply the correct seam sealers to all joints. 13, Reprime over the seam sealer to complete the repair. PpO-0 14. In order to improve corrosion resistance, if necessary, apply a under body anti-corrosion agent to the wheel well (Refer to the CORROSION PROTECTION). 114BODY PANEL REPAIR PROCEDURE - Rear floor REAR FLOOR eterno ue! €0 >> n rs Prowse Prose © MIG plug welding tt MIG butt welding #¢ MIG lap welding 115BODY PANEL REPAIR PROCEDURE - Rear floor side member (assembly) REAR FLOOR SIDE MEMBER (ASSEMBLY) ma : © MIG plug welding +Htt MIG butt welding e+ MIG lap welding 116BODY PANEL REPAIR PROCEDURE - Rear floor and rear floor side member (assembly) NOTE Because the rearfloor side members are desigened toabsorb energy during a rear collision, care must be taken when deciding to use this repair method. This repair is recommended only for moderate dam- age to vehicle, where distortions do not extend forward of the trunk region. If the damage is more severe, then the entire side member assembly should be replaced at factory seams without employing this sectioning procedure. Refer to the body dimension chart and measure the vehicle to determine straigthening and alignment requirements, The body must be returned to its original dimension before begi repair procedure. REMOVAL 1. Drill out all the spotwelds attaching the rear floor panel to the ‘wheel housings and rear floor side members. 2. Make a rough cutting of the rear floor panel where shown in the figure, 3, Remove the rear floor panel. 4, Remove the rear and cross member by driling out all attaching spotwelds. 117BODY PANEL REPAIR PROCEDURE - Rear floor and rear floor side member (assembly) 5. Remove the rear floor panel (rear section) and rear floor side member from the rear body. INSTALLATION 1. Transcribe the cutline to the new rear floor side members. Drill ut the spotwelds attaching the inner reinforcements, Remove remaining portions of side members. 2. Temporarily ft and clamp the rear floor side members in place. NOTE When installing the rear floor side member, temporarily install the rear and outer cross member to measure each measurement point. 3, Measure each measurement point (Refer to BODY DIMEN- SIONS) and correct the installation position. 4, Ifnecessary, make temporarily welds, and then checkto confirm that the fit of rear floor panel is correct, 118 ProsBODY PANEL REPAIR PROCEDURE - Rear floor and rear floor side member (assembly) 5. MIG plug weld the rear floor side members and MIG butt weld seams. 6. Prepare the welds nd surfaces towhich the rear loorwillattach, 7. Transcribe the cutline to the new rear floor panel, adding 30mm for overiap at the old joint. 8. Drill mm holes in overlap area and production locations of the new rear floor panel for MIG plug welding, 9. Fitand clamp the rear floor panel and attach the rear floor panel to the rear floor side members and other panels. 10. MIG plug weld all holes and MIG butt weld the seams. 11. Clean all welded surfaces. 12. Drill mmholesonthe flange attachingthe rear and cross member to the rear floor and rear floor side member ends. 13. Fit and clamp the rear floor and rear floor end crossmember in place, 14. MIG plug weld the rear floor and rear floor end crossmember. 15. Clean and prepare all welds, remove all residue. 16. Apply the two-part epoxy primer to the interior of the rear side members. 119 eno.tese Pr0-650BODY PANEL REPAIR PROCEDURE - Rear floor and rear floor side member (assembly) 17. Apply an anti-corrosion to the interior of the rear floor side members (Refer to the CORROSION PROTECTION), 18. Prepare exterior surfaces for priming, using wax and grease remover. 19. Apply metal conditioner and water rinse. 20. Apply the two-part epoxy primer. 21. ‘Apply the correct seam sealer to all joints (Refer to the BODY ‘SEALING LOCATIONS). 22. Reprime over the seam sealer to complete the repair. 23, After completing body repairs, carefully apply under coating to the under body (Refer to the CORROSION PROTECTION). 24. Inorder to improve corrosion resistance, ifnecessary, apply an Under body anti-corrosion agenttothe panel which isrepaired or replaced (Refer to the CORROSION PROTECTION). 120BODY PANEL REPAIR PROCEDURE - Front and rear door outer panels FRONT AND REAR DOOR OUTER PANELS Canina FRONT DOOR (Inner panel ) (Outer panel ) rosooa 008 REAR DOOR (inner panel ) (Outer panel ) © MIG plug welding ova 008 6 MIG lap welding 121BODY PANEL REPAIR PROCEDURE - Front and rear door outer panels REMOVAL 1. Cut door outer panel hem with a sander. 2. After grinding off the hemming location, remove the outer panel. 3. Dress rusty part with a sander and prepare surface to be hemmed. INSTALLATION 1. Apply adhesive or equivalent to outer pane! hem. 2. Apply mastic sealer or equivalentto the door upper member and door reinforcement beam as shown in the figure. 122BODY PANEL REPAIR PROCEDURE - Front and rear door outer panels Bend the flange hem with ahammer and dolly, then fasten tightly with a hemming too}. NOTE 4. Hemming work should be done in three steps as illus- tration. Ifa hemming tool cannot be used, hem with a hammer and dolly. After completing the hemming work, make MIG spot welds at 50 mm intervals on the inside. Clean and prepare all welds, remove all residue. Apply the two-part epoxy primero the interior of the door panel. 123BODY PANEL REPAIR PROCEDURE - Front and rear door outer panels 7. Apply an anti-corrosion agent to the welded parts and lower inside of the door panel (Refer to the CORROSION PROTEC- TION). 8. Prepare exterior surfaces for priming, using wax and grease remover. 9. Apply metal conditioner and water rinse. 10. Apply conversion coating and water rinse. 11. Apply the two-part epoxy primer. 12. Apply the correct seam sealer to whole panel edge. 13. Reprime over the seam sealer to complete the repair, 124BODY SEALING LOCATIONSBODY SEALING LOCATIONS - Floor FLOOR - 126BODY SEALING LOCATIONS - Floor 6BODY SEALING LOCATIONS - Floor 128BODY SEALING LOCATIONS - Upper and side body UPPER AND SIDE BODY 129BODY SEALING LOCATIONS - Upper and side body 4 130BODY SEALING LOCATIONS - Upper and side body 131CORROSION PROTECTIONBODY CONSTRUCTION - Zinc-galvanized steel panels ZINC-GALVANIZED STEEL PANELS Because galvanized steel panel has excellent resistance, it is used in areas which have a high possibilty of painting deficiency below. 134CORROSION PROTECTION - Zinc-galvanized steel panels 1, Bridge panel 2. Front’end cross member 3. Front end lower reinforcement assembly 4, Dash panel 5. Dash panel reinforcement 6. Cowl top outer panel 7. Cow! top inner panel 8. Side outer panel(LH/RH) 9. Side inner panel(LH/RH) 10. Side outer extension(LH/RH) 11. Fuel filler door 12. Shift lever reinforcement 13, Backbone reinforcement 14. Front floor panel 16. Front floor No. 1 cross member(LH/RH) 16. Body mounting No. 2 bracket(LH/RH) 17. Front floor No. 2 cross member(LH/RH) 18. Body mounting No. 3 bracket(LH/RH) 19. Side sill nner panel(LH/RH) 20. Center floor panel 21. 22. 23. 24, 25. 26. 27, 28, 29. 30. 31. . Rear door outer panel(LH/RH) . Rear door inner panel(LH/RH) BRB 135 Rear floor panel 2nd seat hinge rear bracket Rear floor No. 1 cross member Rear floor No. 2 oross member Rear floor No. 3 cross member Rear floor side member(LH/RH) Rear floor No. 4 cross member Body mounting No. 5 bracket(LH/RH) Rear floor side panel(LH/RH) Front door outer panel(LH/RH) Front door inner panel(LH/RH) Tail gate outer panel Tail gate inner panel Hood outer panel Hood inner panelCORROSION PROTECTION - Antivibration ANTIVIBRATION PADS-LOCATION & SECTION 34199-41000 era tiael 7 198149-H11000 419-H1000 eexz2-4s000 aurarto00 exro141000 rer essa5-tti000 exsert000 exxortt000 exta0.1000 ) 94142-11000 TO enon exr22f000 cS exrasfooo 136CORROSION PROTECTION - Attachment of antivibration pads ee cS SSSR SY 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. If these antivibration pads are peeled off in the course of replacement or repair of a welded panel.cut and attach replacement material (in the shape shown in the figure). For detailed information ‘concerning the locations where antivibration pads are to be attached for individual models, refer to the figure below . ‘34199-41000 4142-41000 4 84143-11000 84194-H1000 pines 4121-41000 ea1a1-H1000 oe satat-H1000 ——_94143-H1000, 1. Heat the “antivibration pad* with a blow drier to soften it 7 ie Lh Zo 2. Align the antivibration pad layer in the position where its to be installed, and then press it down with a roller or a block of wood so that it adheres well. NOTE ‘An infrared lamp can also be used to heat both the antivibration pad layer and the body panels(be sureto wear gloves), con-oor 137CORROSION PROTECTION - Under body coat 2 UEC SEE AEE UNDER BODY COAT In order to provide corrosion, stone chipping and vibration resistance, and under body coat is applied to the under sides of the floor and wheel house. Therefore, when such panel is replaced or repaired, apply under body coat to that part. FLOOR ex Because parts are to be mounted in these locatins, mask the location, before applying the under body coat. Under body coating (Thickness 1.0 mm - 2.0 mm) Front for panel 1 Front floor Sa | panel Sido oftor panel ! SECTION A-A’ SECTION B-B' Tal gate innge Tail gate outer panel pred Fear foor panel SECTION C-c’ 138CORROSION PROTECTION - Under body coat SIDE BODY 4 Because parts are to be mounted in these locatins, mask the location, before applying the under body coat. SECTION B-B* SECTION C-C' 139CORROSION PROTECTION - Cavity wax it CAVITY WAX INJECTION In order to provide greater corrosion resistance, cavity wax injection has been performed for the lower areas of the vehicle, such as the sidemember, the side sill and the inside of other panels which are a hollow construction, When replacing these parts, be such to apply cavity wax to the appropriate areas of the new parts. 2% Wax inject must be done through access holess marked. ZA Cauity wax injection (Thickness 40 1 - 50u) iz iz = = SECTION A-AY 2 és SECTION C-C' ae SECTION D-D' 140CORROSION PROTECTION - Cavity wax injection TAIL GATE %& Wax inject must be done through access holes marked, Cavity wax injection (Thickness 40x - 50u) SECTION B-B’ | \ U WL “we. somm a (MIN) SECTION C-C' ae SECTION D-D' : 141wax it CORROSION PROTECTION - Cay ge ge se 2 a : y we We SO 3 FRONT DOOR REAR DOOR + Wax inject must be done through access holes marked Cavity wax injection (Thickness 40 - 50u) = k [30mm (win) SECTION B-B : —~ \ to ie lgomm kM) SECTION AA oe SECTION C-C' 142CORROSION PROTECTION - Under body anti-corrosion agent 2 eee UNDER BODY ANTI-CORROSION AGENT The undersides of the floor and wheel house are underooated to provide greater corrosion resistance. Therefore, when such panel is replaced or repaired, apply under body anti-corrosion agent to that par. NOTE Do not apply the under body anti-corrosion agent to come in contact with tires, muffler and exhaust pipe. Under body anti-corrosion agent (Thickness 1.0mm-2.0mm) ane assy 143