Body Repair Manual

0-1
GROUP 0
GENERAL
CONTENTS
VEHICLE IDENTIFICATION . . . . . . . 0-2 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

................................. 0-3
MAJOR SPECIFICATIONS . . . . . . . . 0-2
0-2 GENERAL
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION
M4000001003263
<2000>
Model code Seating Engine model Transmission model Fuel supply
capacity system
GF2W XTSHL6Z 5-persons 4B11 (1,998 mL) F1CJA (Front wheel drive 2WD, MPI
DOHC MIVEC INVECS-III CVT with sport mode)
XTSHZL6Z petrol engine W1CJA (Electronic control 4WD,
INVECS-III CVT with sport mode)
<2400>
Model code Seating Engine model Transmission model Fuel supply
capacity system
GF3W XTHHZL6Z 5-persons 4B12 (2,360 mL) W1CJA (Electronic control 4WD, MPI
DOHC MIVEC INVECS-III CVT with sport mode)
petrol engine
MAJOR SPECIFICATIONS
M4000003002943
Item GF2W GF3W

XTSHL6Z XTSHZL6Z XTHHZL6Z
Vehicle dimension Overall length 4,655
mm Overall width 1,800
Overall height (unladen) 1,680
Wheelbase 2,670
Track Front 1,540
Rear 1,540
Front overhang 955
Rear overhang 1,030
Ground clearance (unladen) 215
Vehicle Front Toe-in (at the centre of tyre 1±2
wheel tread) mm
alignment Camber 0°20' ± 0°30'*1
Caster 2° 35' ± 0°45'*1
Kingpin inclination angle 12° 45' ± 1° 30'
Rear Toe-in (at the centre of tyre 3±2
tread) mm
Camber −0° 30' ± 0° 45'*1
GENERAL 0-3
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Item GF2W GF3W

XTSHL6Z XTSHZL6Z XTHHZL6Z
Wheel and tyre Tyre size 215/70R16 215/70R16 100H, 215/70R16
100H 225/55R18 98H*2 100H,
225/55R18
98H*2
Wheel size 16 × 6.5JJ 16 × 6.5JJ, 16 × 6.5J*2, 18 16 × 6.5J,
×7J*2 18 ×7J*2
Offset mm 38 38 38
NOTE: .
*1: Difference between right and left wheels must be less than 0°30'.
*2
: Indicates the optional item.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

M4000004000014
WARNING SRS-related component.

• Improper service or maintenance of any
component of the SRS and any
SRS-related component, can lead to per-
sonal injury or death to service personnel
(from inadvertent firing of the air bag) or
to the driver and passenger (from render-
ing the SRS inoperative).
• The SRS components and seat belt with
pre-tensioner should not be subjected to
heat, so remove the SRS-ECU, driver's
and front passenger's air bag modules,
clock spring, side-airbag modules, Cur-
tain air bag modules, front and side
impact sensor and seat belt pre-tensioner
before drying or baking the vehicle after
painting.
• SRS-ECU, air bag modules, clock
spring, impact sensor: 93° C or more
• Seat belt with pre-tensioner 90°C or
more
• Service or maintenance of any SRS com-
ponent and SRS-related component must
be performed only at an authorized MIT-
SUBISHI dealer.
• MITSUBISHI dealer personnel must thor-
oughly review workshop manual, and
especially its GROUP 52B - Supplemental
Restraint System (SRS), before begin-
ning any service or maintenance of any
component of the SRS and any
1-1
GROUP 1
BODY
CONSTRUCTION
CONTENTS
BODY COMPONENTS. . . . . . . . . . . . 1-2 ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 1-21
BODY MAIN CROSS-SECTIONAL VIEWS DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
................................. 1-4
SILENCER APPLICATION LOCATIONS
MAINTENANCE, SERVICEABILITY . 1-6 ................................. 1-25
BODY CONSTRUCTION CHARACTERISTICS LOCATIONS USING URETHANE FOAM AND

................................. 1-8 FOAM MATERIAL . . . . . . . . . . . . . . . 1-26
FRONT BODY. . . . . . . . . . . . . . . . . . . . . . . 1-8
SIDE BODY. . . . . . . . . . . . . . . . . . . . . . . . . 1-15 STIFFENER AND DAMP SHEET
REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 1-18
APPLICATION LOCATIONS . . . . . . . 1-27
1-2 BODY CONSTRUCTION
BODY COMPONENTS
BODY COMPONENTS
M4010001002186
49
39 48
36
47 50
34 38 46
45 109
103 44
37 43
33 108
35
104 41 42*
102 40 110
107
101* 100*
99* 112 111 51
105 113
32 96**
52
98* 106 114
31 94
93*
97* 53
95**
92* 54
30
29* 18
27 19 56
28* 17 57
26* 90**
25 22 16 58
20 91*
23
24* 62
14 7* 55
21 63
13
15 85
12 6* 59*
61 60*
11*
5 65
10 8 64
84**
9 4 83
86* 66
74*
75*
2 3 89 76 67
68* 69*
77** 70
1
80 78* 73* 71
NOTE: 87
: Anti-corrosion steel panels 88 82* 81 79
: High-tensile steel panels (*: Indicates 590MPa-high-tensile steel panels.) 72*
(**: Indicates 980MPa-ultra-high-tensile steel panels.) ABC00060 AB
1. Front bumper reinforcement 3. Headlamp support panel lower

2. Headlamp support panel upper 4. Headlamp support panel
BODY CONSTRUCTION 1-3
BODY COMPONENTS
5. Front body frame to side sill brace 64. Rear floor side panel
6. Front floor sidemember 65. Rear floor rear end crossmember
7. Front sidemember rear bulkhead 66. Rear floor crossmember
8. Front inner sidemember 67. Rear floor crossmember
9. Headlamp support panel lower 68. Rear floor under stringer
10. Front sidemember plate 69. Rear bumper support
11. Front sidemember extension 70. Rear floor sidemember extension
12. Front outer sidemember 71. Rear floor sidemember
13. Fender shield extension 72 Rear floor side sill inner
14. Front fender gusset 73. Rear floor sidemember bulkhead
15. Front fender shield 74. Rear floor extension
16. Spring house panel 75. Rear floor rear seat under crossmember
17. Fender shield frame upper inner 76. Front floor
18. Front fender bracket rear 77. Front floor side sill inner
19. Front deck frame front upper 78. Front floor sidemember
20. Engine mounting gusset 79. Front floor reinforcement
21. Condense tank reinforcement 80. Front floor crossmember rear centre
22. Front end upper bar side 81. Front floor crossmember front
23. Front fender bracket 82. Front floor sidemember
24. Dash crossmember lower 83. Front floor crossmember rear
25. Dash panel crossmember upper 84. Front floor crossmember front
26. Dash crossmember extension 85. Front floor backbone reinforcement
27. Dash panel 86. Front floor sidemember
28. Dash crossmember side 87. Battery tray stay rear (Left side)
29. Dash panel reinforcement 88. Battery tray stay front (Left side)
30. Cowl top panel 89. Front fender
31. Front deck crossmember 90. Side sill reinforcement
32. Hood panel inner 91. Side sill bulkhead front
33. Hood panel outer 92. Front pillar reinforcement lower inner
34. Front door side door beam 93. Front pillar reinforcement lower support
35. Front door panel inner 94. Front lower inner pillar
36. Front door panel outer 95. Front pillar reinforcement upper
37. Rear door side door beam 96. Front upper inner pillar
38. Rear door panel inner 97. Centre pillar reinforcement
39. Rear door panel outer 98. Rear door hinge reinforcement
40. Roof rail front 99. Centre inner pillar
41. Roof bow A 100. Roof side rail reinforcement centre
42. Roof bow centre lower 101. Roof side rail inner
43. Roof bow centre upper 102. Roof rail extension front inner
44. Roof bow B 103. Roof rail extension rear inner <Vehicles without
45. Roof bow C sunroof>
46. Roof bow D 104. Roof side rail reinforcement rear
47. Roof rail rear 105. Roof side rail reinforcement rear
48. Roof panel 106. Rear pillar reinforcement
49. Tailgate panel outer 107. Rear wheel house panel inner
50. Tailgate panel inner 108. Quarter panel upper inner
51. Quarter panel extension outer 109. Gate pillar reinforcement
52. Quarter panel extension rear lower 110. Rear inner pillar
53. Side outer panel 111. Quarter panel extension lower inner
54. Fuel filler door panel (Left side) 112. Quarter panel lower inner
55. Front deck frame rear upper 113. Quarter panel extension inner
56. Rear bumper reinforcement 114. Rear pillar reinforcement lower
57. Rear end panel outer
58. Rear end inner centre crossmember
59. Rear bumper reinforcement
60. Rear end inner crossmember side
61. Rear bumper bracket
62. Rear floor
63. Rear seat under floor
BODY MAIN CROSS-SECTIONAL VIEWS

M4010002001346
A
B
C
D
ABB00858AB
A D Cowl top
panel upper
Cowl top
stay centre
Roof panel
Cowl top panel lower
Weight assembly
Roof rail front Cowl top panel inner
Map lamp bracket ABB00783AB ABB00786AB
B E Front pillar
Front inner reinforcement lower
pillar lower
Roof side rail

reinforcement
centre
Side outer Side outer

Roof side rail inner panel ABB00784AB panel ABB00787AB
C Centre pillar seat belt

reinforcement upper
Centre pillar
inner upper
F
Front floor
side sill
Centre pillar Side outer inner
reinforcement panel
Side sill
reinforcement
outer rear
ABB00785 AB Side outer panel ABB00788 AB

I
J
ABB00758AB
Quarter outer panel

G Front pillar J extension upper
reinforcement upper Quarter inner Gate inner
Side outer
panel upper panel pillar upper
Gate pillar upper
reinforcement
Front upper
inner pillar Side outer
panel
ABB00789AB Gas spring reinforcement ABB00792 AB
H K Rear pillar
reinforcement lower Quarter inner
front extension
Side outer
Roof panel panel
Roof rail
rear outer
Roof rail
rear inner
ABB00790AB ABB00793 AB
I L Tailgate striker
Rear pillar Quarter inner reinforcement
reinforcement upper upper panel Rear end inner
centre crossmember
Rear end
panel outer
Side outer
panel ABB00791AB Spare tyre bracket ABB00794AB
MAINTENANCE, SERVICEABILITY
M4010003001156
FENDER SHIELD
To facilitate the panel replacement, the dash panel
and the front sidemember brace upper have a pro-
jection and recess for alignment.
ABB00904AB
SIDE STRUCTURE
A panel positioning notch has been added on the
door opening to improve assembling workability
when replacing the panel.
Panel positioning notch ABC00082AB
ABB00754AB
SIDE OUTER PANEL

The extra parts are supplied in 4 different cut forms
as a result of employing the integrated side-frame
side outer panel.
BODY CONSTRUCTION CHARACTERISTICS
Centre outer pillar
Quarter panel outer

Front outer pillar
Front floor side sill outer
ABC00085AB

FRONT BODY • The bolt-on headlamp support panel upper is
M4010010001664 used to improve maintainability.
HEADLAMP SUPPORT
• The crush box structure, which has an octagonal
cross-section at the front end of the front side-
member, has been adopted. This structure can
effectively absorb energy upon frontal impact and
reduces the vehicle repair cost caused by a light
collision.
12 ± 2 N·m ABB00717
12 ± 2 N·m
3
2
4
1
20 ± 5 N·m
A
ABC00054AC
1. Front bumper reinforcement NOTE:

2. Headlamp support panel upper
3. Front end crossmember upper 8 Front bumper
4. Front end crossmember lower reinforcement
2
A
3
Crush box
7 1
5
6
4 ABC00083AB
Tighten the front bumper reinforcement bolts in the

numerical order to 20 ± 5 N⋅m.
ABB00715AB
2 4
A crash box has been established in order to effi-
ciently absorb energy upon impact. 3
Headlamp support
panel upper
1
5 6
ABC00084AB
Tighten the headlamp support panel upper bolts in

the numerical order to 12 ± 2 N⋅m.
FENDER SHIELD
• The front frame structure is supported in three • The padding structure of the front fender bracket
directions by the dash crossmember centre, dash and the front fender bracket rear has been
crossmember lower and front sidemember rear in adopted to have a crushable structure in order to
order to improve the frontal collision characteris- efficiently absorb energy upon impact, improving
tics, and increase the vehicle body rigidity. the pedestrian protection capability.
(Right side)
11 13
12
14
15 16
10 17 18
9
8
19
6
20
7
5
4 21
3 22
2 1 23
ABB00718 AB
(Left side) 13 11
12
16 15
17 9 10
18 8
21 26 25 7
24 27
4
3
23 2
1
ABB00719AB
1. Fender gusset 12. Upper frame rear bulkhead

2. Fender shield extension 13. Front fender bracket rear
3. Fender bracket lower 14. Horn bracket
4. Front fender shield 15. Spring house bracket reinforcement
5. Condense tank reinforcement 16. Spring house corner gusset
6. Engine mounting gusset 17. Spring house bracket front
7. Front end upper bar side 18. Spring house panel rear
8. Front fender bracket 19. Suction hose bracket
9. Front upper inner frame 20. Spring house harness bracket
10. Upper frame centre bulkhead 21. Spring house panel
11. Front deck frame front upper 22. Engine mounting bracket upper
23. Front sidemember FRONT SIDEMEMBER REINFORCEMENT

24. Engine-ECU bracket The 590-MPa class high tensile strength steel panels
25. Relay box bracket have been adopted for the front sidemember exten-
26. Relay box bracket rear
sion, front sidemember rear reinforcement lower,
27. Transmission mounting gusset
front sidemember rear bulkhead, front sidemember
rear, backbone sidemember extension and front
sidemember inner reinforcement to improve the fron-
tal collision characteristics.
(Right side)
3 4
2
26 28
27
5*
1*
29*
32
30 6*
25 7*
24
23 31 8
22 9
14 13
21 10*
15
20
16 12 11
19 17
18
NOTE:
*: Indicates 590MPa-high-tensile steel panels. ABB00720 AB
27
23 24 25 26 28
6
5 7
14 13
A B
ABB00721AB
1. Front sidemember extension 11. Dash crossmember extension lower

2. Sidemember front outer reinforcement 12. Front body frame to side sill brace
3. Brake hose bracket 13. Front suspension crossmember bracket front
4. Front sidemember outer 14. Front sidemember inner
5. Front sidemember rear reinforcement lower 15. Subframe support panel inner
6. Front sidemember rear bulkhead 16. Radiator bracket lower
7. Front sidemember rear 17. Front end crossmember extension lower
8. Height sensor bracket 18. Front sidemember plate front lower
9. Dash crossmember lower bulkhead 19. Towing hook
10. Backbone sidemember extension 20. Subframe support panel outer
21. Subframe bulkhead support

22. Front sidemember plate A
23. Front sidemember inner reinforcement front 30
24. Front sidemember bulkhead front
25. Engine mounting bulkhead 27
26. Front suspension crossmember bulkhead
4
27. Engine mounting bracket
28. Front sidemember brace upper 25
29. Front sidemember inner reinforcement 14
30. Engine mounting reinforcement
31. Headlamp support panel 2 ABB00722 AB
32. Front end upper bar bracket
B 28
26
4
14
13 ABB00723AB
(Left side) 9
8
24 26
10*
7* 25
27
6* 22
31 28
30
23* 29
5* 24 ± 4 N·m
4 21
20 11
19
3*
24 ± 4 N·m 12
13
2 1 14
18
17 15
16
NOTE:
*: Indicates 590MPa-high-tensile steel panels. ABB00724 AB
25
24 27 28
26
6
5 7
21 B A 22
ABB00725AB
1. Front body frame to side sill brace 30. Headlamp support panel
2. Dash crossmember extension lower 31. Front end upper bar bracket
3. Backbone sidemember extension
4. Dash crossmember lower bulkhead
A 24
5. Front sidemember rear
6. Front sidemember rear bulkhead
7. Front sidemember rear reinforcement lower 25
8. Front outer sidemember
9. Brake hose bracket 27
10. Front sidemember extension
11. Front sidemember plate 22
12. Subframe bulkhead support
13. Subframe support panel inner 8
14. Subframe support panel outer 21 ABB00726AB
15. Towing hook
16. Front sidemember plate front lower B
17. Front end crossmember extension lower
24
18. Radiator bracket lower
19. Battery tray stay front 8
20. Battery tray stay rear
21. Front suspension crossmember bracket front
22. Front sidemember inner 22
23. Front sidemember inner reinforcement
24. Front sidemember brace upper 26
25. Transmission mounting reinforcement
26. Front suspension crossmember bulkhead 21 ABB00727AB
27. Transmission mounting bulkhead

28. Front sidemember inner reinforcement front
29. Horn bracket
FRONT DECK
6
4 5
15
3 7
2
8
13
12 14 5
3
9
1
2 4
11
10
11 ABB00728 AB
1. Cowl top panel lower 9. Brake pedal reinforcement upper

2. Cowl top stay side 10. Wiper front bracket
3. Wiper side bracket 11. Harness bracket
4. Upper frame extension inner 12. Wiper bracket centre
5. Fender bracket 13. Harness bracket
6. Cowl top panel upper 14. Cowl top panel inner
7. Deck crossmember bracket 15. Cowl top stay centre
8. Brake pedal support bracket
DASH PANEL
• The front frame structure is supported in three • The 590-MPa class high tensile strength steel
directions by the dash crossmember centre, dash panels have been adopted for the dash cross-
crossmember lower and front sidemember rear in member centre, dash crossmember side and
order to improve the frontal collision characteris- dash panel reinforcement to improve the frontal
tics, and increase the vehicle body rigidity. collision characteristics.
7
6 8
5 18*
16
10 9
4
11
17
3*
15
14*
12*
2 1
NOTE:
*: Indicates 590MPa-high-tensile steel panels. 13* ABB00729AB
1. Brake tube bracket 4. Dash heat protector bracket

2. Harness bracket 5. Dash panel
3. Dash crossmember centre 6. Backbone reinforcement front
7. Dash panel lower SIDE BODY

8. Front floor sidemember reinforcement upper M4010011001623
9. EPS ECU A bracket SIDE STRUCTURE
10. EPS ECU B bracket • The 590 MPa-high-tensile steel panel has been
11. EPS ECU C bracket adopted for the centre pillar and the roof side rail,
12. Dash crossmember side
and the 980 MPa-ultra-high-tensile steel panel
13. Dash crossmember lower
14. Dash crossmember extension
has been adopted for the front pillar and the side
15. Canister bracket sill to improve the collision characteristics.
16. Accelerator pedal bracket • The front pillar, centre pillar and rear pillar have
17. Steering shaft bracket been connected to the roof, and the closed sec-
18. Dash panel reinforcement tion structure has been adopted to the tailgate
opening to improve body rigidity, steering stability,
and riding comfort.
33
32
34 24 27
23
16
75
22 25 28
5
21 26
8 19 20 29
15
9*
14 16
1 30
7 13
13 32
10*
18 31
6**
12 17 35
71
11 39
38
72
65*
4 40
36 41
3 74
43 42
2 73
1 37
44
64** 70*
66
67 45
63 68*
47
62*
57*
55 69
61
63 53 47
60 51**
52
59 48
46
58
56* 54** 50
NOTE:
*: Indicates 590MPa-high-tensile steel panels.
**: Indicates 980MPa-ultra-high-tensile steel panels. 49 ABC00041AB
1. Front inner pillar lower 5. Deck crossmember bracket (Right side)

2. Hood opener bracket (Left side) 6. Front upper inner pillar
3. Cowl side trim bracket 7. Roof rail extension front inner
4. Harness bracket
8. Roof rail extension rear inner <Vehicles without 65. Roof side rail reinforcement centre
sunroof> 66. Centre pillar seat belt reinforcement upper
9. Roof side rail inner 67. Centre pillar seat belt reinforcement lower
10. Centre pillar inner upper 68. Rear door hinge reinforcement
11. Centre pillar inner lower 69. Rear door hinge reinforcement lower
12. Side sill end plate 70. Centre pillar reinforcement
13. Harness bracket 71. Roof side rail reinforcement rear
14. Cargo hook bracket 72. Roof side rail reinforcement rear
15. Rear wheel house reinforcement 73. Second seat belt reinforcement upper
16. Rear wheel house inner panel 74. Rear pillar reinforcement upper
17. Filler pipe mounting bracket (Left side) 75. Harness bracket (Right side)
18. Rear wheel house reinforcement rear (Left side)
19. Harness bracket (Right side)
20. Gate inner pillar extension lower
21. Gate inner pillar extension centre
22. Gate inner pillar extension upper
23. Gate inner pillar upper
24. Gate pillar inner reinforcement (Left side) <Vehicles
with electric tailgate>
25. Gate inner pillar lower
26. Gate pillar lower bulkhead
27. Gate pillar upper reinforcement
28. Gate pillar lower reinforcement
29. Quarter inner upper panel
30. Harness bracket
31. Second seat belt reinforcement lower
32. Quarter inner lower panel
33. Jack support (Right side)
34. Jack bracket (Right side)
35. Rear pillar reinforcement lower
36. Quarter inner front extension
37. Quarter inner front extension lower
38. Quarter outer panel extension upper
39. Gas spring reinforcement
40. Tailgate damper reinforcement side
41. Rear lamp housing
42. Rear lamp housing extension
43. Quarter outer panel extension rear
44. Quarter panel extension lower inner
45. Fuel filler neck bracket (Left side)
46. Side outer panel
47. Nut plate
48. Front fender bracket
49. Fender bracket
50. Front deck frame rear upper
51. Side sill reinforcement outer rear
52. Side sill bulkhead A
53. Side sill reinforcement support front
54. Side sill reinforcement outer front
55. Side sill inner support front
56. Side sill bulkhead front
57. Front pillar reinforcement lower
58. Front door hinge reinforcement lower
59. Front pillar reinforcement bulkhead centre
60. Front door checker reinforcement
61. Front door hinge reinforcement upper
62. Front pillar reinforcement lower support
63. Deck support pipe (Left side)
64. Front pillar reinforcement upper
SIDE STRUCTURE REINFORCEMENT

The ring structure of the side structure reinforcement
has been adopted to improve the side collision char-
acteristics and the rigidity of the whole vehicle.
Roof side rail
reinforcement rear
Gate pillar upper

reinforcement
Roof side rail
reinforcement centre
Front pillar
reinforcement upper Gate pillar lower
reinforcement
Rear pillar reinforcement

upper
Front pillar Rear pillar reinforcement

reinforcement lower lower
Centre pillar
reinforcement
Side sill reinforcement

outer rear

outer front ABB00770 AB
REAR BODY
M4010012001002
REAR END CROSSMEMBER

The 590-MPa class high tensile strength steel panels
have been adopted for the rear end inner crossmem-
ber side to improve the frontal collision characteris-
tics.
8 7
4*
9
3
1
4*
2
NOTE:
*: Indicates 590MPa-high-tensile steel panels. 3 ABB00771AB
1. Rear end inner centre crossmember ROOF

2. Spare tyre bracket M4010013001782
3. Rear bumper bracket The 590-MPa class high tensile strength steel panels
4. Rear end inner crossmember side has been adopted for the roof bow centre lower to
5. Spare tyre reinforcement rear end improve the side collision characteristics.
6. Rear bumper reinforcement
7. Rear end panel outer
8. Nut plate
9. Tailgate striker reinforcement
<Vehicles without Sunroof>
5
19
5.5 ± 1.5 N·m

6 7 8
21 20
5.5 ± 1.5 N·m
19 20
11 6
5.5 ± 1.5 N·m 13
12
14 9
18 10
13
15
17 16*
3
4
9
2 21 ± 8 N·m
NOTE: 1
*: Indicates 590MPa-high-tensile steel panels. 2 3 ABB00772 AB
<Vehicles with Sunroof>

5
19
5.5 ± 1.5 N·m
6 7 8
21 20
5.5 ± 1.5 N·m
19 11 6
20 13
5.5 ± 1.5 N·m
12
14 9
10
13
18 26 22
22
3 23
4
25 24
9
2 21 ± 8 N·m
1
2 3 ABB00773 AB
1. Map lamp bracket 4. Roof rail front

2. Holder bracket 5. Roof panel
3. Sunvisor bracket 6. Tailgate hinge reinforcement
7. Roof rail rear outer 22. Set bracket rear

8. Second seat belt bracket centre 23. Sunroof bracket
9. Roof rail bracket <Vehicles with roof rail> 24. Set bracket front
10. Roof rail rear inner 25. Set bracket front
11. Roof bow D 26. Roof reinforcement
12. Roof bow C
13. Head lining bracket UNDER BODY
14. Roof bow B M4010014001633
15. Roof bow centre upper FRONT FLOOR

16. Roof bow centre lower The 590-MPa class high tensile strength steel panels
17. Roof bow A have been adopted for the front floor sidemember
18. Weight assembly and front floor sidemember front, and the 980-MPa
19. Roof rail bracket <Vehicles with roof rail> class ultra high tensile strength steel panels for the
20. Roof carrier bracket <Vehicles without roof rail>
front floor crossmember front and front floor side sill
21. Roof rail bracket <Vehicles with roof rail>
inner to improve the body rigidity.
8 9
6
10
7
5
4**
18 ± 7 N·m
3
3
11
2*
1 19
15 12**
18
17
13
NOTE : 14*
*: Indicates 590MPa-high-tensile steel panels. 16*
**: Indicates 980MPa-ultra-high-tensile steel panels. ABB00774 AB
1. Front floor 12. Front floor side sill inner

2. Front floor sidemember 13. Front floor reinforcement
3. Nut plate 14. Front floor sidemember front
4. Front floor crossmember front 15. Front floor sidemember plate
5. Parking brake lever reinforcement 16. Front floor sidemember
6. Backbone reinforcement 17. Backbone crossmember front
7. Parking brake cable reinforcement 18. Muffler hanger hook
8. Seat centre bracket rear 19. Front floor crossmember rear centre
9. Seat side bracket rear
10. Front floor crossmember rear
11. Seat belt reinforcement
REAR FLOOR
have been adopted for the rear floor extension, sec-
ond seat rear reinforcement centre and rear seat
crossmember to improve the side collision character-
istics.
2
5
6
7
9
1*
15 14* 8
13*
10
17
11
12 18
16
15
16
NOTE :
*: Indicates 590MPa-high-tensile steel panels. ABC00047AB
1. Rear floor extension 15. Rear seat crossmember bulkhead side

2. Second seat front bracket centre 16. Sidemember front floor extension
3. Rear seat under floor 17. Rear seat crossmember bulkhead inner
4. Rear floor 18. Rear floor sidemember
5. Rear floor side panel
6. Rear floor crossmember rear end
7. Rear floor crossmember centre REAR FLOOR SIDEMEMBER REIN-
8. Third seat bracket centre front FORCEMENT
9. Rear floor crossmember front
10. Fuel tank rear bracket
11. Nut plate have been adopted for the rear bumper support, rear
12. Front stringer floor side sill inner and rear floor sidemember bulk-
13. Second seat rear reinforcement centre head to improve the rear collision characteristics.
14. Rear seat crossmember
4 3
27
6
25 5 7*
2 23 24
22
21 28
26
20
11 8
19* 3
1 18
17
16
12
10 9
15
14
NOTE :
*: Indicates 590MPa-high-tensile steel panels. 13* ABB00776AB
1 16 28
B 27 6
A
13
19
25
20 26 3
17 12
18 21
ABB00777AB
1. Rear floor sidemember reinforcement 17. Rear floor sidemember extension front
2. Third seat bracket side front 18. Rear tie down plate
3. Rear floor sidemember extension 19. Rear floor sidemember bulkhead
4. Muffler hanger rear (Right side) 20. Rear floor sidemember reinforcement rear
5. Rear floor crossmember extension rear 21. Trailing arm bracket
6. Third seat anchor reinforcement 22. Rear floor crossmember extension front
7. Rear bumper support 23. Rear floor crossmember extension centre
8. Shipping pipe 24. Rear floor crossmember extension centre lower
9. Rear spring house panel 25. Rear floor sidemember bulkhead rear
10. Rear spring house bracket 26. Rear floor sidemember reinforcement rear
11. Rear spring house reinforcement 27. Rear suspension bracket rear
12. Rear suspension bracket front 28. Pipe nut
13. Rear floor side sill inner
14. Rear brake hose bracket
15. Rear parking brake cable rear bracket
16. Rear floor sidemember lower
A B
1
1
16 16
21 13 20 12
ABB00778AB ABB00779AB
DOOR
M4010015001120
An uneven thickness steel sheet* has been used for
the front door panel inners to make the forward part
of the vehicle thicker for reduction in vehicle weight
and higher rigidity.
NOTE: *: A steel sheet of varying thickness that is
welded into one steel sheet.
(Front door)
1 2
13
4
11
8
12
10
7
5
6 Welded area
ABB00780AB
(Rear door)
14 15
16
21
24 17
25
22
23 20
18
19
ABB00781AB
1. Front door panel outer 14. Rear door panel outer

2. Front door window upper sash 15. Rear door window upper sash
3. Front door window rear sash 16. Rear door window rear sash
4. Front door latch reinforcement 17. Rear door latch reinforcement
5. Front door panel inner 18. Rear door panel inner
6. Nut plate 19. Nut plate
7. Front door side door beam 20. Rear door side door beam
8. Front door outer stiffener rear 21. Rear door outer stiffener rear
9. Front door outer stiffener front 22. Rear door outer stiffener front
10. Front door mirror reinforcement 23. Rear door hinge reinforcement
11. Front door window front sash 24. Rear door window front sash
12. Front door beltline outer reinforcement 25. Rear door beltline outer reinforcement
13. Front door beltline inner reinforcement

M4010000100128
A silencer (spray-type anti-vibration agent) have
been adhered on the top part of the floor and the
inside of the cowl top panel inner to improve
anti-vibration performance and to shut out exhaust
gas heat.
LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL
NOTE:
: 2.5 mm film thick spray-type anti-vibration agent. (Place two 1.6 mm melting sheet one on top of another.)
: 4.0 mm film thick spray-type anti-vibration agent. (Place three 1.6 mm melting sheet one on top of another.)
( ) indicates the number of 1.6 mm thick melting sheets that are used for repair. ABC00051AB
LOCATIONS USING URETHANE FOAM AND FOAM

MATERIAL
M4010018000405
CAUTION before welding work.

The sound dampening foam material may burn 1. The sound dampening foam material has been
when heated. Always observe the following adopted to the upper and lower sections of the
instructions: front pillar, roof side rail section, centre pillar
• Never use a gas burner to burn the areas lower section, wheel house arch, and rear end
where sound dampening foam material are inside to shield from external noise.
used. 2. Urethane foam has been inserted into the centre
• When cutting the parts which are provided pillar lower section to shield from external noise.
with sound dampening foam material, ensure
to use tools (air saw, etc.) that do not gener-
ate fire.
• If there are residual sound dampening foam
material remaining on the cut section (body
side), remove the sound dampening foam
material from periphery of the welding area
STIFFENER AND DAMP SHEET APPLICATION LOCATIONS
1
1
1
ABB00855AB

M4010001400490
To enhance the surface stiffness, a stiffener is
adhered to the inside of the side outer panel, and a
damping sheet is adhered to the inside of the dash
panel.
NOTE: .
• The main contents of a stiffener are epoxy resin.
It comes in a sheet form and contains a mixture
of glass fibre and filler, and cures (stiffens) when
heated.
• No spare part of the stiffener for repair is availa-
ble in the field. If the stiffener is damaged,
replace it together with the panel.
Stiffener
Stiffener
ABB00856AB
Damp sheet
ABB00857AB
2-1
GROUP 2
BODY DIMENSIONS
CONTENTS
BODY DIMENSIONS AND MEASUREMENT TYPE B (ACTUAL-MEASUREMENT

METHODS . . . . . . . . . . . . . . . . . . . . . 2-2 DIMENSIONS). . . . . . . . . . . . . . . . . . . 2-7
UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 2-7
TYPE A (PROJECTED DIMENSIONS) SUSPENSION INSTALLATION DIMENSIONS
................................. 2-3 ...................................... 2-9
UNDER BODY . . . . . . . . . . . . . . . . . . . . . . 2-3 FRONT BODY . . . . . . . . . . . . . . . . . . . . . . . 2-11
SUSPENSION INSTALLATION DIMENSIONS SIDE BODY . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
...................................... 2-5 REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 2-17
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2-2 BODY DIMENSIONS
BODY DIMENSIONS AND MEASUREMENT METHODS
BODY DIMENSIONS AND MEASUREMENT METHODS

M4020001000448
• •
Projected dimension
Centre of hole
Height
Probe
AB302138AE AB302140AF
Type A (projected dimensions) is the dimension Insert the tracking gauge probes securely into the
when a measurement location is projected onto measurement holes.
the plane. • When the standard dimensions in the illustration
NOTE: The height indicates a distance from the are enclosed by rectangle, this indicates that the
assumed standard line established 100 mm symmetrical left and right positions have the
below the lowest measurement point. same dimensions.
•
•
Ac
dim tual
en -me
sio as
n ure
d
A
A'
AB302139AE AB302141AD
Type B (actual-measurement dimensions) is the When using a notch for dimension measurement, set
actual distance between the measurement the measuring point at the centre of the outer
points. Measure using a tracking gauge or a panel notch.
measuring tape, etc. • The body centre points are shown for the pur-
NOTE: . pose of checking the position of the left and right
• Make the lengths of the tracking gauge symmetry location.
probes the same (A=A’).
• Do not bend or twist the measuring tape.
BODY DIMENSIONS 2-3
TYPE A (PROJECTED DIMENSIONS)

UNDER BODY
M4020005002598
Unit: mm
711 833
171
701 752 962

540 510
624 462
976 910 6 894 1262 877

197
960 875 5 894 1022 1056
564 375
2 4 350 393 582

374 11
1 3 7 8 440
10 12
9
1050
Centre line of the vehicle ABB00759AB
Unit: mm
1218
1394
6 1025 1416
1079 763 1138
983 641 1272
1216 1342
1180
1028 5 1125
960
544
686 1126
3 4 7 8 11
1 2 10 12
9
Centre line of the vehicle
ABB00760AB
No. Standard measurement point Hole shape Size mm

1* Centre of front end side panel mounting hole Round 16
2* Centre of front sidemember inner positioning hole Round 25
3* Centre of front axle crossmember mounting hole Round 15.5
4* Centre of front sidemember rear water draining hole Round 16
5 Centre of propeller shaft assembly mounting hole (left side) Round 11
6 Centre of propeller shaft assembly mounting hole (right side) Round 11
7* Centre of front floor sidemember front positioning hole Round 16
8* Centre of front floor sidemember front positioning hole Round 16
9* Centre of rear floor sidemember lower positioning hole Oblong 33.9×18
10* Centre of rear suspension bracket front water draining hole Round 16
2-4 BODY DIMENSIONS

11* Centre of rear floor sidemember lower positioning hole Round 25
12* Centre of trailer hitch mounting hole Round 11
NOTE: The * mark indicates the mounting position for the frame centring gauge.
Unit: mm
486
2 11 12
3 10
1 6
4 8 9
5
7
347 294 286 354 358
187 259
100 157 105 105 154
510 716
350 326
1049 750
1220 1136
1712
NOTE: The assumed standard line is established 100 mm below the measurement point No.4. ABB00756AB
1, 2 3 4
1 ABB00743AB ABB00745AB ABB00943AB
5, 6 7 8, 9
5 8
6
9
ABB00747AB ABB00748AB ABB00749AB
BODY DIMENSIONS 2-5
10, 11 12
10
11
SUSPENSION INSTALLATION
DIMENSIONS
M4020013002463
Unit: mm
822
510 694
603 289
1129 886 1288 1092 903
910 875 894 1000 1093
15 16
3 293 217 579 441 17
254
13 4 8 98 714
19 18
14
Unit: mm
1231
945 1145 1212 1047
1253
907 1294
1171
1028
1075
3 13 4 8 15 17
16
14

3 Centre of front axle crossmember mounting hole Round 15.5
4 Centre of front sidemember rear water draining hole Round 16
2-6 BODY DIMENSIONS

8 Centre of front floor sidemember front positioning hole Round 16
14 Centre of trailing arm assembly mounting hole Round 14
16 Centre of rear suspension crossmember mounting hole Round 15
18 Centre of rear shock absorber assembly mounting hole Round 64
19 Centre of front strut assembly mounting hole Round 92.6
A Vehicle centre B Vehicle centre Unit: mm
6˚54´ 6˚30´
539
3˚06´
A 1122
19
B
0˚ 18
15
3 16
14
13 17
782 4 8
462
294 284 354
162 222
100 105
217 1066 570
Standard line 510 820
1258
NOTE: The assumed standard line is established 100 mm below the measurement point No.4. ABB00764AB
3 4, 13 8
13
4
BODY DIMENSIONS 2-7
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
14, 15 16, 17, 18 19

18
16
14 15 17
ABB00750AB ABB00751AB ABB00744 AB

UNDER BODY
M4020005002606
Unit: mm
719 856
235
702 774 965

542 546
644 6 487
976
910 875 222 894 894 1262 1022 877 1056
960
567 5 378
2 4 350 399 582

1
3 7 8 377 460
10
11
12
1079
9
ABB00765AB
Unit: mm
1273
765 1138 1225 1027 1418
1185
6 643
996 1415 1230 1356
1046
5 1125
1081 565 960
704 1127
1 2 3 4 7 8 11
10 12
9
ABB00766AB
2-8 BODY DIMENSIONS

1 Centre of front end side panel mounting hole Round 16
2 Centre of front sidemember inner positioning hole Round 25
5 Centre of propeller shaft assembly mounting hole (left side) Round 11
6 Centre of propeller shaft assembly mounting hole (right side) Round 11
9 Centre of rear floor sidemember lower positioning hole Oblong 33.9×18
10 Centre of rear suspension bracket front water draining hole Round 16
11 Centre of rear floor sidemember lower positioning hole Round 25
12 Centre of trailer hitch mounting hole Round 11
1, 2 3 4
1 ABB00743AB ABB00745AB ABB00943AB
5, 6 7 8, 9
5 8
6
9
10, 11 12
10
11
BODY DIMENSIONS 2-9
SUSPENSION INSTALLATION
DIMENSIONS
M4020013002474
Unit: mm
841
546 707
614 295
910 886 875 1288 894 1092 1000 903
15 16
322 226 590 446
262
3 13 4 8 98 727 17
14
ABB00767AB
Unit: mm
1236
1151 1219 1050
954
1265
909
1300
1046 1173
1077
3 13 4 8 15 17
16
14
ABB00768AB

2-10 BODY DIMENSIONS
3 4, 13 8
13
4
14, 15 16, 17
17
16
14 15
BODY DIMENSIONS 2-11
FRONT BODY
M4020006001651
Unit: mm
38 Body centre point
1184
39
966
1644
1137
1494
568 1446
36
1010
412 35 34
28 1518 280
1430
32
916 27 415
30 1509
450
24
928 29
23
1052 450
22
ABB00687AB
Unit: mm
36
786
724
936
34
796 1568
1500
1497
28 793
32
27 937
629
1078
628
1082
1016 1020
894
22
21
ABB00677AB
33 Body centre point Unit: mm
353 1450
37
1490
344 1496
396
518
36
1473 34
786 35
872
1392
276 814 32
820 31
30 1005
26 869
24 1026
258
163 29
25
296
969 23
289
167
22
700 250
20 Body centre point 21

ABB00678AB

20 Body centre point of front end crossmember upper (Body centre Round 6
point)
21 Centre of intercooler mounting hole Round 12
22 Centre of front bumper reinforcement mounting hole Round 9
23 Centre of front bumper reinforcement mounting hole (left side) Round 12
24 Centre of front bumper reinforcement mounting hole (right side) Round 12
25 Centre of fender gusset positioning hole (left side) Round 15
26 Centre of fender gusset positioning hole (right side) Round 15
27 Centre of headlamp support panel upper mounting hole (left side) Round 11
28 Centre of headlamp support panel upper mounting hole (right side) Round 11
29 Centre of front sidemember inner positioning notch (left side) − −
30 Centre of front sidemember inner positioning notch (right side) − −
31 Centre of fender mounting hole Round 6.6
32 Centre of front end upper bar side positioning hole Oblong 8×12
33 Cowl top panel lower positioning notch (Body centre point) − −
35 Centre of front strut assembly mounting hole Round 11.5
36 Centre of hood hinge mounting hole Round 9
38 Centre of pin mounting hole (Body centre point) Rectangle 8×10
39 Corner of roof panel − −
20, 21 22, 23, 25 24, 26
20 26
25
23 24
21
22
27, 31, 32 28 29
32
27
31

30 33 34, 35
34
35
36, 37 38 39
37
36
SIDE BODY
M4020007001397
Unit: mm
42 46
44
40
713 867 48
1163
770 677 746
1232 878
986
869 758
41 45 49
1115 1126
43 47
ABB00680AB
Unit: mm
42 46
716
951
52
1117 897 54
50
1122 378
988
410
1197
1067
51 53
ABB00681AB

40 Front pillar positioning notch − −
42 Roof side rail positioning notch − −
43 Side sill positioning notch − −
44 Centre pillar positioning notch − −
48 Quarter panel positioning notch − −
50 Centre of front door upper hinge mounting hole Round 11
51 Centre of front door lower hinge mounting hole Round 11
52 Centre of rear door upper hinge mounting hole Round 11
53 Centre of rear door lower hinge mounting hole Round 11
54 Centre of rear door switch mounting hole Round 5
40 41, 51 42
41
51
ABB00703 AB ABB00704AB ABB00705AB

43 44 45, 53
45 53
46, 48 47 49
46
48
50 52 54
ABB00730AB ABB00731AB ABB00732 AB

REAR BODY
M4020008001367
Unit: mm
55
730
1073
56
724
762
1307 1042 1056
1545
58
1314 1120
272
614
59 1175
1417 62 1166
60 1056
61
ABB00733AB
Unit: mm
1166
57
1308
693
111
1115
60
61
ABB00733AB

55 Centre of tailgate hinge mounting hole Round 12
56 Centre of tailgate gas spring assembly mounting hole Round 9
57 Centre of rear combination lamp assembly mounting hole Square 8.5
58 Centre of rear combination lamp assembly mounting hole Round 8
59 Centre of rear bumper assembly mounting hole Round 7

60 Centre of rear bumper reinforcement mounting hole Round 15
61 Centre of rear bumper reinforcement mounting hole Round 15
62 Centre of tailgate striker mounting hole Round 14
55, 56 55 57, 58 57 59
58
56
60, 61 62
60
61
INTERIOR
M4020009001724
Unit: mm
1238
1273 46
1382 1372
1380 42 48
44
40
1432
1439 49
1430 45
41 1430
1430
47
43
ABB00702 AB
Unit: mm
46
42
44
40 48
1252 1234
1238 1202 1195
786 768 49
1034
45
41 725
803
47
43
ABB00710AB
64 Body centre point Unit: mm
998
1093
769
65 1116
600
66
ABB00741AB

63 Centre of backbone reinforcement positioning hole (Body centre point) Round 15

64 Alignment projection on the rear seat under floor (Body centre point) − −
65 Centre of rear shock absorber assembly mounting hole Round 14
66 Centre of rear end trim mounting hole Round 8.5
40 41 42
ABB00703 AB ABB00814AB ABB00705AB
43 44 45
46, 48 47 49
46
48
63 64 65

66
ABB00851AB
Unit: mm
67 69
1428
1431 1435 102
106
1431
68 70
ABB00676AB

67 Centre of front deck crossmember mounting hole Round 13
67, 68 69, 70
69
67
68 70
3-1
GROUP 3
WELDED PANEL
REPLACEMENT
CONTENTS
ULTRA HIGH STRENGTH STEEL PLATE REAR END CROSSMEMBER . . . . . . 3-23

................................. 3-2
REAR FLOOR. . . . . . . . . . . . . . . . . . . 3-24
FRONT END CROSSMEMBER . . . . . 3-2
QUARTER INNER. . . . . . . . . . . . . . . . 3-25
FENDER SHIELD. . . . . . . . . . . . . . . . 3-3
QUARTER INNER LOWER . . . . . . . . 3-29
FRONT SIDEMEMBER (PARTIAL
REPLACEMENT) . . . . . . . . . . . . . . . . 3-8 FRONT DOOR OUTER PANEL (WELDED
TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
FRONT PILLAR . . . . . . . . . . . . . . . . . 3-9
FRONT DOOR OUTER PANEL (ADHESION
CENTRE PILLAR . . . . . . . . . . . . . . . . 3-12 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
SIDE SILL. . . . . . . . . . . . . . . . . . . . . . 3-15 REAR DOOR OUTER PANEL (WELDED TYPE)

................................. 3-35
QUARTER OUTER . . . . . . . . . . . . . . 3-18
REAR DOOR OUTER PANEL (ADHESION
ROOF . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
3-2 WELDED PANEL REPLACEMENT
ULTRA HIGH STRENGTH STEEL PLATE
ULTRA HIGH STRENGTH STEEL PLATE

M4030002800073
ADVANTAGES OF ULTRA HIGH • For the part in which the ultra high strength steel
STRENGTH STEEL PLATE plate is used, do not repair it by cutting and bond-
ing to avoid the reduction in strength by heat.
The ultra high strength steel plate has the following
Instead, replace the whole assembly including
advantages as compared with conventional high
the part.
strength steel plate.
• Be careful with rough extending work, because
• It has tensile strength approximately 1.7 times
the ultra high strength steel plate has higher ten-
higher than the conventional high strength steel
sile strength and a higher yielding point than high
sheet.
strength steel plate and general steel plate. Care-
• It has a higher yielding point and yielding ratio
less work will cause symptom such as over-pull-
(yielding point/tensile strength).
ing and springback. Do not extend it completely
These advantages allow thinner and lighter plates
at a time. Do it gradually while removing the dis-
and better fuel efficiency than the high strength steel
tortion by sheet metal processing with a hammer.
plate.
• Plug welding of φ 8 mm diameter plug for repair
ensures the strength equivalent to spot welding
PRECAUTION UPON MAINTENANCE OF
for 2 steel sheets. For 3 sheets, weld 2 sheets
ULTRA HIGH STRENGTH STEEL PLATE each time instead of welding from one side to
• Use a spot cutter for ultra high strength steel give sufficient welding strength.
plate to ensure that the spot-welded area is cut
off.
FRONT END CROSSMEMBER

M4030003100408
Symbol Operation description

Spot welding
MIG plug welding : indicates two panels to be welded
( : indicates three panels to be welded )
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
ABC00011AB
(Use access holes to apply liberally to butt-welded joints.)
WELDED PANEL REPLACEMENT 3-3
FENDER SHIELD
REPAIR WELDS
ABB00797AB
FENDER SHIELD
M4030004001731

Spot welding
MIG spot welding
Braze welding
ABC00012AB
FENDER SHIELD
REPAIR WELDS
A
ABB00843 AB
NOTE: Refer to the Front End Crossmember section on P.3-2 for the welding point with headlamp support
panel lower.
FENDER SHIELD
24 ± 4 N·m
B
I
C
H
B
D
C
ABB00844AB
FENDER SHIELD
(With the front deck frame front upper E

and front deck frame rear upper removed)
D
F G
H H
(Right side) (Left side)
ABB00845AB
FENDER SHIELD
I J
ABB00846AB
NOTE ON REPAIR WORK INSTALLATION

REMOVAL
Front sidemember Hole position
inner
Front body frame

to side sill brace
Front sidemember Front

outer sidemember
outer
ABB00848 AB
Front body frame
to side sill brace ABB00847AB Before installing a new front sidemember, remove
Turn up the front sidemember outer as shown to cut the front floor sidemember from the existing front
off the welded point between the front sidemember sidemember. The welding point between the front
inner and the front body frame to side sill brace. sidemember inner and the front body frame-to-side
sill brace is not visible from the front sidemember
outer. Drill a hole into the front sidemember outer at
the same point as the welding point which is visible
from the front sidemember inner. Then cut the weld-
ing point from front body frame-to-side sill brace.
Then weld the front sidemember inner to the front
body frame-to-side sill brace and the front sidemem-
ber outer.
FRONT SIDEMEMBER (PARTIAL REPLACEMENT)
FRONT SIDEMEMBER (PARTIAL REPLACEMENT)

M4030000100937

Spot welding
MIG spot welding
Braze welding
ABC00013AB
REPAIR WELDS
(Right side) (Left side)
50 mm
45 mm
A B
ABC00059AB
NOTE: .
• Refer to the Front End Crossmember section on P.3-2 for the welding point with the headlamp support
panel lower.
• Refer to the Fender Shield section on P.3-3 for the welding points with the headlamp support panel and
headlamp support panel lower.
FRONT PILLAR
FRONT PILLAR
M4030005002113
CAUTION
When repairing the area using sound dampening foam material do not use firing tools since the
sound dampening foam material may burn.

Spot welding
MIG spot welding
Braze welding
ABC99914AB
REPAIR WELDS
Sound dampening
foam material
F
270 mm
A
The same position as the

E new front outer pillar parts
ABB00889 AB
FRONT PILLAR
Sound dampening
foam material E
F G
(With the front deck frame rear upper (With the side outer panel removed)
and side outer panel removed)
ABB00890AB
NOTE: Refer to the Fender Shield section on P.3-3 for the welding points with the front deck frame rear
upper.
NOTE ON REPAIR WORK

FRONT PILLAR
REMOVAL 3. When installing the new front pillar reinforcement

lower inner parts, in order to prevent the dripping
Cutting of sound dampening foam material to be filled into
position the front pillar in the next process, install the front
pillar silencer lower to the front pillar
reinforcement lower inner, and then apply the
270 mm butyl-tape to close the hole and gap of the front
pillar silencer lower.
ABC00045AB
1. Cut the side outer panel as shown to separate the

front pillar reinforcement lower from the front pillar
upper reinforcement and the side sill
reinforcement outer rear.
INSTALLATION
1. Install the new front lower inner pillar parts.
Side sill bulkhead A

outer rear
NOTE:
: Body sealant ABB00893AB
AB900563 AB 4. Prior to assembling the new front outer pillar

2. When installing the new side sill reinforcement parts, apply the body sealant to the area shown in
parts, remove the side sill reinforcement outer the figure.
rear and the side sill bulkhead A from the side sill
reinforcement.
Front pillar
silencer lower
Front pillar
reinforcement lower
ABB00872AB
Front inner
A pillar lower
NOTE:
: Sound dampening foam material
ABC00044AB
CENTRE PILLAR
5. After installing the front outer pillar, seal the hole

and flange with bolt and sheet-metal tape, and
then fill the hole with foam materials as shown in
the figure.
Sound dampening foam material: 3M ATD
Part No.08463
AB100787
6. Wait 2 hours after filling the sound dampening

foam material to remove the bolt and aluminium
tape, then melt the sound dampening foam
material with a soldering gun so a clip, etc. can
thoroughly be inserted in the hole filled with sound
dampening foam material.
CENTRE PILLAR
M4030006001362
CAUTION

Spot welding
MIG spot welding
Braze welding
ABC00015AB
CENTRE PILLAR
REPAIR WELDS
A
D
Cutting position 90 mm
B
F
B C
Sound dampening
foam material
The same position as the The same position as the
new centre outer pillar part new centre outer pillar part C
ABB00947AB
CENTRE PILLAR
Roof rail extension rear inner

<Vehicles without sunroof>
Cutting position
D E
F
(With the side outer panel removed)
ABB00948AB
Roof rail extension rear inner

NOTE ON REPAIR WORK
Roof side rail inner
REMOVAL
Cutting
position
Cutting Cutting
Cutting position position
position
Centre pillar inner upper ABB00902AB

ABB00902
2. Remove the roof rail extension rear inner as the

centre pillar inner upper remains on the vehicle
body and cannot be removed. Slit the roof side rail
ABB00901AB inner as shown, and pull it towards you to remove
it.
1. To cut the welding points between the centre pillar
reinforcement and side sill reinforcement outer
rear, cut the side outer panel as shown.
SIDE SILL
INSTALLATION
50 mm 50 mm
75 mm
75 mm
60 mm
60 mm
20 mm 25 mm
Side outer Cutting position 450 mm
panel
ABB00944AB Centre pillar
reinforcement
1. To guarantee the strength of the centre pillar
cut-off area, cut off the side outer panel as shown.
Centre pillar
inner upper A
Side outer
panel
NOTE:
Centre pillar : Body loose panel cushion ABB00903AB
inner lower
3. When installing the new centre outer pillar part,
because the sound dampening foam material
cannot be filled into the centre pillar, machine the
ABB00900AB body loose panel cushion (MR565301 or
MR435765) as a substitute according to the
2. When installing the new centre inner pillar parts, method shown in the figure, and then attach it to
remove the centre pillar inner lower from the the body.
centre inner pillar.
SIDE SILL
M4030007001677
CAUTION

Spot welding
MIG spot welding
Braze welding
ABC00016AB
SIDE SILL
REPAIR WELDS Sound dampening

foam material
25 mm 50 mm
40 mm C
A B
D
Sound dampening
foam material
Sound dampening
foam material
A B C
ABB00916 AB
SIDE SILL
D E
ABB00917AB
NOTE ON REPAIR WORK INSTALLATION

REMOVAL
Centre pillar
inner upper
80 mm
Centre pillar
inner lower
ABB00900AB
Quarter inner
front extension lower 1. When installing the new centre inner pillar parts,
remove the centre pillar inner upper from the
centre inner pillar.
Side sill reinforcement outer rear
Side sill end plate

ABC00018 AB
When removing the side sill reinforcement outer rear,

cut the centre pillar reinforcement 80 mm downward Side sill bulkhead A
from the installation hole of the rear door hinge AB501219 AD
because the centre pillar reinforcement interferes
2. When installing the new side sill reinforcement
with it. Remove the side sill end plate and the quarter
parts, use only the side sill reinforcement outer
inner front extension lower as the side sill reinforce-
rear and the side sill bulkhead A.
ment outer rear interferes with them.
3. After installing the side sill reinforcement, install
the side sill end plate and the quarter panel
extension front.
QUARTER OUTER
4. When assembling the new front floor side sill (1) Machine the body loose panel cushion
outer parts, carry out the following procedure. (MR565301 or MR435765) for replacement as
shown and apply it to the body side because
the sound dampening foam material cannot be
50 mm
filled into the centre pillar.
50 mm
75 mm
75 mm
60 mm
60 mm
20 mm 25 mm
450 mm
Centre pillar
reinforcement NOTE:
: Body sealant ABC00046AB
(2) Apply body sealant in the area shown in the

figure of the front floor side sill outer.
A
Side outer
panel
NOTE:
: Body loose panel cushion ABB00903AB
QUARTER OUTER
M4030008001391
CAUTION

Spot welding
MIG spot welding
Braze welding
ABB00859 AB
QUARTER OUTER
REPAIR WELDS
C
240 mm
D
B
20 mm
Centre of clip
mounting hole
E
Sound dampening
foam material
The same position as
the new quarter
panel outer parts.
Right side
4 points on
left side
A B C
ABB00865 AB
QUARTER OUTER
100 mm
Centre of tailgate
gas spring assembly
mounting hole
D E
ABB00866AB
NOTE: 1. When installing the new quarter panel extension

rear lower parts, apply the body sealant to the
areas as shown in advance.
2. When assembling the new quarter panel outer
parts, carry out the following procedure.
15 mm 190 mm
A
NOTE: : Cuttable range ABB00867AB
Partial replacement is possible depending on the

range of damage.
NOTE ON REPAIR WORK 40 mm
INSTALLATION
Rear pillar
reinforcement
lower
Side outer
panel Quarter inner
front extension
NOTE: NOTE: A
: Body sealant ABB00877 AB : Body loose panel cushion ABB00870AB
ROOF
(1) Machine the body loose panel cushion

(MR565301 or MR435765) for replacement as
shown and apply it to the body side because
the sound dampening foam material cannot be
filled into the wheel arch.
Left side
NOTE: : Body sealant ABC00062AB
(2) Apply the body sealant in advance to the

areas as shown.
ROOF
M4030011001744

Spot welding
MIG spot welding
Braze welding
ABB00938AB
ROOF
REPAIR WELDS
A
A
A
5.5 ± 1.5 N·m
A
ABB00939AB
Adhesive: Urethane body sealer INSTALLATION

Brand: 3M ATD Part No.08684, 08782 or
equivalent
NOTE ON REPAIR WORK
Roof rack seal
AB900631AB
When installing the new roof carrier bracket and roof

rail bracket, install the roof rack seal to avoid water
ingress.

M4030015000743

Spot welding
MIG spot welding
Braze welding
ABB00816AB
REPAIR WELDS
A
ABB00821AB
REAR FLOOR
REAR FLOOR
M4030010001309

Spot welding
MIG spot welding
Braze welding
ABB00828AB
REPAIR WELDS
A
ABB00827AB
B
A B
ABB00826AB
AB
NOTE: Refer to the Rear End Crossmember section on P.3-23 for the welding points with the rear end panel.
QUARTER INNER
QUARTER INNER
M4030012001446
CAUTION

Spot welding
MIG spot welding
Braze welding
ABB00860AB
REPAIR WELDS
E
70 mm
Left side
Right side
Right side
C
B
Sound dampening
foam material
A
D
H
F G
A
(With the rear pillar reinforcement and
rear pillar reinforcement lower removed)
ABB00925AB
QUARTER INNER
Right side
Sound dampening
foam material
Left side
B C
(Left side)
D C
(Right side)
AB
ABB00926AB
QUARTER INNER
10.0 ± 4.0 N·m Sound dampening

foam material
Left side Left side

G H
(Right side)
ABB00927AB
NOTE: Refer to the Quarter Outer section on P.3-18 for the welding points with the quarter outer.
QUARTER INNER
NOTE ON REPAIR WORK 2. When installing the new rear pillar reinforcement
INSTALLATION lower part, machine the body loose panel cushion
shown and apply it to the rear pillar reinforcement
80 mm lower part because the sound dampening foam
40 mm material cannot be filled into the rear pillar
reinforcement lower.
Rear end Gate pillar
silencer side lower bulkhead
A
40 mm
Roof side rail

reinforcement
rear
ABB00891AB
3. When installing the new gate pillar reinforcement

parts, in order to prevent the dripping of sound
Quarter inner dampening foam material to be filled into the gate
upper panel Side outer
panel
pillar in the next process, install the rear end
NOTE: A silencer side to the gate pillar lower bulkhead, and
: Body loose panel cushion ABC00079AB then apply the butyl-tape to close the gap of the
rear end silencer side.
1. When installing the new quarter panel upper inner
parts, machine the body loose panel cushion
(MR565301 or MR435765) for replacement as B
shown and apply it to the quarter panel upper
inner parts because the sound dampening foam
material cannot be filled into the quarter panel
upper inner.
40 mm
35 mm
A
Gate inner pillar Gate pillar lower
85 mm extension lower reinforcement
NOTE: B
: Sound dampening foam material
ABB00871AB
4. After installing the quarter panel extension rear

Rear pillar Quarter inner lower, seal the hole and flange with sheet-metal
reinforcement front extension
lower tape, and then fill the hole with the sound
dampening foam material as shown in the figure
NOTE: A of the instructions.
QUARTER INNER LOWER
Sound dampening foam material: 3M ATD 5. Wait 2 hours after filling the sound dampening
Part No.08463 foam material to remove the bolt and aluminium
tape, then melt the sound dampening foam
material with a soldering gun so a clip, etc. can
thoroughly be inserted in the hole filled with sound
dampening foam material.
AB100787
QUARTER INNER LOWER

M4030001100338
CAUTION

Spot welding
MIG spot welding
Braze welding
ABB00861 AB
QUARTER INNER LOWER
REPAIR WELDS
70 mm
Left side
Right side
Right side
C
Sound dampening
foam material
A
(With the rear pillar reinforcement and B
rear pillar reinforcement lower removed) ABB00933AB
QUARTER INNER LOWER
C
(Left side)
C
(Right side)
ABB00934AB
NOTE: Refer to the Quarter Outer section on P.3-18 for the welding points with the quarter outer.
FRONT DOOR OUTER PANEL (WELDED TYPE)
NOTE ON REPAIR WORK When installing the new rear pillar reinforcement
lower part, machine the body loose panel cushion
INSTALLATION
shown and apply it to the rear pillar reinforcement
lower part because the sound dampening foam
material cannot be filled into the rear pillar reinforce-
ment lower.
40 mm
35 mm
85 mm
Rear pillar Quarter inner

reinforcement front extension
lower
NOTE: A
FRONT DOOR OUTER PANEL (WELDED TYPE)

M4030001501061

Spot welding
MIG spot welding
Braze welding
ABB00817AB
FRONT DOOR OUTER PANEL (ADHESION TYPE)
REPAIR WELDS
50 mm
NOTE: A
: Adhesive ABB00805 AB
Adhesive: Urethane body sealer Brand: 3M ATD Part No.08684, 08782 or

equivalent
NOTE: After hemming the new front door panel outer part, MIG spot weld the flange overlap section at a pitch
of 50 mm.

M4030001701139

Spot welding
MIG spot welding
Braze welding
ABB00818AB
REPAIR WELDS
NOTE:
: Adhesive 1 A
: Adhesive 2 ABB00806AB
• Adhesive 1: Urethane body sealer NOTE ON REPAIR WORK

INSTALLATION
equivalent
• Adhesive 2: Epoxyayresin adhesive 1. When installing the new front door panel outer
Brand: 3M ATD Part No.8115 or equivalent part, grind the bonding surface and remove the
paint to improve adhesion. Then, degrease the
front door panel outer.
2. Install the front door panel outer and hem it. Then,
wipe off the adhesive that squeezed out.
REAR DOOR OUTER PANEL (WELDED TYPE)
REAR DOOR OUTER PANEL (WELDED TYPE)

M4030001600797

Spot welding
MIG spot welding
Braze welding
ABB00819AB
REPAIR WELDS
50 mm
NOTE: A
: Adhesive ABB00807 AB
Adhesive: Urethane body sealer Brand: 3M ATD Part No.08684, 08782 or

equivalent
NOTE: After hemming the new front door panel outer part, MIG spot weld the flange overlap section at a pitch
of 50 mm.
REAR DOOR OUTER PANEL (ADHESION TYPE)
REAR DOOR OUTER PANEL (ADHESION TYPE)

M4030001800779

Spot welding
MIG spot welding
Braze welding
ABB00820AB
REPAIR WELDS
NOTE:
: Adhesive 1
: Adhesive 2 A ABB00808 AB
• Adhesive 1: Urethane body sealer NOTE ON REPAIR WORK

INSTALLATION
equivalent
• Adhesive 2: Epoxyayresin adhesive 1. When installing the new rear door panel outer
Brand: 3M ATD Part No.8115 or equivalent part, grind the bonding surface and remove the
paint to improve adhesion. Then, degrease the
rear door panel outer.
2. Install the rear door panel outer and hem it. Then,
wipe off the adhesive that squeezed out.
4-1
GROUP 4
CORROSION
PROTECTION
CONTENTS
BODY SEALING LOCATIONS . . . . . 4-2 UNDERCOAT APPLICATION LOCATIONS

................................. 4-6
4-2 CORROSION PROTECTION
BODY SEALING LOCATIONS

M4040001002480
If the sealant application is directly visible on the NOTE: The bold dotted line indicates the application
outer plate and requires appearance quality of the area on the underside.
application in areas such as the drip rail, pillar, clinch
and so on, then apply the sealant so that it is flat, or
wipe off any excess mounding after the application.
Be careful not to obstruct the water draining hole.
FLOOR
3
2 4
1
ABB00755AB
UPPER BODY
6
8
7 9
ABB00753AB
CORROSION PROTECTION 4-3
SIDE BODY
Left side only
13 15
10
14 16 17
11 12
ABC00078 AB
1 3
Driver's side only
ABC00032 AB ABC00023AB
2 4
ABC00022 AB ABC00024 AB
5 9
ABC00033AB ABC00019AB
6 10
Driver's side only ABC00034AB ABC00036AB
7 11
ABC00035 AB ABC00025AB
8 12
CORROSION PROTECTION 4-5
13 17
14 Hood
ABC00028AB ABB00684AB
15 Left side only Front door
16 Rear door
UNDERCOAT APPLICATION LOCATIONS
Tail gate
ABB00685 AB
UNDERCOAT APPLICATION LOCATIONS

M4040003001610
• The under parts of the body is undercoated for • To avoid splashing of undercoat material during
anti-corrosive, anti-rust, anti-chipping, and the coating, protect component installation holes
anti-vibration performance. with masking tape.
• After correcting the body, restore as shown in the
instructions of the figure, if necessary.
NOTE:
: Undercoat (film thickness is at least 0.8 mm) ABB00757AB
5-1
GROUP 5
SYNTHETIC-RESIN
PARTS
CONTENTS
LOCATION OF SYNTHETIC-RESIN PARTS ................................. 5-2

5-2 SYNTHETIC-RESIN PARTS
LOCATION OF SYNTHETIC-RESIN PARTS

M4050001002102
The location and material of each of the principal
synthetic-resin parts are shown below.
8
7 10
40 2
35
3 1, 4
27
26
28
6
25
29
23 5
24 ABC00037 AB
17 16
32 38 17
31
13 37
34
14
12
36 33
15
30
19
22 9 18
21 20
39
11 ABC00038AB
SYNTHETIC-RESIN PARTS 5-3
No. Part Name Name Of Resin Abbreviat Heat-resis

ion tant Temp
[°C ]
1 Door mirror outer cover (colour) Acrylonitrile butadiene styrene ABS 80
2 Tailgate garnish
3 Radiator grille Acrylonitrile styrene acrylate ASA 80
4 Door mirror outer cover (black)
5 Headlamp Polycarbonate PC 120
6 Door outside handle Polycarbonate+Polyethylene PC+PET 120
terephthalate
7 Front roof rail cover
8 Rear roof rail cover
9 Rear splash shield Polyethylene terephthalate+Allyl PET+AC 80
chloride
10 Rear wiper arm assembly Glass fibre reinforced polyethylene PET-GF45 80
terephthalate (45%)
11 Shift lever panel assembly Polyoxymethylene POM 80
12 Front door sash trim Polypropylene PP 80
13 Inside rear view mirror
14 Quarter trim lower
15 Rear end trim
16 Tailgate upper trim
17 Tailgate opening side trim
18 Rear splash shield
19 Rear scuff plate
20 Front scuff plate
21 Cowl side trim
22 Front splash shield
23 Front bumper lamp hole cover Rubber modified polypropylene PP+E/P 80
24 Front fog lamp bezel
25 Front bumper face
26 Radiator grille
27 Rear bumper face
28 Rear mud guard
29 Side air dam
30 Front door trim Talc filled polypropylene (10%) PP-TD10 110 − 120
31 Centre pillar trim lower
32 Rear door trim
33 Tailgate trim
34 Front pillar trim Talc filled rubber modified PP+E/P-T 80
polypropylene (15%) D15
5-4 SYNTHETIC-RESIN PARTS
No. Part Name Name Of Resin Abbreviat Heat-resis

ion tant Temp
[°C ]
35 Front deck garnish Talc filled polypropylene (20%) PP-TD20 120 − 130
36 Instrument panel
37 Centre pillar trim upper
38 Quarter trim upper
39 Rear console
40 Roof drip moulding assembly Thermoplastic elastomer TPO 80 − 100
NOTE: .
• A slash (/) in the material symbol indicates that two different materials make two-layer construction. A plus
sign (+) indicates that the two different materials mix each other.
• The indicated heat-resistant temperature for parts which are composed of two or more types of material is
the value for the material with the lowest heat-resistant temperature.
• The material symbols for synthetic-resin parts are embossed on the parts in hidden places.
6-1
GROUP 6
BODY COLOUR
CONTENTS
BODY COLOUR CODE . . . . . . . . . . . 6-2 FRONT END . . . . . . . . . . . . . . . . . . . . . . . . 6-3

WHEELHOUSE . . . . . . . . . . . . . . . . . . . . . . 6-3
BODY COLOUR CHARTS. . . . . . . . . 6-2 FRONT BUMPER . . . . . . . . . . . . . . . . . . . . 6-4
REAR BUMPER . . . . . . . . . . . . . . . . . . . . . 6-4
BODY COLOURING . . . . . . . . . . . . . 6-3
6-2 BODY COLOUR
BODY COLOUR CODE
BODY COLOUR CODE

M4060001001382
Body colour code is stamped on the vehicle informa-
tion code plate, which is attached on the hood.
Body colour code
AC905413 ABA00001AB
BODY COLOUR CHARTS

M4060002004049
Check the vehicle’s body colour code, and then use
this body colour chart to determine the refinishing
paint supplier from which the colour can be pur-
chased.
Colour Colour Colour Colour name Coating film Composition of film
code number structure
SILVER A31 CMA10031 Cool Silver Metallic 2M Metallic
REDDISH BROWN C07 CMC10007 Copper Metallic 2M Metallic
DARK BLUE D14 CMD10014 Cosmic Blue Mica 2P Interferenced Pearl
GREY U17 CMU10017 Titanium Grey Metallic 2M Metallic
BLUISH SILVER U21 CMU10021 Technical Silver Metallic 2M Metallic
WHITE W13 CMW10013 White Pearl 3P Pearl
WHITE W37 CMW10037 White Solid 2S Solid
BLACK X42 AC11342 Black Mica 2P Interferenced Pearl
NOTE: .
• The coating film structure indicates top coating only (2S: 2 coat solid, 2M: 2 coat metallic, 2P: 2 coat pearl,
3P: 3 coat pearl).
• For painting, inner panel colours should be similar to the outer panel colours.
• The roof rail is coated in Black (AC10657).
BODY COLOUR 6-3
BODY COLOURING
BODY COLOURING
FRONT END
M4060015000757
NOTE: : Black (AC10657) ABC00017AB
WHEELHOUSE
M4060012000974
(EXCEPT COLOUR CODE D14, X42)

<Front>
<Rear>
NOTE:
: Black (AC10657)
: Black (AC10657) <Except vehicle with rear splash shield> ABC00008AB
6-4 BODY COLOUR
BODY COLOURING
FRONT BUMPER
M4060000500392
A 1
1 Body Colour 2
2 Material colour A ABC00009AB
REAR BUMPER
M4060000300257
2
1 Body Colour A
2 Material colour ABC00010 AB

Body Repair Manual

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0-1

VEHICLE IDENTIFICATION . . . . . . . 0-2 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Item GF2W GF3W

Item GF2W GF3W

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

WARNING SRS-related component.

BODY COMPONENTS. . . . . . . . . . . . 1-2 ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

BODY CONSTRUCTION CHARACTERISTICS LOCATIONS USING URETHANE FOAM AND

1. Front bumper reinforcement 3. Headlamp support panel lower

BODY MAIN CROSS-SECTIONAL VIEWS

Roof side rail

Side outer Side outer

C Centre pillar seat belt

ABB00785 AB Side outer panel ABB00788 AB

Quarter outer panel

Panel positioning notch ABC00082AB

SIDE OUTER PANEL

Centre outer pillar

Quarter panel outer

Front floor side sill outer

BODY CONSTRUCTION CHARACTERISTICS

1. Front bumper reinforcement NOTE:

Tighten the front bumper reinforcement bolts in the

Tighten the headlamp support panel upper bolts in

1. Fender gusset 12. Upper frame rear bulkhead

23. Front sidemember FRONT SIDEMEMBER REINFORCEMENT

1. Front sidemember extension 11. Dash crossmember extension lower

21. Subframe bulkhead support

27. Transmission mounting bulkhead

1. Cowl top panel lower 9. Brake pedal reinforcement upper

1. Brake tube bracket 4. Dash heat protector bracket

7. Dash panel lower SIDE BODY

1. Front inner pillar lower 5. Deck crossmember bracket (Right side)

SIDE STRUCTURE REINFORCEMENT

Gate pillar upper

Rear pillar reinforcement

Front pillar Rear pillar reinforcement

Side sill reinforcement

Side sill reinforcement

REAR END CROSSMEMBER

1. Rear end inner centre crossmember ROOF

<Vehicles without Sunroof>

5.5 ± 1.5 N·m

<Vehicles with Sunroof>

5.5 ± 1.5 N·m

1. Map lamp bracket 4. Roof rail front

7. Roof rail rear outer 22. Set bracket rear

15. Roof bow centre upper FRONT FLOOR

1. Front floor 12. Front floor side sill inner

1. Rear floor extension 15. Rear seat crossmember bulkhead side

1. Front door panel outer 14. Rear door panel outer

SILENCER APPLICATION LOCATIONS

LOCATIONS USING URETHANE FOAM AND FOAM

CAUTION before welding work.

STIFFENER AND DAMP SHEET APPLICATION LOCATIONS

BODY DIMENSIONS AND MEASUREMENT TYPE B (ACTUAL-MEASUREMENT

BODY DIMENSIONS AND MEASUREMENT METHODS

TYPE A (PROJECTED DIMENSIONS)

701 752 962

976 910 6 894 1262 877

2 4 350 393 582

No. Standard measurement point Hole shape Size mm