Body Repair: Section

BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY
SECTION BRM BODY REPAIR

B
E
CONTENTS
FOR EUROPE (LHD) Front Pillar ...............................................................40 F
Center Pillar .............................................................44
VEHICLE INFORMATION ............................. 4 Outer Sill (Partial Replacement) ..............................47
Outer Sill .................................................................48 G
BODY EXTERIOR PAINT COLOR ..................... 4 Inner Sill ...................................................................50
Body Exterior Paint Color ....................................... 4 Rear Fender ............................................................53
Rear Fender Extension ............................................56
PRECAUTION ............................................... 5 Outer Rear Wheelhouse ..........................................56
H
PRECAUTIONS ................................................... 5 Inner Rear Wheelhouse ...........................................57

Precautions for Removing Battery Terminal ............. 5 Inner Rear Pillar Reinforcement ..............................58
Inner Rear Pillar .......................................................59 I
REPAIRING HIGH STRENGTH STEEL .............. 7 Rear Panel ..............................................................61
High Strength Steel (HSS) ........................................ 7 Rear Floor Rear .....................................................62
Rear Side Member Extension (SUV Models) ..........63 J
PREPARATION ........................................... 12 Rear Side Member Extension (Wagon Models) ......63
Roof (Normal Roof Models) .....................................65
REPAIRING MATERIAL ....................................12 Roof (Sunroof Models) ............................................66
Foam Repair ........................................................... 12 BRM
Roof Rail ..................................................................67
BODY COMPONENT PARTS ............................14 SERVICE DATA AND SPECIFICATIONS
Ultra High Strength Steel Part ................................. 14 L
Underbody Component Parts .................................. 14
(SDS) ............................................................ 68
Body Component Parts ........................................... 17 BODY ALIGNMENT .......................................... 68
Body Center Marks ..................................................68 M
REMOVAL AND INSTALLATION ............... 21
Description ...............................................................69
CORROSION PROTECTION .............................21 Engine Compartment ...............................................69
Description .............................................................. 21 Underbody ...............................................................72
Passenger Compartment .........................................75 N
Undercoating ........................................................... 21
Body Sealing ........................................................... 22 Rear Body ...............................................................78
BODY CONSTRUCTION ....................................26 LOCATION OF PLASTIC PARTS .................... 80 O

Body Construction ................................................... 26 Precautions for Plastics ...........................................80
Location of Plastic Parts ..........................................81
REPLACEMENT OPERATIONS ........................28 FOR EUROPE (RHD) P
Description .............................................................. 28
Welding of Ultra High Strength Steel ...................... 29 VEHICLE INFORMATION ........................... 83
Radiator Core Support ............................................ 31
Hoodledge ............................................................... 31 BODY EXTERIOR PAINT COLOR ................... 83
Hoodledge (Partial Replacement) ........................... 33 Body Exterior Paint Color ......................................83
Front Side Member ................................................. 35
Front Side Member (Partial Replacement) .......... 38
PRECAUTION .............................................. 84
BRM-1
PRECAUTIONS ................................................. 84 Passenger Compartment ...................................... 154
Precautions for Removing Battery Terminal ........... 84 Rear Body ............................................................ 157
REPAIRING HIGH STRENGTH STEEL ............ 86 LOCATION OF PLASTIC PARTS .................... 159
High Strength Steel (HSS) ...................................... 86 Precautions for Plastics ........................................ 159
Location of Plastic Parts ....................................... 160
PREPARATION ........................................... 91 FOR RUSSIA
REPAIRING MATERIAL .................................... 91 VEHICLE INFORMATION ......................... 162
Foam Repair ........................................................... 91
BODY EXTERIOR PAINT COLOR ................... 162
BODY COMPONENT PARTS ........................... 93 Body Exterior Paint Color ................................... 162
Ultra High Strength Steel Part ................................ 93
Underbody Component Parts ................................. 93 PRECAUTION ........................................... 163
Body Component Parts .......................................... 96
PRECAUTIONS ................................................ 163
REMOVAL AND INSTALLATION .............. 100 Precautions for Removing Battery Terminal ......... 163
CORROSION PROTECTION ........................... 100 REPAIRING HIGH STRENGTH STEEL ........... 165
Description .............................................................100 High Strength Steel (HSS) .................................... 165
Undercoating .........................................................100
Body Sealing .........................................................101 PREPARATION ......................................... 170
BODY CONSTRUCTION ................................. 105 REPAIRING MATERIAL ................................... 170
Body Construction .................................................105 Foam Repair ......................................................... 170
REPLACEMENT OPERATIONS ..................... 107 BODY COMPONENT PARTS .......................... 172

Description .............................................................107 Ultra High Strength Steel Part ............................... 172
Welding of Ultra High Strength Steel .....................108 Underbody Component Parts ............................... 172
Radiator Core Support ...........................................110 Body Component Parts ......................................... 175
Hoodledge .............................................................110
Hoodledge (Partial Replacement) .........................112 REMOVAL AND INSTALLATION ............. 179
Front Side Member ................................................114
CORROSION PROTECTION ........................... 179
Front Side Member (Partial Replacement) .........117
Description ............................................................ 179
Front Pillar .............................................................119
Undercoating (MR20DD Engine Models) .............. 179
Center Pillar ...........................................................123
Undercoating (Except For MR20DD Engine Mod-
Outer Sill (Partial Replacement) ............................126
els) ........................................................................ 180
Outer Sill ...............................................................127
Body Sealing (MR20DD Engine Models) .............. 181
Inner Sill .................................................................129
Body Sealing (QR25DE Engine Models) .............. 184
Rear Fender ..........................................................132
Body Sealing (R9M Engine Models) ..................... 187
Rear Fender Extension ..........................................135
Outer Rear Wheelhouse ........................................135 BODY CONSTRUCTION .................................. 190
Inner Rear Wheelhouse .........................................136 Body Construction ................................................. 190
Inner Rear Pillar Reinforcement ............................137
Inner Rear Pillar .....................................................138 REPLACEMENT OPERATIONS ...................... 192
Rear Panel ............................................................140 Description ............................................................ 192
Rear Floor Rear ...................................................141 Welding of Ultra High Strength Steel .................... 193
Rear Side Member Extension (SUV Models) ........142 Radiator Core Support .......................................... 195
Rear Side Member Extension (Wagon Models) ....142 Hoodledge ............................................................. 195
Roof (Normal Roof Models) ...................................144 Hoodledge (Partial Replacement) ......................... 197
Roof (Sunroof Models) ..........................................145 Front Side Member ............................................... 199
Roof Rail ................................................................146 Front Side Member (Partial Replacement) ........ 202
Front Pillar ............................................................. 204
SERVICE DATA AND SPECIFICATIONS Center Pillar .......................................................... 208
(SDS) .......................................................... 147 Outer Sill (Partial Replacement) ........................... 211
Outer Sill .............................................................. 212
BODY ALIGNMENT ......................................... 147 Rear Fender .......................................................... 215
Body Center Marks ................................................147 Rear Panel ........................................................... 218
Description .............................................................148 Rear Floor Rear ................................................... 219
Engine Compartment .............................................148 Rear Side Member Extension (SUV Models) ........ 220
Underbody .............................................................151
BRM-2
Rear Side Member Extension (Wagon Models) .... 220 Engine Compartment (Except For MR20DD En-
gine Models) .......................................................... 227 A
SERVICE DATA AND SPECIFICATIONS Underbody ............................................................. 230
(SDS) .......................................................... 222 Passenger Compartment (MR20DD Engine Mod-
els) ......................................................................... 233 B
BODY ALIGNMENT ......................................... 222 Passenger Compartment (Except For MR20DD
Body Center Marks (MR20DD Engine Models) .... 222 Engine Models) ...................................................... 236
Body Center Marks (Except For MR20DD Engine Rear Body ............................................................. 239
Models) ................................................................. 223 C
Description ............................................................ 224 LOCATION OF PLASTIC PARTS .................. 241
Engine Compartment (MR20DD Engine Models).. 224 Precautions for Plastics ......................................... 241
Location of Plastic Parts ........................................ 242 D
BRM
BRM-3
BODY EXTERIOR PAINT COLOR
< VEHICLE INFORMATION > [FOR EUROPE (LHD)]
VEHICLE INFORMATION
Body Exterior Paint Color INFOID:0000000010843415
JSKIA4358ZZ
Color code BAX6 BEAN BEAR BG41 BK23 BKAD BQAB BRAQ
Dark Ol- Dark
Description Red Orange Black Silver Gray White
ive Blue
Component
Paint type note 2S 2PM 2PM 2P 2M 2M 3P 2M
Hard clear
× × × × – – – ×
coat
Door mirror cover Body color BAX6 BEAN BEAR BG41 BK23 BKAD BQAB BRAQ
Chromium
Front grille Cr Cr Cr Cr Cr Cr Cr Cr
plate
Bumper fascia Body color BAX6 BEAN BEAR BG41 BK23 BKAD BQAB BRAQ
Fillet molding Material color – – – – – – – –

Chromium
Door outside handle Cr Cr Cr Cr Cr Cr Cr Cr
plate
Rear spoiler (Side) Black G01 G01 G01 G01 G01 G01 G01 G01
Rear spoiler (Upper) Body color BAX6 BEAN BEAR BG41 BK23 BKAD BQAB BRAQ
Chromium
Back door finisher Cr Cr Cr Cr Cr Cr Cr Cr
plate
Back door Body color BAX6 BEAN BEAR BG41 BK23 BKAD BQAB BRAQ
Sill cover Material color – – – – – – – –
Side guard molding Material color – – – – – – – –

NOTE:
• 2M: 2-Coat Metallic
• 2P: 2-Coat pearl
• 2S: 2-Coat solid
• 2PM: 2-Coat Pearl metallic
BRM-4
PRECAUTIONS
< PRECAUTION > [FOR EUROPE (LHD)]
PRECAUTION A
PRECAUTIONS
Precautions for Removing Battery Terminal INFOID:0000000010843416
B
• With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key
or remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time. C
• When disconnecting the 12V battery terminal, turn off the ACC
power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below. D
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC E
detection or ECU data damage may occur.
• For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch. F
NOTE:
SEF289H
If the ignition switch is turned ON with any one of the terminals of
main battery and sub battery disconnected, then DTC may be detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC. G
NOTE:
The removal of 12V battery may cause a DTC detection error.
H
HOW TO DISCONNECT 12V BATTERY TERMINAL
Disconnect 12V battery terminal according to Instruction 1 or Instruction 2 described below.
For vehicles parked by ignition switch OFF, refer to Instruction 2.
I
INSTRUCTION 1
1. Open the hood.
2. Turn key switch to the OFF position with the driver side door opened. J
3. Get out of the vehicle and close the driver side door.
4. Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time. BRM
D4D engine : 20 minutes

HRA2DDT : 12 minutes L
K9K engine : 4 minutes
M9R engine : 4 minutes
R9M engine : 4 minutes M
V9X engine : 4 minutes
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of N
this caution results in the activation of ACC power supply according to the Auto ACC function.
5. Remove 12V battery terminal.
CAUTION: O
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF)
1. Unlock the door with intelligent key or remote keyless entry. P
NOTE:
At this moment, ACC power is supplied.
2. Open the driver side door.
3. Open the hood.
4. Close the driver side door.
5. Wait at least 3 minutes.
BRM-5
PRECAUTIONS
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
CAUTION:
BRM-6
REPAIRING HIGH STRENGTH STEEL
A
High Strength Steel (HSS) INFOID:0000000010843417
High strength steel is used for body panels in order to reduce vehicle weight. B
Accordingly, precautions in repairing automotive bodies made of high strength steel are described below:
BRM
BRM-7
Tensile strength Major applicable parts

• Rear seat crossmember reinforcement
(Rear seat crossmember assembly component part)
• Center front floor (Front)
(Center front floor component part)
• Trans control reinforcement
• Front floor (Front)
(Front floor component part)
• 2nd crossmember
• 3rd crossmember
• Inner sill reinforcement
(Inner sill component part)
• Side dash
(Side dash component part)
• Inner front pillar reinforcement (RH only)
• Front suspension spring support
(Front strut housing assembly component part)
• Front bumper stay
• Front side member closing plate (Front)
(Front side member closing plate component part)
• Front side member flange
• Front tie down hook
• Front side member (Front)
(Front side member assembly component part)
440 - 780 MPa
• Front side member brace
• Front suspension mounting bracket
• Rear crossmember center assembly
• Rear side member
(Rear side member component part)
• Rear side member rear reinforcement
• Inner sill extension
• Rear side member reinforcement
• Outer rear anchor reinforcement
• Rear spring mounting bracket
• Spring mounting reinforcement
• Rear side member extension
• Inner center pillar assembly (Lower)
• Outer front pillar reinforcement (Rear)
• Lower center pillar brace (Lower)
• Lower front pillar hinge brace
• Outer sill reinforcement
• Rear pillar gusset
(Inner rear pillar component part)
• Rear pillar seat belt anchor
• Rear bumper stay
BRM-8
Tensile strength Major applicable parts A

• Front side member rear extension
• Inner sill
B
• Lower dash crossmember
(Lower dash complete component part)
• Front bumper armature assembly C
• Front side member closing plate (Rear)
• Front side member (Rear)
(Front side member assembly component part) D
• Inner center pillar (Upper)
980 - 1500 MPa
(Inner center pillar assembly component part)
• Upper center pillar brace
(Inner center pillar assembly component part) E
• Center pillar seat belt anchor
• Outer front pillar reinforcement
(Outer front pillar reinforcement component part) F
• Center pillar hinge brace (Upper)
(Lower center pillar brace component part)
• Center pillar extension
G
• Inner center rear bumper reinforcement
Read the following precautions when repairing HSS: H

1. Additional points to consider
• The repair of reinforcements (such as side members) by heat-
ing is not recommended, because it may weaken the compo- I
nent. When heating is unavoidable, never heat HSS parts
above 550°C (1,022°F).
Verify heating temperature with a thermometer. J
(Crayon-type and other similar type thermometer are appropri-
ate.)
BRM
PIIA0115E
L
• When straightening body panels, use caution in pulling any HSS panel. Because HSS is very strong,
pulling may cause deformation in adjacent sections of the body. In this case, increase the number of
measuring points, and carefully pull the HSS panel. M
• When cutting HSS panels, avoid gas (torch) cutting if possible.
Instead, use a saw to avoid weakening surrounding areas due
to heat. If gas (torch) cutting is unavoidable, allow a minimum N
margin of 50 mm (1.97 in).
P
PIIA0117E
BRM-9
• When welding HSS panels, use spot welding whenever possi-
ble in order to minimize weakening surrounding areas due to
heat.
If spot welding is impossible, use MIG. welding. Do not use
gas (torch) for welding because it is inferior in welding
strength.
PIIA0144E
• Spot welding on HSS panels is harder than that of an ordinary

steel panel.
Therefore, when cutting spot welds on a HSS panel, use a low
speed high torque drill (1,000 to 1,200 rpm) to increase drill bit
durability and facilitate the operation.
PIIA0145E
2. Precautions in spot welding HSS

This work should be performed under standard working condi-
tions. Always note the following when spot welding HSS:
• The electrode tip diameter must be sized properly according to
the metal thickness.
PIIA0146E
• The panel surfaces must fit flush to each other, leaving no

gaps.
PIIA0147E
BRM-10
• Follow the specifications for the proper welding pitch.
Unit: mm (in) A
Thickness (T) Minimum pitch (L)
0.6 (0.024) 10 (0.39) or more
0.8 (0.031) 12 (0.47) or more B
1.0 (0.039) 18 (0.71) or more
1.2 (0.047) 20 (0.79) or more
1.6 (0.063) 27 (1.06) or more C
1.8 (0.071) 31 (1.22) or more
JSKIA0781ZZ
BRM
BRM-11
REPAIRING MATERIAL
< PREPARATION > [FOR EUROPE (LHD)]
PREPARATION
REPAIRING MATERIAL
Foam Repair INFOID:0000000010843418
During factory body assembly, foam insulators are installed in certain body panels and locations around the
vehicle. Use the following procedure(s) to replace any factory-installed foam insulators.
URETHANE FOAM APPLICATIONS
Use commercially available Urethane foam for sealant (foam material) repair of material used on vehicle.
<Urethane foam for foaming agent> 3M™ Automix™ Flexible Foam 08463 or equiva-
lent
Read instructions on product for fill procedures.
Example of foaming agent filling operation procedure
1. Fill procedures after installation of service part.
a. Eliminate foam material remaining on vehicle side.
b. Clean area after eliminating form insulator and foam material.
c. Install service part.
d. Insert nozzle into hole near fill area and fill foam material or fill enough to close gap with the service part.
JSKIA0129GB
Urethane foam
Nozzle insert hole
: Vehicle front
2. Fill procedures before installation of service part.

b. Clean area after eliminating foam insulator and foam material.
c. Fill foam material on wheelhouse outer side.
BRM-12
REPAIRING MATERIAL
A
Urethane foam
Fill while avoiding flange area
: Vehicle front B
NOTE:
Fill enough to close gap with service part while avoiding flange
area. C
d. Install service part.
NOTE: JSKIA0130GB
Refer to label for information on working times. D
BRM
BRM-13
BODY COMPONENT PARTS
Ultra High Strength Steel Part INFOID:0000000010843419
DESCRIPTION
Ultra high strength steel parts signify high strength steel plates with tensile strength of 980 MPa or more.
When replacing parts made of ultra high strength steel or parts including ultra high strength steel, never per-
form the prohibition described below:
PROHIBITION
WARNING:
Never cut ultra high strength steel parts or perform butt welding. Violation of this prohibition causes
extreme strength degradation, and the strength before damage cannot be secured.
PART REPLACEMENT
To replace an ultra high strength part, be sure to replace it by panel supply unit of ultra high strength steel part.
For the welding method, refer to BRM-29, "Welding of Ultra High Strength Steel"
Underbody Component Parts INFOID:0000000010843420
Refer to parts catalogue for the replacement parts.
BRM-14
BRM
JSKIA4701ZZ
P
SUV models Wagon models
: Both sided anti-corrosive precoated steel sections

: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections
BRM-15
Both sided
Tensile strength anti-corrosive
No. Parts name
(MPa) precoated
steel sections
Rear floor rear Under 440 ×
Spare tire clamp bracket Under 440 —
Rear floor side assembly (RH & LH) Under 440 ×
Rear floor front Under 440 —
Rear floor board reinforcement 590 ×
Rear floor front extension (Upper RH & LH) Under 440 ×
Rear seat crossmember assembly 590 ×
Center front floor 780 ×
980MPacaution
T=1.8 mm (0.071 in)
Front floor (RH & LH) c. Inside (RH only) 590 ×
caution
980MPa
T=2.0 mm (0.079 in)
Inner sill (RH & LH) 980MPacaution 590 ×

T=1.4 mm (0.055 in)
Cowl top Under 440 ×
Upper dash assembly Under 440 ×
Lower dash complete d. 980MPacaution 590 ×

T=1.4 mm (0.055 in)
Side dash (RH & LH) 590 ×
Lower dash crossmember 980MPacaution 440 ×

T=2.0 mm (0.079 in)
Front strut housing assembly (RH & LH) 590 ×
Upper hoodledge (RH & LH) Under 440 ×
Lower hoodledge (RH & LH) Under 440 ×
Hoodledge reinforcement (RH & LH) Under 440 ×
Front hoodledge reinforcement (RH & LH) Under 440 ×
Upper front fender bracket (RH & LH) Under 440 ×
Front fender bracket (RH & LH) Under 440 ×
Upper radiator core support assembly (RH & LH) Under 440 ×
Front bumper armature assembly 1500MPacaution — —

T=1.0 mm (0.039 in)
Front bumper stay (RH & LH) 590 —
Hoodledge connector assembly (RH & LH) Under 440 ×
Front side member closing plate (RH & LH) e. 980MPacaution 590 ×
T=2.0 mm (0.079 in)
Front side member assembly (RH & LH) f. 980MPacaution 590 ×

T=2.0 mm (0.079 in)
Side radiator core support (RH & LH) Under 440 ×
Front suspension mounting bracket (RH & LH) 590 ×
BRM-16
Both sided
Tensile strength anti-corrosive A
No. Parts name
(MPa) precoated
steel sections
Rear floor front extension (Lower) Under 440 × B
Rear crossmember center assembly 590 ×
Rear side member (RH & LH) 590 ×

C
Muffler mounting bracket assembly (RH & LH) Under 440 ×
Rear side member extension (RH & LH) 780 ×

D
Rear 3rd seat mounting bracket assembly (RH & LH) Under 440 ×
CAUTION:
If the high strength steel (ultra high strength steel) of this is broken, replace by assembly for the supply part. E
NOTE:
• For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with.
• Tensile strength column shows the largest strength value of a part in the component part. F
Body Component Parts INFOID:0000000010843421
Refer to parts catalogue for the replacement parts. G
BRM
BRM-17
JSKIA4702ZZ
Sunroof models Normal roof models Right side

BRM-18
Both sided A
No. Parts name
(MPa) precoated
steel sections
B
Roof Under 440 —
Front roof rail Under 440 —
Roof bow No.4 Under 440 — C

Roof bow No.5 Under 440 —
Rear roof rail Under 440 — D


E
Upper inner front pillar (RH & LH) 590 —

caution
F
Inner center pillar assembly (RH & LH) d. 980MPa 590 —
T=1.0 mm (0.039 in)
Hood 440 ×
G
Front fender (RH & LH) Under 440 ×
Side body assembly (RH & LH) Refer to No. −

H
Outer front pillar reinforcement (RH & LH) e. 980MPacaution 590 —
T=1.0 mm (0.039 in)
f. 980MPacaution I
T=1.0 mm (0.039 in)
Lower center pillar brace (RH & LH) 590 —
g. 980MPacaution
T=1.0 mm (0.039 in) J
Outer front side body (RH & LH) Under 440 ×
Lower front pillar hinge brace (RH & LH) 590 —

BRM
Front fender bracket assembly (RH & LH) Under 440 ×
Outer sill reinforcement (RH & LH) 590 ×

L
Outer sill assembly (RH & LH) Under 440 ×
Inner rear pillar (RH & LH) 590 —
Upper rear pillar reinforcement (RH & LH) Under 440 — M

SUV models 440
Back pillar assembly (Inner RH & LH) —
Wagon models 590
N
Inner rear wheelhouse (RH & LH) Under 440 ×
Inner rear wheelhouse rear extension (RH & LH) Under 440 ×
O
Outer rear wheelhouse extension (RH & LH) Under 440 ×
Outer rear wheelhouse (RH & LH) Under 440 ×
Jack mounting bracket Under 440 — P
Front door assembly (RH & LH) 590 ×
Outer front door panel (RH & LH) Under 440 ×
Rear door assembly (RH & LH) 440 ×
Outer rear door panel (RH & LH) Under 440 ×
BRM-19
Both sided
No. Parts name
(MPa) precoated
steel sections
Rear fender assembly (RH & LH) Under 440 ×
Outer back pillar (RH & LH) Under 440 —
Back pillar assembly (Outer RH & LH) Under 440 —
Rear fender extension (RH & LH) Under 440 ×
Fuel filler lid assembly Under 440 ×
Upper rear panel Under 440 ×
Upper rear bumper retainer Under 440 ×
Rear bumper stay (RH & LH) 590 —
Inner center rear bumper reinforcement 1270MPacaution — —

T=1.2 mm (0.047 in)
CAUTION:
If the high strength steel (ultra high strength steel) of this is broken, replace by assembly for the supply part.
NOTE:
• Tensile strength column shows the largest strength value of a part in the component part.
BRM-20
CORROSION PROTECTION
< REMOVAL AND INSTALLATION > [FOR EUROPE (LHD)]
REMOVAL AND INSTALLATION A

Description INFOID:0000000010843422
B
To provide improved corrosion prevention, the following anti-corrosive measures have been implemented in
NISSAN production plants. When repairing or replacing body panels, it is necessary to use the same anti-cor-
rosive measures. C
Anti-Corrosive Precoated Steel (Galvannealed Steel)

To improve repairability and corrosion resistance, a new type of anti-
D
corrosive precoated steel sheet is adopted replacing conventional
zinc-coated steel sheet.
Galvannealed steel is electroplated and heated to form Zinc-iron
alloy, which provides excellent and long term corrosion resistance E
with cationic electrodeposition primer.
SIIA2294E
G
NISSAN genuine parts are fabricated from galvannealed steel. Therefore, it is recommended that NISSAN
genuine parts or an equivalent be used for panel replacement to maintain the anti-corrosive performance built
H
into the vehicle at the factory.
Phosphate Coating Treatment and Cationic Electrodeposition Primer
A phosphate coating treatment and a cationic electrodeposition I
primer, which provide excellent corrosion protection, are applied to
all body components.
CAUTION:
Confine paint removal during welding operation to an absolute J
minimum.
BRM
PIIA0095E L
NISSAN genuine parts are also treated in the same manner. Therefore, it is recommended that NISSAN gen-
uine parts or an equivalent be used for panel replacement to maintain anti-corrosive performance built into the M
vehicle at the factory.
Undercoating INFOID:0000000010860040
N
The underside of the floor and wheelhouse are undercoated to prevent rust, vibration, noise and stone chip-
ping. Therefore, when such a panel is replaced or repaired, apply undercoating to that part. Use an undercoat-
ing which is rust resistant, soundproof, vibration-proof, shock-resistant, adhesive, and durable.
O
Precautions in Undercoating
1. Never apply undercoating to any place unless specified (such as the areas above the muffler and three
way catalyst that are subjected to heat). P
2. Never undercoat the exhaust pipe or other parts that become hot.
3. Never undercoat rotating parts.
4. Apply bitumen wax after applying undercoating.
5. After putting seal on the vehicle, put undercoating on it.
BRM-21
JSKIA4703ZZ
: Undercoated areas
: Sealed portions
Body Sealing INFOID:0000000010860041
The following figure shows the areas that are sealed at the factory. Sealant that is applied to these areas
should be smooth and free from cuts or gaps. Care should be taken not to apply an excess amount of sealant
and not to allow other unaffected parts to come into contact with the sealant.
BRM-22
BRM
N
JSKIA4704ZZ
: Vehicle front O
: Sealed portions
BRM-23
JSKIA4705ZZ
: Vehicle front
: Sealed portions
BRM-24
BRM
JSKIA4706ZZ
P
: Vehicle front
: Sealed portions
BRM-25
BODY CONSTRUCTION
BODY CONSTRUCTION
Body Construction INFOID:0000000010843427
JSKIA4707ZZ
Outer side body Outer front pillar reinforcement Upper inner front pillar
Weld nut Side dash Upper hinge plate
Inner front pillar reinforcement Upper dash Rear hoodledge reinforcement
BRM-26
BODY CONSTRUCTION
Lower front pillar hinge brace Lower hinge plate Lower dash
A
Outer sill reinforcement Lower front pillar reinforcement Inner sill reinforcement
Inner sill Front floor Front side member outrigger
Inner center pillar Center pillar hinge brace Lower center pillar hinge brace B
Anchor plate Inner sill extension Rear floor front extension
Inner rear wheelhouse Outer rear wheelhouse Inner rear pillar
C
Inner rear pillar reinforcement Rear pillar seat belt anchor Back pillar seat belt anchor
Rear roof rail brace Upper back pillar reinforcement Center back pillar main
BRM
BRM-27
REPLACEMENT OPERATIONS
• This section is prepared for technicians who have attained a high level of skill and experience in repairing
collision-damaged vehicles and also use modern service tools and equipment. Persons unfamiliar with body
repair techniques should not attempt to repair collision-damaged vehicles by using this section.
• Technicians are also encouraged to read the Body Repair Manual (Fundamentals) in order to ensure that the
original functions and quality of the vehicle are maintained. The Body Repair Manual (Fundamentals) con-
tains additional information, including cautions and warnings, that are not including in this manual. Techni-
cians should refer to both manuals to ensure proper repair.
• Please note that this information is prepared for worldwide usage, and as such, certain procedures might not
apply in some regions or countries.
The symbols used in this section for welding operations are shown below.
Symbol marks Description
2-spot welds
JSKIA0049ZZ
JSKIA0053ZZ
3-spot welds
JSKIA0050ZZ
JSKIA0054ZZ
MIG plug weld
For 3 panels plug weld method
JSKIA0051ZZ
JSKIA0055ZZ
MIG seam weld / Point weld
JSKIA0052ZZ JSKIA0056ZZ
BRM-28
• Front pillar butt joint can be determined anywhere within shaded
area as shown in the figure. The best location for the butt joint is at A
position A due to the construction of the vehicle.
PIIA0150E
D
• Determine cutting position and record distance from the locating
indent. Use this distance when cutting the service part. Cut outer
front pillar over 60 mm (2.36 in) above the inner front pillar cut E
position.
G
JSKIA0104GB
• Prepare a cutting jig to make outer pillar easier to cut. Also, this will H
permit the service part to be accurately cut at the joint position.
BRM
JSKIA0105GB
• An example of cutting operation using a cutting jig is as per the fol-

L
lowing.
1. Mark cutting lines.
A: Cut position of outer pillar
B: Cut position of inner pillar M
2. Align cutting line with notch on jig. Clamp jig to pillar.
3. Cut outer pillar along groove of jig (at position A).
4. Remove jig and cut remaining portions.
N
5. Cut inner pillar at position B in same manner.
PIIA0153E
O
Welding of Ultra High Strength Steel INFOID:0000000010843429
SPOT WELDING P
Spot welding is limited to ultra high strength steel (tensile strength: 980 MPa) according to the welding condi-
tions listed below.
CAUTION:
• If the below welding conditions cannot be met, then perform plug welding.
• Never spot weld ultra high strength steel of tensile strength more than 980 MPa. For this type of ultra
high strength steel, perform plug welding.
BRM-29
• The below welding condition is applicable only to this vehicle. Never apply this same welding condi-
tion to other vehicles.
Welding condition
Welder tip diameter 6 mm
Welding pressure (Gun force) 3500 N
Welding current 8200 A
Weld time 0.22 sec (11 cyc: 50 Hz area,
13 cyc: 60 Hz area)
Panel configuration Combination of a plate of ten-
sile strength 980 MPa and that
of tensile strength less than
980 MPa. (Up to 3 plates)
PLUG WELDING
To weld ultra high strength steel of tensile strength 980 MPa or more, perform plug welding observing the
welding hole diameter described in the manual.
CAUTION:
• To perform plug welding, use fuel mixture (Ar 80% + CO2 20%) for shielding gas of welder.
• Never use carbon dioxide gas (CO2 100%) as shielding gas of welder. Using CO2 100% gas results in
inadequate weld strength.
• When welding hole diameter cannot be met, make multiple holes (smaller diameter) so that the sum
of the hole areas equals the area of the original weld hole.
EXAMPLE
JSKIA3503GB
Body sealing
: Vehicle front
: Drill φ6 mm (0.24 in) hole for the plug welding hole (ultra high strength steel).
: N·m (kg-m, ft-lb)
: For spot welding of steel plate of tensile strength 980 MPa, observe the indicated welding conditions. Refer to ″Welding of
Ultra High Strength Steel″.
BRM-30
Radiator Core Support INFOID:0000000010843430
BRM
JSKIA3843ZZ O
: Vehicle front
: Weld the parts onto the back of the component part. P
Replacement part
z Upper radiator core support assem- z Side radiator core support
bly
Hoodledge INFOID:0000000010843431
Work after radiator core support is removed.
BRM-31
JSKIA4916ZZ
: Vehicle front
Replacement part
z Front strut housing assembly z Hoodledge reinforcement z Hoodledge connector assembly
BRM-32
BRM
N
JSKIA4616ZZ
: Vehicle front O
View F and H: Before installing hoodledge reinforcement
Hoodledge (Partial Replacement) INFOID:0000000010843432 P
BRM-33
JSKIA4617ZZ
: Vehicle front
Replacement part
BRM-34
BRM
N
JSKIA4618ZZ
: Vehicle front O
View E: Before installing hoodledge reinforcement
Front Side Member INFOID:0000000010843433 P
Work after upper radiator core support assembly and hoodledge are removed.
BRM-35
JSKIA4918ZZ
: Vehicle front
: Weld the parts onto the back of the component part.
Replacement part
z Front side member closing plate z Front side member assembly z Front suspension mounting bracket
BRM-36
BRM
N
JSKIA4919GB
: Vehicle front O
: Drill φ12 mm (0.47 in) hole for the plug welding hole (ultra high strength steel). P
View E: Before installing front suspension mounting bracket
BRM-37
JSKIA3850ZZ
: Vehicle front
View H: Before installing front suspension mounting bracket

Front Side Member (Partial Replacement) INFOID:0000000010843434
Work after upper radiator core support assembly and hoodledge connector assembly are removed.
BRM-38
BRM
N
JSKIA4604GB
Unit: mm (in) O
: Vehicle front
Replacement part P
z Front side member closing plate z Front side member assembly (RH)
(RH)
POINT
The front side member on the left can also be replaced partially by cutting at the position shown in the figure.
BRM-39
JSKIA3852GB
Front side member assembly cutting Front side member closing plate cut-
position (LH) ting position (LH)
Unit: mm (in)
: Vehicle front
Replacement part
z Front side member closing plate (LH) z Front side member assembly (LH)
Front Pillar INFOID:0000000010843435
Work after hoodledge reinforcement is removed.
BRM-40
BRM
N
JSKIA4920GB
Urethane foam Body sealing O

Unit: mm (in)
: Vehicle front
Replacement part
z Side body assembly z Upper inner front pillar z Side dash
BRM-41
JSKIA4921GB
Unit: mm (in)
: Vehicle front
: For spot welding of steel plate of tensile strength 980 MPa, observe the indicated welding conditions. Refer to BRM-29, "Weld-
ing of Ultra High Strength Steel"
View D: Before installing side body assembly

View F: Before installing outer front side body
BRM-42
BRM
N
JSKIA4922GB
Unit: mm (in) O
: Vehicle front
View H and J: Before installing side body assembly

View O: Before installing outer front side body
BRM-43
Center Pillar INFOID:0000000010843436
JSKIA4608GB
Unit: mm (in)
: Vehicle front
BRM-44
Replacement part
z Side body assembly z Inner center pillar assembly A
BRM
O
JSKIA3857GB
Unit: mm (in)
P
: Vehicle front
View B and F: Before installing outer front side body
BRM-45
JSKIA4609GB
Unit: mm (in)
: Vehicle front
BRM-46
Outer Sill (Partial Replacement) INFOID:0000000010843437
BRM
JSKIA4626GB O
Unit: mm (in)
: Vehicle front P
Replacement part
z Outer sill assembly z Outer sill reinforcement
View A and B: Before installing outer sill assembly
BRM-47
Outer Sill INFOID:0000000010843438
JSKIA4923GB
Urethane foam Body sealing

Unit: mm (in)
: Vehicle front
Replacement part
BRM-48
View A: Before installing outer sill assembly
A
BRM
JSKIA4611GB
O
Body sealing
Unit: mm (in)
: Vehicle front P
BRM-49
JSKIA4924GB
Unit: mm (in)
: Vehicle front
View J: Before installing outer sill assembly

Inner Sill INFOID:0000000011005179
Work after outer sill assembly and outer sill reinforcement are removed.
BRM-50
BRM
N
JSKIA4927GB
Lower front pillar hinge brace (reus- Urethane foam O

able)
Unit: mm (in)
: Vehicle front P
Replacement part
z Inner sill
View A: Before installing outer sill assembly and front fender bracket assembly
BRM-51
JSKIA4928GB
Unit: mm (in)
: Vehicle front
BRM-52
Rear Fender INFOID:0000000010843439
BRM
JSKIA3863GB O

Unit: mm (in) P
: Vehicle front
Replacement part
z Rear fender assembly
BRM-53
JSKIA4613GB
Body sealing
Unit: mm (in)
: Vehicle front
BRM-54
BRM
N
JSKIA3865GB
Adhesive O
Unit: mm (in)
: Vehicle front
P
View J: Before installing rear fender
View M: Right side rear fender
BRM-55
Rear Fender Extension INFOID:0000000011005180
JSKIA4930GB
Body sealing
Unit: mm (in)
: Vehicle front
Replacement part
z Rear fender extension
Outer Rear Wheelhouse INFOID:0000000011005183
Work after rear fender is removed.
BRM-56
BRM
N
JSKIA4931GB
: Vehicle front O
Replacement part P
z Outer rear wheelhouse
Inner Rear Wheelhouse INFOID:0000000011005182
Work after rear fender and outer rear wheelhouse are removed.
BRM-57
JSKIA4932ZZ
Replacement part
z Inner rear wheelhouse
Inner Rear Pillar Reinforcement INFOID:0000000011005184
BRM-58
BRM
N
JSKIA4933GB
Unit: mm (in) O
Replacement part
z Upper rear pillar reinforcement
P
Inner Rear Pillar INFOID:0000000011005185
BRM-59
JSKIA4934GB
Urethane foam
: Vehicle front
: N·m (kg-m, in-lb)
Replacement part
z Inner rear pillar z Upper rear pillar reinforcement
BRM-60
Rear Panel INFOID:0000000010843440
BRM
JSKIA4614GB O
: Vehicle front
: Welding method, the number of welding points, and the tightening torque apply to both side of the vehicle. P
Replacement part
z Upper rear panel
BRM-61
Rear Floor Rear INFOID:0000000010843441
Work after rear panel is removed.
JSKIA3869ZZ
Left side Right side
: Vehicle front
: Welding method and the number of welding points apply to both side of the vehicle.
Replacement part
z Rear floor rear
BRM-62
Rear Side Member Extension (SUV Models) INFOID:0000000010843442
A
BRM
O
JSKIA3872ZZ
: Vehicle front P
Replacement part
z Rear side member extension
Rear Side Member Extension (Wagon Models) INFOID:0000000010843443
BRM-63
JSKIA4034ZZ
: Vehicle front
Replacement part
z Rear side member extension z Rear 3rd seat mounting bracket as-
sembly
BRM-64
Roof (Normal Roof Models) INFOID:0000000011005186
BRM
JSKIA3873ZZ O
Body sealing adhesive
: Vehicle front P
: Adhesive portion apply to both side of the vehicle.
Replacement part
z Roof z Roof bow No.1 z Roof bow No.2
z Roof bow No.3 z Roof bow No.4 z Roof bow No.5
BRM-65
Roof (Sunroof Models) INFOID:0000000011005188
JSKIA4935ZZ
: Vehicle front
Replacement part
BRM-66
Roof Rail INFOID:0000000011005189
A
Work after roof is removed.
BRM
O
JSKIA4936GB
: Vehicle front P
Replacement part
z Front roof rail z Rear roof rail
BRM-67
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS) [FOR EUROPE (LHD)]
SERVICE DATA AND SPECIFICATIONS (SDS)

BODY ALIGNMENT
Body Center Marks INFOID:0000000010860042
A mark is placed on each part of the body to indicate the vehicle center. When repairing the vehicle frame
(members, pillars, etc.) damaged by an accident which it enables more accurate and effective repair by using
these marks together with body alignment specifications.
JSKIA4708ZZ
: Vehicle front
Unit: mm (in)
Points Portion Marks
A Front roof Embossment
B Cowl top Indent
C Cowl top Hole φ8 (0.31)
D Trans control reinforcement Hole 14×12 (0.55×0.47)
BRM-68
BODY ALIGNMENT
A
E Rear seat crossmember Embossment
F Rear roof Embossment
B
• All dimensions indicated in the figures are actual.

• When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and gauge itself C
to make sure there is no free play.
• When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
• Measurements should be taken at the center of the mounting holes.
D
• An asterisk (*) following the value at the measuring point indicates that the measuring point on the other side
is symmetrically the same value.
• The coordinates of the measurement points are the distances measured from the standard line of ″X″, ″Y″
and ″Z″. E
• ″Z″: Imaginary base line [200 mm (7.87 in) below datum line (″0Z″ at design plan)]
J
JSKIA0073GB
Vehicle center Front axle center Imaginary base line

BRM
Engine Compartment INFOID:0000000010860044
MEASUREMENT L
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.
M
BRM-69
BODY ALIGNMENT
JSKIA4709GB
Unit: mm (in)
«The others»
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo
– 777 (30.59)* – 596 (23.46)* – 1000 (39.37)
– 852 (33.54)* – 1169 (46.02)* – 967 (38.07)
– 535 (21.06) – 986 (38.82) – 1425 (56.10)
– 546 (21.50) – 1509 (59.41) – 290 (11.42)
– 721 (28.39) – 1212 (47.72)* – 296 (11.65)
– 700 (27.56) – 1171 (46.10) – 362 (14.25)
– 789 (31.06) – 331 (13.03) – 375 (14.76)
– 869 (34.21) – 1435 (56.50) – 962 (37.87)*
– 884 (34.80) – 853 (33.58) – 1005 (39.57)*
– 872 (34.33) – 1003 (39.49) – 1071 (42.17)
– 474 (18.66) – 977 (38.46) – 1081 (42.56)*
– 1321 (52.01)* – 1073 (42.24) – 1059 (41.69)
– 1262 (49.68) – 1033 (40.67) – 1053 (41.46)
– 445 (17.52) – 973 (38.31) – 1027 (40.43)
– 1058 (41.65) – 959 (37.76) – 1021 (40.20)
MEASUREMENT POINTS
BRM-70
BODY ALIGNMENT
BRM
L
JSKIA4710ZZ
: Vehicle front M
Unit: mm (in)
Point Material Point Material N

Front side member hole center
Cowl top hole center of center positioning mark : φ9 (0.35)
φ8 (0.31) : φ8 (0.31) O
: φ14 (0.55)
Engine mounting bracket hole center 12×10
Hood hinge installing hole center φ12 (0.47)
(0.47×0.39) P
Front suspension installing hole center 16×10
Hoodledge connector hole center φ12 (0.47)
(0.63×0.39)
: φ11 (0.43)
Front fender installing hole center φ7 (0.28)
: φ12 (0.47)
: φ13 (0.51)
BRM-71
BODY ALIGNMENT
Point Material Point Material
Front hoodledge reinforcement hole center φ12 Torque rod mounting bracket hole center φ14
(0.47) (0.55)
Upper radiator core support hole center
: φ7 (0.28)
: φ13 (0.51)
Underbody INFOID:0000000010860045
MEASUREMENT
vehicle.
BRM-72
BODY ALIGNMENT
BRM
JSKIA4422GB
P
Unit: mm (in)
: Vehicle front
: Vehicle left side
MEASUREMENT POINTS
BRM-73
BODY ALIGNMENT
JSKIA4423ZZ
: Vehicle front
BRM-74
BODY ALIGNMENT
Unit: mm (in)
Coordinates Coordinates A
Points Remarks Points Remarks
X Y Z X Y Z
478.0 −566.6 375.5 ±650.0 1954.0 272.9
Hole φ18 (0.71) Hole φ16 (0.63)
(18.819) (−22.307) (14.783) (±25.591) (76.929) (10.744) B
−501.0 −566.6 375.5 ±525.4 2480.4 380.0
Hole φ18 (0.71) Hole φ12 (0.47)
(−19.724) (−22.307) (14.783) (±20.685) (97.653) (14.961)
: Hole φ30 (1.18)

C
462.4 −346.0 502.5 ±330.0 2501.0 434.0
Hole φ16 (0.63) : Hole 32×30
(18.205) (−13.622) (19.783) (±12.992) (98.464) (17.087)
(1.26×1.18)
−474.7 −372.0 502.5 549.0 2911.0 435.0 D
Hole φ16 (0.63) Hole φ20 (0.79)
(−18.689) (−14.646) (19.783) (21.614) (114.606) (17.126)
: Hole φ30 (1.18)

±305.0 301.0 277.8 −525.5 2897.2 435.0 E
: Hole 32×30 Hole φ20 (0.79)
(±12.008) (11.850) (10.936) (−20.689) (114.063) (17.126)
(1.26×1.18)
±410.0 660.0 190.4 551.0 3248.0 433.8 Hole 16×14
Hole φ14 (0.55) F
(±16.142) (25.984) (7.495) (21.693) (127.874) (17.079) (0.63×0.55)
±410.0 800.0 191.4 −523.5 3248.0 433.8 Hole 16×14
Hole φ12 (0.47)
(±16.142) (31.496) (7.535) (−20.610) (127.874) (17.079) (0.63×0.55)
±410.0 1270.0 189.2 ±598.6 7.4 911.9 G
Hole φ12 (0.47) Hole φ33 (1.30)
(±16.142) (50.000) (7.449) (±23.566) (0.291) (35.902)
±410.0 1751.0 180.2
Hole φ13 (0.51)
(±16.142) (68.937) (7.094) H
Passenger Compartment INFOID:0000000010860046
I
MEASUREMENT
vehicle. J
BRM
BRM-75
BODY ALIGNMENT
JSKIA4711GB
Unit: mm (in)
«The others»
Unit: mm (in)
- 1334 (52.52) - 1665 (65.55)* - 1077 (42.40)*
- 1616 (63.62)* - 1458 (57.40) - 943 (37.13)*
- 1494 (58.82)* - 1670 (65.75)* - 794 (31.26)*
- 1634 (64.33)* - 1461 (57.52) - 1179 (46.42)*
- 1441 (56.73) - 1749 (68.86)* - 1092 (42.99)*
- 1738 (68.43)* - 1567 (61.69)* - 782 (30.79)*
- 1458 (57.40) - 1281 (50.43) - 1592 (62.68)
- 1886 (74.25)* - 1602 (63.07)* - 1172 (46.14)*
- 1689 (66.50)* - 1419 (55.87) - 1175 (46.26)*
- 1327 (52.24) - 1462 (57.56) - 1623 (63.90)
- 1569 (61.77)* - 1110 (43.70)* - 1235 (48.62)*
- 1458 (57.40) - 979 (38.54)* - 1137 (44.76)*
- 1461 (57.52) - 890 (35.04)* - 1588 (62.52)
- 1326 (52.20) - 1233 (48.54)* - 1619 (63.74)
- 1562 (61.50)* - 1068 (42.05)*
- 1498 (58.98)* - 836 (32.91)*
BRM-76
BODY ALIGNMENT
MEASUREMENT POINTS
A
BRM
JSKIA4712ZZ
M
: Vehicle front
Unit: mm (in)
N
Cowl top indent of center positioning mark Center pillar indent O
Roof flange end of center positioning mark Rear fender indent P
Trans control reinforcement hole center of center

Outer side body joggle
positioning mark 14×12 (0.55×0.47)
BRM-77
BODY ALIGNMENT
Rear seat crossmember positioning mark of cen-
Outer side body indent
ter positioning mark
Door hinge installing hole center
Front pillar indent : φ12 (0.47)
: φ9 (0.35)
Rear Body INFOID:0000000010860047
MEASUREMENT
vehicle.
JSKIA4428GB
Unit: mm (in)
«The others»
Unit: mm (in)
– 612 (24.09)* – 1131 (44.53) – 762 (30.00)*
– 797 (31.38)* – 323 (12.72)* – 1202 (47.32)
– 1042 (41.02)* – 1210 (47.64)* – 578 (22.76)*
MEASUREMENT POINTS
BRM-78
BODY ALIGNMENT
I
JSKIA4429ZZ
: Vehicle front J
Unit: mm (in)

BRM
Roof flange end of center positioning mark Lower back pillar main joggle
Center back pillar main joggle Lower back pillar main hole center φ7 (0.28)
Center back pillar main hole center φ7 (0.28) Back door striker installing hole center L
BRM-79
LOCATION OF PLASTIC PARTS
Precautions for Plastics INFOID:0000000010843453
Heat resisting
Abbre- Resistance to gasoline and
Material name temperature Other cautions
viation solvents
°C (°F)
Gasoline and most solvents are
PE Polyethylene 60 (140) harmless if applied for a very Flammable
short time (wipe out quickly).
ABS Acrylonitrile Butadiene Styrene 80 (176) Avoid gasoline and solvents. —
AES Acrylonitrile Ethylene Styrene 80 (176) ↑ —
EPM/ Ethylene Propylene (Diene) co-
80 (176) harmless if applied for a very Flammable
EPDM polymer
PS Polystyrene 80 (176) Avoid solvents. Flammable
Poisonous gas is emitted
PVC Poly Vinyl Chloride 80 (176) harmless if applied for a very
when burned.
TPO Thermoplastic Olefine 80 (176) ↑ Flammable
AAS Acrylonitrile Acrylic Styrene 85 (185) Avoid gasoline and solvents. —
PMMA Poly Methyl Methacrylate 85 (185) ↑ —
EVAC Ethylene Vinyl Acetate 90 (194) ↑ —
Flammable, avoid bat-
PP Polypropylene 90 (194) harmless if applied for a very
tery acid.
PUR Polyurethane 90 (194) Avoid gasoline and solvents. —
UP Unsaturated Polyester 90 (194) ↑ Flammable
ASA Acrylonitrile Styrene Acrylate 100 (212) ↑ Flammable
PPE Poly Phenylene Ether 110 (230) ↑ —
TPU Thermoplastic Urethane 110 (230) ↑ —
PBT+ Poly Butylene Terephthalate +
120 (248) ↑ Flammable
PC Polycarbonate
PC Polycarbonate 120 (248) ↑ —
POM Poly Oxymethylene 120 (248) ↑ Avoid battery acid.
Avoid immersing in wa-
PA Polyamide 140 (284) ↑
ter.
PBT Poly Butylene Terephthalate 140 (284) ↑ —
PAR Polyarylate 180 (356) ↑ —
PET Polyethylene terephthalate 180 (356) ↑ —
PEI Polyetherimide 200 (392) ↑ —
CAUTION:
• When repairing and painting a portion of the body adjacent to plastic parts, consider their characteristics (influence of heat
and solvent) and remove them if necessary or take suitable measures to protect them.
• Plastic parts should be repaired and painted using methods suiting the materials, characteristics.
BRM-80
Location of Plastic Parts INFOID:0000000010843454
JSKIA4713ZZ
I
Component Material Component Material
Cover ABS Rear spoiler PC + ABS
J
PBT + PET +
Base Lens PMMA
Door mirror Glass fiber High mount stop lamp
Case ASA Housing ABS
BRM
Finisher ASA Back door finisher ABS
Lens PMMA Lens PC
Side turn signal lamp License plate lamp L
Housing ABS Housing PC
Side roof molding PVC + Stainless Lens PC
Rear fog lamp
Wind shield molding PVC Housing PC M
Lens PC Back door PP
Front combination lamp
Housing PP Lens PMMA
Reflex reflector N
Front grille ABS Housing ABS
Bumper fascia PP + EPM Lens PMMA

Rear combination lamp
Lens Glass Housing ASA O
Front fog lamp PBT + ASA +
Housing Sill cover PP
Glass fiber
P
Fillet molding PP Side guard molding PP
Front fender protector PP Grip cover PC + PET

Door outside handle
Door outside molding PVC + Stainless Grip body PC + ABS
BRM-81
JSKIA4714ZZ

Side luggage finisher PP Cluster lid C PC + ABS
Lens PC Glove box PP

Personal lamp
Housing PP Lower side panel PP + EPM
Center pillar garnish PP Finisher PC + ABS

Switch finisher PP Manual A/C Switch PC
Map lamp
Console PP Case ABS
Lid box PC + ABS A/C Control Finisher PC + ABS
Front pillar garnish PP Automatic Switch PC
Cluster lid A PP A/C Case PC + ABS
Center ventilator grille PC + ABS Lens PC

Skin TPO Body PP
Pad PUR Console box PP
Instrument panel Center console
A/T console
Core PP + EPDM PC + ABS
finisher
BRM-82
< VEHICLE INFORMATION > [FOR EUROPE (RHD)]
VEHICLE INFORMATION A
B
JSKIA4358ZZ
G
Dark Ol- Dark
H
ive Blue
Component
I
Hard clear
× × × × – – – ×
coat
Door mirror cover Body color BAX6 BEAN BEAR BG41 BK23 BKAD BQAB BRAQ J
Chromium
plate
Bumper fascia Body color BAX6 BEAN BEAR BG41 BK23 BKAD BQAB BRAQ BRM
Chromium
Door outside handle Cr Cr Cr Cr Cr Cr Cr Cr L
plate
Rear spoiler (Upper) Body color BAX6 BEAN BEAR BG41 BK23 BKAD BQAB BRAQ M
Chromium
plate
Back door Body color BAX6 BEAN BEAR BG41 BK23 BKAD BQAB BRAQ N
Side guard molding Material color – – – – – – – – O

NOTE:
• 2P: 2-Coat pearl P
BRM-83
PRECAUTIONS
< PRECAUTION > [FOR EUROPE (RHD)]
PRECAUTION
PRECAUTIONS
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time.
“How to disconnect 12V battery terminal” described below.
NOTE:
battery terminal is disconnected before ECU stops, accidental DTC
tery and the sub battery before turning ON the ignition switch.
NOTE:
SEF289H
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
INSTRUCTION 1
1. Open the hood.
2. Turn key switch to the OFF position with the driver side door opened.
of the specified time.

HRA2DDT : 12 minutes
R9M engine : 4 minutes
CAUTION:
CAUTION:
1. Unlock the door with intelligent key or remote keyless entry.
NOTE:
3. Open the hood.
BRM-84
PRECAUTIONS
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of A
CAUTION: B
BRM
BRM-85
High strength steel is used for body panels in order to reduce vehicle weight.
BRM-86

B
• Front floor (Front) C
• 2nd crossmember
• 3rd crossmember D
• Side dash E
• Front suspension spring support F
G
• Front tie down hook H
440 - 780 MPa
• Front side member brace I
• Rear side member J
BRM
(Rear side member component part) L
(Rear side member component part) M
• Inner center pillar assembly (Lower) N
• Outer sill reinforcement O
P
BRM-87

• Inner sill
• Front bumper armature assembly
980 - 1500 MPa
(Outer front pillar reinforcement component part)
Read the following precautions when repairing HSS:

ing is not recommended, because it may weaken the compo-
above 550°C (1,022°F).
Verify heating temperature with a thermometer.
ate.)
PIIA0115E
measuring points, and carefully pull the HSS panel.
to heat. If gas (torch) cutting is unavoidable, allow a minimum
PIIA0117E
BRM-88
ble in order to minimize weakening surrounding areas due to A
heat.
B
strength.
PIIA0144E
D
steel panel.
Therefore, when cutting spot welds on a HSS panel, use a low E
F
G
PIIA0145E
2. Precautions in spot welding HSS H

I
PIIA0146E BRM

gaps. L
PIIA0147E
BRM-89
Unit: mm (in)
0.6 (0.024) 10 (0.39) or more
0.8 (0.031) 12 (0.47) or more
1.0 (0.039) 18 (0.71) or more
1.2 (0.047) 20 (0.79) or more
1.6 (0.063) 27 (1.06) or more
1.8 (0.071) 31 (1.22) or more
JSKIA0781ZZ
BRM-90
REPAIRING MATERIAL
< PREPARATION > [FOR EUROPE (RHD)]
PREPARATION A
REPAIRING MATERIAL
B
C
D
lent
Read instructions on product for fill procedures. E
a. Eliminate foam material remaining on vehicle side. F
G
BRM
L
JSKIA0129GB
Urethane foam
M
Nozzle insert hole
: Vehicle front
2. Fill procedures before installation of service part. N

O
BRM-91
REPAIRING MATERIAL
Urethane foam
: Vehicle front
NOTE:
area.
NOTE: JSKIA0130GB
Refer to label for information on working times.
BRM-92
A
DESCRIPTION B
form the prohibition described below: C
PROHIBITION
WARNING:
Never cut ultra high strength steel parts or perform butt welding. Violation of this prohibition causes D
PART REPLACEMENT
E
F
BRM
BRM-93
JSKIA4715ZZ
SUV models Wagon models

BRM-94
Both sided A
No. Parts name
(MPa) precoated
steel sections
B
Rear floor side assembly (RH & LH) Under 440 × C

Rear floor board reinforcement 590 × D


E
980MPacaution
T=1.8 mm (0.071 in) F
Front floor (RH & LH) c. Inside (RH only) 590 ×
caution
980MPa
T=2.0 mm (0.079 in) G

T=1.4 mm (0.055 in)
H
980MPacaution I
Lower dash complete d. 590 ×
T=1.4 mm (0.055 in)
J
T=2.0 mm (0.079 in)
Front strut housing assembly (RH & LH) 590 × BRM

L

M
Upper radiator core support assembly (RH & LH) Under 440 × N

T=1.0 mm (0.039 in)
O
980MPacaution P
Front side member closing plate (RH & LH) e. 590 ×
T=2.0 mm (0.079 in)
Front side member assembly (RH & LH) f. 980MPacaution 590 ×

T=2.0 mm (0.079 in)
BRM-95
Both sided
No. Parts name
(MPa) precoated
steel sections
Rear floor front extension (Lower) Under 440 ×
Rear 3rd seat mounting bracket assembly (RH & LH) Under 440 ×
CAUTION:
NOTE:
Body Component Parts INFOID:0000000010860048
BRM-96
BRM
JSKIA4702ZZ
P

BRM-97
Both sided
No. Parts name
(MPa) precoated
steel sections
Roof Under 440 —
Rear roof rail Under 440 —

caution
T=1.0 mm (0.039 in)
Hood 440 ×

T=1.0 mm (0.039 in)
f. 980MPacaution
T=1.0 mm (0.039 in)
g. 980MPacaution
T=1.0 mm (0.039 in)
Upper rear pillar reinforcement (RH & LH) Under 440 —

SUV models 440
Back pillar assembly (Inner RH & LH) —
Wagon models 590
Inner rear wheelhouse (RH & LH) Under 440 ×
Jack mounting bracket Under 440 —
BRM-98
Both sided
No. Parts name
(MPa) precoated
steel sections
Rear fender assembly (RH & LH) Under 440 × B

C

D
Rear bumper stay (RH & LH) 590 — E

T=1.2 mm (0.047 in)
F
CAUTION:
NOTE:
G
BRM
BRM-99
< REMOVAL AND INSTALLATION > [FOR EUROPE (RHD)]
REMOVAL AND INSTALLATION

rosive measures.
alloy, which provides excellent and long term corrosion resistance
SIIA2294E
A phosphate coating treatment and a cationic electrodeposition
CAUTION:
Confine paint removal during welding operation to an absolute
minimum.
PIIA0095E
uine parts or an equivalent be used for panel replacement to maintain anti-corrosive performance built into the
Undercoating INFOID:0000000010843497
way catalyst that are subjected to heat).
BRM-100
JSKIA4717ZZ F
: Undercoated areas
: Sealed portions G
Body Sealing INFOID:0000000010843499
The following figure shows the areas that are sealed at the factory. Sealant that is applied to these areas H
I
BRM
BRM-101
JSKIA4718ZZ
: Vehicle front
: Sealed portions
BRM-102
BRM
JSKIA4719ZZ
P
: Vehicle front
: Sealed portions
BRM-103
JSKIA4441ZZ
: Vehicle front
: Sealed portions
BRM-104
BODY CONSTRUCTION
BODY CONSTRUCTION
A
BRM
JSKIA4721ZZ
Upper dash Rear hoodledge reinforcement Lower front pillar hinge brace
BRM-105
BODY CONSTRUCTION
Lower hinge plate Lower dash Outer sill reinforcement
Lower front pillar reinforcement Inner sill Front floor
Front side member outrigger Inner center pillar Center pillar hinge brace
Lower center pillar hinge brace Anchor plate Inner sill extension
Rear floor front extension Inner rear wheelhouse Outer rear wheelhouse
Inner rear pillar Inner rear pillar reinforcement Rear pillar seat belt anchor
Back pillar seat belt anchor Rear roof rail brace Upper back pillar reinforcement
Center back pillar main
BRM-106
A
• This section is prepared for technicians who have attained a high level of skill and experience in repairing B
original functions and quality of the vehicle are maintained. The Body Repair Manual (Fundamentals) con- C
• Please note that this information is prepared for worldwide usage, and as such, certain procedures might not D
E
F
2-spot welds
G
JSKIA0049ZZ
H
JSKIA0053ZZ
3-spot welds
I
JSKIA0050ZZ
BRM
JSKIA0054ZZ L
MIG plug weld
M
JSKIA0051ZZ
N
JSKIA0055ZZ

P
BRM-107
area as shown in the figure. The best location for the butt joint is at
PIIA0150E

front pillar over 60 mm (2.36 in) above the inner front pillar cut
position.
JSKIA0104GB
• Prepare a cutting jig to make outer pillar easier to cut. Also, this will
JSKIA0105GB

lowing.
B: Cut position of inner pillar
PIIA0153E
SPOT WELDING
tions listed below.
CAUTION:
BRM-108
tion to other vehicles. A
Welding condition
Welding pressure (Gun force) 3500 N B
C
13 cyc: 60 Hz area)
sile strength 980 MPa and that D
PLUG WELDING E
CAUTION: F
• When welding hole diameter cannot be met, make multiple holes (smaller diameter) so that the sum G
EXAMPLE
H
BRM
JSKIA3503GB
M
Body sealing
: Vehicle front
N
O
BRM-109
JSKIA3843ZZ
: Vehicle front
Replacement part
bly
BRM-110
BRM
N
JSKIA4598ZZ
: Vehicle front O
Replacement part
z Front strut housing assembly z Hoodledge reinforcement z Hoodledge connector assembly P
BRM-111
JSKIA4599ZZ
: Vehicle front

Hoodledge (Partial Replacement) INFOID:0000000011010380
BRM-112
BRM
N
JSKIA4600ZZ
: Vehicle front O
Replacement part
z Upper hoodledge z Lower hoodledge z Hoodledge reinforcement
z Hoodledge connector assembly P
BRM-113
JSKIA4601ZZ
: Vehicle front

Front Side Member INFOID:0000000010843507
BRM-114
BRM
N
JSKIA3848ZZ
: Vehicle front O
Replacement part
BRM-115
JSKIA4603GB
: Vehicle front
BRM-116
BRM
N
JSKIA3850ZZ
: Vehicle front O
BRM-117
JSKIA4604GB
Unit: mm (in)
: Vehicle front
Replacement part
(RH)
POINT
BRM-118
E
JSKIA3852GB
F
Unit: mm (in)
: Vehicle front G
Replacement part
H

I
BRM
BRM-119
JSKIA4605GB

Unit: mm (in)
: Vehicle front
Replacement part
BRM-120
BRM
N
JSKIA4606GB
Unit: mm (in) O
: Vehicle front
: For spot welding of steel plate of tensile strength 980 MPa, observe the indicated welding conditions. Refer to BRM-108,
"Welding of Ultra High Strength Steel"

BRM-121
JSKIA4607GB
Unit: mm (in)
: Vehicle front

BRM-122
BRM
JSKIA4608GB O
Unit: mm (in)
: Vehicle front P
BRM-123
Replacement part
z Side body assembly z Inner center pillar assembly
JSKIA3857GB
Unit: mm (in)
: Vehicle front
BRM-124
BRM
N
JSKIA4609GB
Unit: mm (in) O
: Vehicle front
BRM-125
JSKIA3859GB
Unit: mm (in)
: Vehicle front
Replacement part
BRM-126
BRM
JSKIA4925GB O

Unit: mm (in) P
: Vehicle front
Replacement part
z Outer sill assembly z Outer sill reinforcement z Front fender bracket assembly
BRM-127
JSKIA4611GB
Body sealing
Unit: mm (in)
: Vehicle front
BRM-128
BRM
N
JSKIA4926GB
Unit: mm (in) O
: Vehicle front
View J: Before installing outer sill assembly and front fender bracket assembly
Inner Sill INFOID:0000000011010468
Work after outer sill assembly and outer sill reinforcement are removed.
BRM-129
JSKIA4927GB
Lower front pillar hinge brace (reus- Urethane foam

able)
Unit: mm (in)
: Vehicle front
Replacement part
z Inner sill
BRM-130
BRM
N
JSKIA4929GB
Unit: mm (in) O
: Vehicle front
BRM-131
JSKIA3863GB

Unit: mm (in)
: Vehicle front
Replacement part
BRM-132
BRM
N
JSKIA4613GB
Body sealing O
Unit: mm (in)
: Vehicle front
P
BRM-133
JSKIA3865GB
Adhesive
Unit: mm (in)
: Vehicle front

BRM-134
Rear Fender Extension INFOID:0000000011005437
BRM
JSKIA4930GB O
Body sealing
Unit: mm (in) P
: Vehicle front
Replacement part
z Rear fender extension
Outer Rear Wheelhouse INFOID:0000000011005438
BRM-135
JSKIA4931GB
: Vehicle front
Replacement part
z Outer rear wheelhouse
Inner Rear Wheelhouse INFOID:0000000011005439
Work after rear fender and outer rear wheelhouse are removed.
BRM-136
BRM
N
JSKIA4932ZZ
Replacement part O
z Inner rear wheelhouse
Inner Rear Pillar Reinforcement INFOID:0000000011005440

P
BRM-137
JSKIA4933GB
Unit: mm (in)
Replacement part
z Upper rear pillar reinforcement
Inner Rear Pillar INFOID:0000000011005441
BRM-138
BRM
N
JSKIA4934GB
Urethane foam O
: Vehicle front
P
Replacement part
z Inner rear pillar z Upper rear pillar reinforcement
BRM-139
JSKIA4614GB
: Vehicle front
: Welding method, the number of welding points, and the tightening torque apply to both side of the vehicle.
Replacement part
z Upper rear panel
BRM-140
A
BRM
O
JSKIA3869ZZ

P
: Vehicle front
Replacement part
z Rear floor rear
BRM-141
JSKIA3872ZZ
: Vehicle front
Replacement part
BRM-142
BRM
N
JSKIA4034ZZ
: Vehicle front O
Replacement part
sembly P
BRM-143
Roof (Normal Roof Models) INFOID:0000000011005442
JSKIA3873ZZ
: Vehicle front
Replacement part
z Roof bow No.3 z Roof bow No.4 z Roof bow No.5
BRM-144
Roof (Sunroof Models) INFOID:0000000011005443
BRM
JSKIA4935ZZ O
: Vehicle front P
Replacement part
BRM-145
Roof Rail INFOID:0000000011005444
Work after roof is removed.
JSKIA4936GB
: Vehicle front
Replacement part
z Front roof rail z Rear roof rail
BRM-146
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS) [FOR EUROPE (RHD)]
SERVICE DATA AND SPECIFICATIONS (SDS) A

BODY ALIGNMENT
Body Center Marks INFOID:0000000010843518
B
these marks together with body alignment specifications. C
BRM
JSKIA4722ZZ
O
: Vehicle front
P
Unit: mm (in)
B Cowl top Indent
BRM-147
BODY ALIGNMENT

• When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and gauge itself
and ″Z″.
JSKIA0073GB
Engine Compartment INFOID:0000000010843521
MEASUREMENT
vehicle.
BRM-148
BODY ALIGNMENT
I
JSKIA4723GB
Unit: mm (in)
J
«The others»
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo BRM
– 777 (30.59)* – 596 (23.46)* – 1000 (39.37)
– 852 (33.54)* – 1169 (46.02)* – 967 (38.07)

L
– 535 (21.06) – 986 (38.82) – 1425 (56.10)
– 546 (21.50) – 1509 (59.41) – 290 (11.42)
721 (28.39) 1212 (47.72)* 296 (11.65)

M
– – –
– 700 (27.56) – 1171 (46.10) – 362 (14.25)
– 789 (31.06) – 331 (13.03) – 375 (14.76) N

– 869 (34.21) – 1435 (56.50) – 962 (37.87)*
– 884 (34.80) – 853 (33.58) – 1005 (39.57)* O

– 872 (34.33) – 1003 (39.49) – 1071 (42.17)
– 474 (18.66) – 977 (38.46) – 1081 (42.56)*

P
– 1321 (52.01)* – 1073 (42.24) – 1059 (41.69)
– 1262 (49.68) – 1033 (40.67) – 1053 (41.46)
– 445 (17.52) – 973 (38.31) – 1027 (40.43)
– 1058 (41.65) – 959 (37.76) – 1021 (40.20)
MEASUREMENT POINTS
BRM-149
BODY ALIGNMENT
JSKIA4724ZZ
: Vehicle front
Unit: mm (in)

φ8 (0.31) : φ8 (0.31)
: φ14 (0.55)
(0.47×0.39)
(0.63×0.39)
: φ11 (0.43)
: φ12 (0.47)
: φ13 (0.51)
BRM-150
BODY ALIGNMENT
A
(0.47) (0.55)
: φ7 (0.28)
B
: φ13 (0.51)
Underbody INFOID:0000000010843523 C
MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the D
vehicle.
BRM
BRM-151
BODY ALIGNMENT
JSKIA4422GB
Unit: mm (in)
: Vehicle front
: Vehicle left side
MEASUREMENT POINTS
BRM-152
BODY ALIGNMENT
BRM
L
JSKIA4423ZZ
: Vehicle front M
BRM-153
BODY ALIGNMENT
Unit: mm (in)
Coordinates Coordinates
X Y Z X Y Z
478.0 −566.6 375.5 ±650.0 1954.0 272.9
Hole φ18 (0.71) Hole φ16 (0.63)
(18.819) (−22.307) (14.783) (±25.591) (76.929) (10.744)
−501.0 −566.6 375.5 ±525.4 2480.4 380.0
Hole φ18 (0.71) Hole φ12 (0.47)
(−19.724) (−22.307) (14.783) (±20.685) (97.653) (14.961)
: Hole φ30 (1.18)

462.4 −346.0 502.5 ±330.0 2501.0 434.0
Hole φ16 (0.63) : Hole 32×30
(18.205) (−13.622) (19.783) (±12.992) (98.464) (17.087)
(1.26×1.18)
−474.7 −372.0 502.5 549.0 2911.0 435.0
Hole φ16 (0.63) Hole φ20 (0.79)
(−18.689) (−14.646) (19.783) (21.614) (114.606) (17.126)
: Hole φ30 (1.18)

±305.0 301.0 277.8 −525.5 2897.2 435.0
: Hole 32×30 Hole φ20 (0.79)
(±12.008) (11.850) (10.936) (−20.689) (114.063) (17.126)
(1.26×1.18)
±410.0 660.0 190.4 551.0 3248.0 433.8 Hole 16×14
Hole φ14 (0.55)
(±16.142) (25.984) (7.495) (21.693) (127.874) (17.079) (0.63×0.55)
±410.0 800.0 191.4 −523.5 3248.0 433.8 Hole 16×14
Hole φ12 (0.47)
(±16.142) (31.496) (7.535) (−20.610) (127.874) (17.079) (0.63×0.55)
±410.0 1270.0 189.2 ±598.6 7.4 911.9
Hole φ12 (0.47) Hole φ33 (1.30)
(±16.142) (50.000) (7.449) (±23.566) (0.291) (35.902)
±410.0 1751.0 180.2
Hole φ13 (0.51)
(±16.142) (68.937) (7.094)
Passenger Compartment INFOID:0000000010843524
MEASUREMENT
vehicle.
BRM-154
BODY ALIGNMENT
I
JSKIA4457GB
Unit: mm (in)
J
«The others»
Unit: mm (in)
- 1334 (52.52) - 1665 (65.55)* - 1077 (42.40)*
- 1616 (63.62)* - 1458 (57.40) - 943 (37.13)*

L
- 1494 (58.82)* - 1670 (65.75)* - 794 (31.26)*
- 1634 (64.33)* - 1461 (57.52) - 1179 (46.42)*
1441 (56.73) 1749 (68.86)* 1092 (42.99)*

M
- - -
- 1738 (68.43)* - 1567 (61.69)* - 782 (30.79)*
- 1458 (57.40) - 1281 (50.43) - 1592 (62.68) N

- 1886 (74.25)* - 1602 (63.07)* - 1172 (46.14)*
- 1689 (66.50)* - 1419 (55.87) - 1175 (46.26)* O

- 1327 (52.24) - 1462 (57.56) - 1623 (63.90)
- 1569 (61.77)* - 1110 (43.70)* - 1235 (48.62)*

P
- 1458 (57.40) - 979 (38.54)* - 1137 (44.76)*
- 1461 (57.52) - 890 (35.04)* - 1588 (62.52)
- 1326 (52.20) - 1233 (48.54)* - 1619 (63.74)
- 1562 (61.50)* - 1068 (42.05)*
- 1498 (58.98)* - 836 (32.91)*
BRM-155
BODY ALIGNMENT
MEASUREMENT POINTS
JSKIA4726ZZ
: Vehicle front
Unit: mm (in)
Cowl top indent of center positioning mark Center pillar indent
Roof flange end of center positioning mark Rear fender indent

BRM-156
BODY ALIGNMENT
A
B
: φ9 (0.35)
Rear Body INFOID:0000000010843526 C
MEASUREMENT
vehicle.
BRM
JSKIA4428GB
M
Unit: mm (in)
«The others» N
Unit: mm (in)

O
– 612 (24.09)* – 1131 (44.53) – 762 (30.00)*
– 797 (31.38)* – 323 (12.72)* – 1202 (47.32)
– 1042 (41.02)* – 1210 (47.64)* – 578 (22.76)* P
MEASUREMENT POINTS
BRM-157
BODY ALIGNMENT
JSKIA4429ZZ
: Vehicle front
Unit: mm (in)

Center back pillar main hole center φ7 (0.28) Back door striker installing hole center
BRM-158
A
B
Heat resisting
viation solvents
°C (°F)
C
ABS Acrylonitrile Butadiene Styrene 80 (176) Avoid gasoline and solvents. — D
E
EPDM polymer
F
when burned.
TPO Thermoplastic Olefine 80 (176) ↑ Flammable G
H
tery acid. I
UP Unsaturated Polyester 90 (194) ↑ Flammable J
BRM
PC Polycarbonate
L
Avoid immersing in wa- M
ter.
PAR Polyarylate 180 (356) ↑ — N
O
CAUTION:
P
BRM-159
JSKIA4713ZZ

PBT + PET +
Base Lens PMMA
Lens PMMA Lens PC
Side turn signal lamp License plate lamp
Rear fog lamp
Wind shield molding PVC Housing PC

Reflex reflector

Lens Glass Housing ASA
Glass fiber

Door outside handle
BRM-160
H
JSKIA3819ZZ

I

Personal lamp
Housing PP Lower side panel PP + EPM J

Switch finisher PP Manual A/C Switch PC BRM
Map lamp
Console PP Case ABS
L
Center ventilator grille PC + ABS Lens PC M

Skin TPO Body PP
Instrument panel Center console N
A/T console
finisher
BRM-161
< VEHICLE INFORMATION > [FOR RUSSIA]
VEHICLE INFORMATION
JSKIA4358ZZ
Dark Ol- Dark
ive Blue
Component
Hard clear
× × × × – – – ×
coat
Door mirror cover Body color BAX6 BEAN BEAR BG41 BK23 BKAD BQAB BRAQ
Chromium
plate
Bumper fascia Body color BAX6 BEAN BEAR BG41 BK23 BKAD BQAB BRAQ

Chromium
Door outside handle Cr Cr Cr Cr Cr Cr Cr Cr
plate
Rear spoiler (Upper) Body color BAX6 BEAN BEAR BG41 BK23 BKAD BQAB BRAQ
Chromium
plate
Back door Body color BAX6 BEAN BEAR BG41 BK23 BKAD BQAB BRAQ
Side guard molding Material color – – – – – – – –

NOTE:
BRM-162
PRECAUTIONS
< PRECAUTION > [FOR RUSSIA]
PRECAUTION A
PRECAUTIONS
B
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time. C
“How to disconnect 12V battery terminal” described below. D
NOTE:
battery terminal is disconnected before ECU stops, accidental DTC E
tery and the sub battery before turning ON the ignition switch. F
NOTE:
SEF289H
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC. G
NOTE:
H
I
INSTRUCTION 1
1. Open the hood.
2. Turn key switch to the OFF position with the driver side door opened. J
of the specified time. BRM

HRA2DDT : 12 minutes L
R9M engine : 4 minutes M
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of N
CAUTION: O
1. Unlock the door with intelligent key or remote keyless entry. P
NOTE:
3. Open the hood.
BRM-163
PRECAUTIONS
CAUTION:
CAUTION:
BRM-164
A
High strength steel is used for body panels in order to reduce vehicle weight. B
BRM
BRM-165

• Front floor (Front)
• 2nd crossmember
• 3rd crossmember
• Side dash
• Front suspension spring support
• Front tie down hook
440 - 780 MPa
• Front side member brace
• Rear side member
• Inner center pillar assembly (Lower)
• Outer sill reinforcement
BRM-166

• Inner sill
B
• Front bumper armature assembly C
(Front side member assembly component part) D
980 - 1500 MPa
(Inner center pillar assembly component part) E
(Outer front pillar reinforcement component part) F
G
Read the following precautions when repairing HSS: H

ing is not recommended, because it may weaken the compo- I
above 550°C (1,022°F).
Verify heating temperature with a thermometer. J
ate.)
BRM
PIIA0115E
L
measuring points, and carefully pull the HSS panel. M
to heat. If gas (torch) cutting is unavoidable, allow a minimum N
P
PIIA0117E
BRM-167
ble in order to minimize weakening surrounding areas due to
heat.
strength.
PIIA0144E

steel panel.
Therefore, when cutting spot welds on a HSS panel, use a low
PIIA0145E
2. Precautions in spot welding HSS

PIIA0146E

gaps.
PIIA0147E
BRM-168
Unit: mm (in) A
0.6 (0.024) 10 (0.39) or more
0.8 (0.031) 12 (0.47) or more B
1.0 (0.039) 18 (0.71) or more
1.2 (0.047) 20 (0.79) or more
1.6 (0.063) 27 (1.06) or more C
1.8 (0.071) 31 (1.22) or more
JSKIA0781ZZ
BRM
BRM-169
REPAIRING MATERIAL
< PREPARATION > [FOR RUSSIA]
PREPARATION
REPAIRING MATERIAL
lent
Read instructions on product for fill procedures.
JSKIA0129GB
Urethane foam
Nozzle insert hole
: Vehicle front
2. Fill procedures before installation of service part.

BRM-170
REPAIRING MATERIAL
A
Urethane foam
: Vehicle front B
NOTE:
area. C
NOTE: JSKIA0130GB
Refer to label for information on working times. D
BRM
BRM-171
DESCRIPTION
form the prohibition described below:
PROHIBITION
WARNING:
Never cut ultra high strength steel parts or perform butt welding. Violation of this prohibition causes
PART REPLACEMENT
BRM-172
BRM
JSKIA4728ZZ
P
R9M engine models QR20DE engine models MR20DD engine models

BRM-173
Both sided
No. Parts name
(MPa) precoated
steel sections
Rear floor side assembly (RH & LH) Under 440 ×
Rear floor board reinforcement 590 ×
980MPacaution
T=1.8 mm (0.071 in)
Front floor (RH & LH) d. Inside (RH only) 590 ×
caution
980MPa
T=2.0 mm (0.079 in)

T=1.4 mm (0.055 in)
Lower dash complete e. 980MPacaution 590 ×

T=1.4 mm (0.055 in)

T=2.0 mm (0.079 in)
Front strut housing assembly (RH & LH) 590 ×
Upper radiator core support assembly (RH & LH) Under 440 ×

T=1.0 mm (0.039 in)
Front side member closing plate (RH & LH) f. 980MPacaution 590 ×
T=2.0 mm (0.079 in)
Front side member assembly (RH & LH) g. 980MPacaution 590 ×

T=2.0 mm (0.079 in)
BRM-174
Both sided
No. Parts name
(MPa) precoated
steel sections
Rear floor front extension (Lower) Under 440 × B

C

D
CAUTION:
NOTE:
E
Body Component Parts INFOID:0000000010860049 F

G
BRM
BRM-175
JSKIA4702ZZ

BRM-176
Both sided A
No. Parts name
(MPa) precoated
steel sections
B
Roof Under 440 —
Roof bow No.4 Under 440 — C

Rear roof rail Under 440 — D


E

caution
F
T=1.0 mm (0.039 in)
Hood 440 ×
G

H
T=1.0 mm (0.039 in)
f. 980MPacaution I
T=1.0 mm (0.039 in)
g. 980MPacaution
T=1.0 mm (0.039 in) J

BRM

L
Upper rear pillar reinforcement (RH & LH) Under 440 — M
Back pillar assembly (Inner RH & LH) 440 —
Inner rear wheelhouse (RH & LH) Under 440 × N


O
Jack mounting bracket Under 440 —

P
Rear fender assembly (RH & LH) Under 440 ×
BRM-177
Both sided
No. Parts name
(MPa) precoated
steel sections
Rear bumper stay (RH & LH) 590 —

T=1.2 mm (0.047 in)
CAUTION:
NOTE:
BRM-178
< REMOVAL AND INSTALLATION > [FOR RUSSIA]
REMOVAL AND INSTALLATION A

B
rosive measures. C

D
alloy, which provides excellent and long term corrosion resistance E
SIIA2294E
G
H
A phosphate coating treatment and a cationic electrodeposition I
CAUTION:
Confine paint removal during welding operation to an absolute J
minimum.
BRM
PIIA0095E L
uine parts or an equivalent be used for panel replacement to maintain anti-corrosive performance built into the M
Undercoating (MR20DD Engine Models) INFOID:0000000010843603
N
O
way catalyst that are subjected to heat). P
BRM-179
JSKIA4730ZZ
: Undercoated areas
: Sealed portions
Undercoating (Except For MR20DD Engine Models) INFOID:0000000010843604
way catalyst that are subjected to heat).
JSKIA4703ZZ
: Undercoated areas
: Sealed portions
BRM-180
Body Sealing (MR20DD Engine Models) INFOID:0000000010843605
A
and not to allow other unaffected parts to come into contact with the sealant. B
BRM
JSKIA4732ZZ
P
: Vehicle front
: Sealed portions
BRM-181
JSKIA4705ZZ
: Vehicle front
: Sealed portions
BRM-182
BRM
JSKIA4706ZZ
P
: Vehicle front
: Sealed portions
BRM-183
Body Sealing (QR25DE Engine Models) INFOID:0000000010843606
JSKIA4735ZZ
: Vehicle front
: Sealed portions
BRM-184
BRM
JSKIA4705ZZ
P
: Vehicle front
: Sealed portions
BRM-185
JSKIA4706ZZ
: Vehicle front
: Sealed portions
BRM-186
Body Sealing (R9M Engine Models) INFOID:0000000010860050
A
and not to allow other unaffected parts to come into contact with the sealant. B
BRM
JSKIA4704ZZ
P
: Vehicle front
: Sealed portions
BRM-187
JSKIA4705ZZ
: Vehicle front
: Sealed portions
BRM-188
BRM
JSKIA4706ZZ
P
: Vehicle front
: Sealed portions
BRM-189
BODY CONSTRUCTION
BODY CONSTRUCTION
JSKIA4741ZZ
Inner front pillar reinforcement Upper dash Rear hoodledge reinforcement
BRM-190
BODY CONSTRUCTION
Lower front pillar hinge brace Lower hinge plate Lower dash
A
Outer sill reinforcement Lower front pillar reinforcement Inner sill reinforcement
Inner sill Front floor Front side member outrigger
Inner center pillar Center pillar hinge brace Lower center pillar hinge brace B
Anchor plate Inner sill extension Rear floor front extension
Inner rear wheelhouse Outer rear wheelhouse Inner rear pillar
C
Inner rear pillar reinforcement Rear pillar seat belt anchor Rear roof rail brace
Upper back pillar reinforcement Center back pillar main
BRM
BRM-191
• This section is prepared for technicians who have attained a high level of skill and experience in repairing
original functions and quality of the vehicle are maintained. The Body Repair Manual (Fundamentals) con-
• Please note that this information is prepared for worldwide usage, and as such, certain procedures might not
2-spot welds
JSKIA0049ZZ
JSKIA0053ZZ
3-spot welds
JSKIA0050ZZ
JSKIA0054ZZ
MIG plug weld
JSKIA0051ZZ
JSKIA0055ZZ
BRM-192
area as shown in the figure. The best location for the butt joint is at A
PIIA0150E
D
front pillar over 60 mm (2.36 in) above the inner front pillar cut E
position.
G
JSKIA0104GB
• Prepare a cutting jig to make outer pillar easier to cut. Also, this will H
BRM
JSKIA0105GB

L
lowing.
B: Cut position of inner pillar M
N
PIIA0153E
O
SPOT WELDING P
tions listed below.
CAUTION:
BRM-193
tion to other vehicles.
Welding condition
Welding pressure (Gun force) 3500 N
13 cyc: 60 Hz area)
sile strength 980 MPa and that
PLUG WELDING
CAUTION:
• When welding hole diameter cannot be met, make multiple holes (smaller diameter) so that the sum
EXAMPLE
JSKIA3503GB
Body sealing
: Vehicle front
BRM-194
BRM
JSKIA3843ZZ O
: Vehicle front
Replacement part
bly
BRM-195
JSKIA4598ZZ
: Vehicle front
Replacement part
BRM-196
BRM
N
JSKIA4599ZZ
: Vehicle front O
Hoodledge (Partial Replacement) INFOID:0000000010843612 P
BRM-197
JSKIA4617ZZ
: Vehicle front
Replacement part
BRM-198
BRM
N
JSKIA4618ZZ
: Vehicle front O
Front Side Member INFOID:0000000010843613 P
BRM-199
JSKIA4918ZZ
: Vehicle front
Replacement part
BRM-200
BRM
N
JSKIA4919GB
: Vehicle front O
BRM-201
JSKIA3850ZZ
: Vehicle front

BRM-202
BRM
N
JSKIA4604GB
Unit: mm (in) O
: Vehicle front
Replacement part P
(RH)
POINT
BRM-203
JSKIA3852GB
Unit: mm (in)
: Vehicle front
Replacement part
BRM-204
BRM
N
JSKIA4920GB
Urethane foam Body sealing O

Unit: mm (in)
: Vehicle front
Replacement part
BRM-205
JSKIA4921GB
Unit: mm (in)
: Vehicle front

BRM-206
BRM
N
JSKIA4922GB
Unit: mm (in) O
: Vehicle front

BRM-207
JSKIA4608GB
Unit: mm (in)
: Vehicle front
BRM-208
Replacement part
z Side body assembly z Inner center pillar assembly A
BRM
O
JSKIA3857GB
Unit: mm (in)
P
: Vehicle front
BRM-209
JSKIA4609GB
Unit: mm (in)
: Vehicle front
BRM-210
BRM
JSKIA4626GB O
Unit: mm (in)
: Vehicle front P
Replacement part
BRM-211
JSKIA4923GB

Unit: mm (in)
: Vehicle front
Replacement part
BRM-212
View A: Before installing outer sill assembly
A
BRM
JSKIA4611GB
O
Body sealing
Unit: mm (in)
: Vehicle front P
BRM-213
JSKIA4924GB
Unit: mm (in)
: Vehicle front
View J: Before installing outer sill assembly
BRM-214
BRM
JSKIA3863GB O

Unit: mm (in) P
: Vehicle front
Replacement part
BRM-215
JSKIA4613GB
Body sealing
Unit: mm (in)
: Vehicle front
BRM-216
BRM
N
JSKIA3865GB
Adhesive O
Unit: mm (in)
: Vehicle front
P
BRM-217
JSKIA4614GB
: Vehicle front
: Welding method, the number of welding points, and the tightening torque apply to both side of the vehicle.
Replacement part
z Upper rear panel
BRM-218
A
BRM
O
JSKIA3869ZZ

P
: Vehicle front
Replacement part
z Rear floor rear
BRM-219
JSKIA3872ZZ
: Vehicle front
Replacement part
BRM-220
BRM
N
JSKIA4034ZZ
: Vehicle front O
Replacement part
sembly P
BRM-221
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS) [FOR RUSSIA]
SERVICE DATA AND SPECIFICATIONS (SDS)

BODY ALIGNMENT
Body Center Marks (MR20DD Engine Models) INFOID:0000000010860057
JSKIA4742ZZ
: Vehicle front
Unit: mm (in)
B Cowl top Indent
BRM-222
BODY ALIGNMENT
A
Body Center Marks (Except For MR20DD Engine Models) INFOID:0000000010860060

B
(members, pillars, etc.) damaged by an accident which it enables more accurate and effective repair by using C
BRM
O
JSKIA4708ZZ
: Vehicle front P
Unit: mm (in)
B Cowl top Indent
BRM-223
BODY ALIGNMENT

• When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and gauge itself
and ″Z″.
JSKIA0073GB
Engine Compartment (MR20DD Engine Models) INFOID:0000000010860058
MEASUREMENT
vehicle.
BRM-224
BODY ALIGNMENT
I
JSKIA4744GB
Unit: mm (in)
J
«The others»
Unit: mm (in)
– 777 (30.59)* – 1169 (46.02)* – 1425 (56.10)
– 852 (33.54)* – 1509 (59.41) – 290 (11.42)

L
– 535 (21.06) – 1212 (47.72)* – 296 (11.65)
– 546 (21.50) – 1435 (56.50) – 362 (14.25)
721 (28.39) 853 (33.58) 375 (14.76)

M
– – –
– 700 (27.56) – 1003 (39.49) – 962 (37.87)*
– 789 (31.06) – 977 (38.46) – 1005 (39.57)* N

– 869 (34.21) – 1073 (42.24) – 1071 (42.17)
– 884 (34.80) – 1033 (40.67) – 1081 (42.56)* O

– 872 (34.33) – 973 (38.31) – 1059 (41.69)
– 1321 (52.01)* – 959 (37.76) – 1053 (41.46)

P
– 1058 (41.65) – 1000 (39.37) – 1027 (40.43)
– 596 (23.46)* – 967 (38.07) – 1021 (40.20)
MEASUREMENT POINTS
BRM-225
BODY ALIGNMENT
JSKIA4745ZZ
: Vehicle front
Unit: mm (in)

Cowl top hole center of center positioning mark
: φ7 (0.28)
φ8 (0.31)
: φ13 (0.51)
: φ9 (0.35)
: φ8 (0.31)
: φ14 (0.55)
Front suspension installing hole center 16×10 Engine mounting bracket hole center 12×10
(0.63×0.39) (0.47×0.39)
BRM-226
BODY ALIGNMENT
A
Front fender installing hole center φ7 (0.28) Hoodledge connector hole center φ12 (0.47)
Front hoodledge reinforcement hole center φ12 : φ11 (0.43) B
(0.47) : φ12 (0.47)
: φ13 (0.51)
Engine Compartment (Except For MR20DD Engine Models) INFOID:0000000010860061

C
MEASUREMENT
vehicle.
BRM
M
JSKIA4709GB
Unit: mm (in)
N
«The others»
BRM-227
BODY ALIGNMENT
Unit: mm (in)
– 777 (30.59)* – 596 (23.46)* – 1000 (39.37)
– 852 (33.54)* – 1169 (46.02)* – 967 (38.07)
– 535 (21.06) – 986 (38.82) – 1425 (56.10)
– 546 (21.50) – 1509 (59.41) – 290 (11.42)
– 721 (28.39) – 1212 (47.72)* – 296 (11.65)
– 700 (27.56) – 1171 (46.10) – 362 (14.25)
– 789 (31.06) – 331 (13.03) – 375 (14.76)
– 869 (34.21) – 1435 (56.50) – 962 (37.87)*
– 884 (34.80) – 853 (33.58) – 1005 (39.57)*
– 872 (34.33) – 1003 (39.49) – 1071 (42.17)
– 474 (18.66) – 977 (38.46) – 1081 (42.56)*
– 1321 (52.01)* – 1073 (42.24) – 1059 (41.69)
– 1262 (49.68) – 1033 (40.67) – 1053 (41.46)
– 445 (17.52) – 973 (38.31) – 1027 (40.43)
– 1058 (41.65) – 959 (37.76) – 1021 (40.20)
MEASUREMENT POINTS
BRM-228
BODY ALIGNMENT
BRM
L
JSKIA4710ZZ
: Vehicle front M
Unit: mm (in)
Point Material Point Material N

φ8 (0.31) : φ8 (0.31) O
: φ14 (0.55)
(0.47×0.39) P
(0.63×0.39)
: φ11 (0.43)
: φ12 (0.47)
: φ13 (0.51)
BRM-229
BODY ALIGNMENT
(0.47) (0.55)
: φ7 (0.28)
: φ13 (0.51)
Underbody INFOID:0000000010860054
MEASUREMENT
vehicle.
BRM-230
BODY ALIGNMENT
BRM
JSKIA4422GB
P
Unit: mm (in)
: Vehicle front
: Vehicle left side
MEASUREMENT POINTS
BRM-231
BODY ALIGNMENT
JSKIA4423ZZ
: Vehicle front
BRM-232
BODY ALIGNMENT
Unit: mm (in)
Coordinates Coordinates A
X Y Z X Y Z
478.0 −566.6 375.5 ±650.0 1954.0 272.9
Hole φ18 (0.71) Hole φ16 (0.63)
(18.819) (−22.307) (14.783) (±25.591) (76.929) (10.744) B
−501.0 −566.6 375.5 ±525.4 2480.4 380.0
Hole φ18 (0.71) Hole φ12 (0.47)
(−19.724) (−22.307) (14.783) (±20.685) (97.653) (14.961)
: Hole φ30 (1.18)

C
462.4 −346.0 502.5 ±330.0 2501.0 434.0
Hole φ16 (0.63) : Hole 32×30
(18.205) (−13.622) (19.783) (±12.992) (98.464) (17.087)
(1.26×1.18)
−474.7 −372.0 502.5 549.0 2911.0 435.0 D
Hole φ16 (0.63) Hole φ20 (0.79)
(−18.689) (−14.646) (19.783) (21.614) (114.606) (17.126)
: Hole φ30 (1.18)

±305.0 301.0 277.8 −525.5 2897.2 435.0 E
: Hole 32×30 Hole φ20 (0.79)
(±12.008) (11.850) (10.936) (−20.689) (114.063) (17.126)
(1.26×1.18)
±410.0 660.0 190.4 551.0 3248.0 433.8 Hole 16×14
Hole φ14 (0.55) F
(±16.142) (25.984) (7.495) (21.693) (127.874) (17.079) (0.63×0.55)
±410.0 800.0 191.4 −523.5 3248.0 433.8 Hole 16×14
Hole φ12 (0.47)
(±16.142) (31.496) (7.535) (−20.610) (127.874) (17.079) (0.63×0.55)
±410.0 1270.0 189.2 ±598.6 7.4 911.9 G
Hole φ12 (0.47) Hole φ33 (1.30)
(±16.142) (50.000) (7.449) (±23.566) (0.291) (35.902)
±410.0 1751.0 180.2
Hole φ13 (0.51)
(±16.142) (68.937) (7.094) H
Passenger Compartment (MR20DD Engine Models) INFOID:0000000010860059
I
MEASUREMENT
vehicle. J
BRM
BRM-233
BODY ALIGNMENT
JSKIA4748GB
Unit: mm (in)
«The others»
Unit: mm (in)
- 1334 (52.52) - 1665 (65.55)* - 1077 (42.40)*
- 1616 (63.62)* - 1458 (57.40) - 943 (37.13)*
- 1494 (58.82)* - 1670 (65.75)* - 794 (31.26)*
- 1634 (64.33)* - 1461 (57.52) - 1179 (46.42)*
- 1441 (56.73) - 1749 (68.86)* - 1092 (42.99)*
- 1738 (68.43)* - 1567 (61.69)* - 782 (30.79)*
- 1458 (57.40) - 1281 (50.43) - 1592 (62.68)
- 1886 (74.25)* - 1602 (63.07)* - 1172 (46.14)*
- 1689 (66.50)* - 1419 (55.87) - 1175 (46.26)*
- 1327 (52.24) - 1462 (57.56) - 1623 (63.90)
- 1569 (61.77)* - 1110 (43.70)* - 1235 (48.62)*
- 1458 (57.40) - 979 (38.54)* - 1137 (44.76)*
- 1461 (57.52) - 890 (35.04)* - 1588 (62.52)
- 1326 (52.20) - 1233 (48.54)* - 1619 (63.74)
- 1562 (61.50)* - 1068 (42.05)*
- 1498 (58.98)* - 836 (32.91)*
BRM-234
BODY ALIGNMENT
MEASUREMENT POINTS
A
BRM
JSKIA4749ZZ
M
: Vehicle front
Unit: mm (in)
N
Cowl top indent of center positioning mark Center pillar indent O
Roof flange end of center positioning mark Rear fender indent P

BRM-235
BODY ALIGNMENT
: φ9 (0.35)
Passenger Compartment (Except For MR20DD Engine Models) INFOID:0000000010860062
MEASUREMENT
vehicle.
JSKIA4711GB
Unit: mm (in)
«The others»
BRM-236
BODY ALIGNMENT
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo A

- 1334 (52.52) - 1665 (65.55)* - 1077 (42.40)*
- 1616 (63.62)* - 1458 (57.40) - 943 (37.13)* B

- 1494 (58.82)* - 1670 (65.75)* - 794 (31.26)*
- 1634 (64.33)* - 1461 (57.52) - 1179 (46.42)*

C
- 1441 (56.73) - 1749 (68.86)* - 1092 (42.99)*
- 1738 (68.43)* - 1567 (61.69)* - 782 (30.79)*

D
- 1458 (57.40) - 1281 (50.43) - 1592 (62.68)
- 1886 (74.25)* - 1602 (63.07)* - 1172 (46.14)*
- 1689 (66.50)* - 1419 (55.87) - 1175 (46.26)* E
- 1327 (52.24) - 1462 (57.56) - 1623 (63.90)
- 1569 (61.77)* - 1110 (43.70)* - 1235 (48.62)* F

- 1458 (57.40) - 979 (38.54)* - 1137 (44.76)*
- 1461 (57.52) - 890 (35.04)* - 1588 (62.52)

G
- 1326 (52.20) - 1233 (48.54)* - 1619 (63.74)
- 1562 (61.50)* - 1068 (42.05)*

H
- 1498 (58.98)* - 836 (32.91)*
MEASUREMENT POINTS
I
BRM
BRM-237
BODY ALIGNMENT
JSKIA4712ZZ
: Vehicle front
Unit: mm (in)
Cowl top indent of center positioning mark Center pillar indent
Roof flange end of center positioning mark Rear fender indent

: φ9 (0.35)
BRM-238
BODY ALIGNMENT
Rear Body INFOID:0000000010860056
A
MEASUREMENT
vehicle. B
JSKIA4428GB
BRM
Unit: mm (in)
«The others»
L
Unit: mm (in)
– 612 (24.09)* – 1131 (44.53) – 762 (30.00)* M

– 797 (31.38)* – 323 (12.72)* – 1202 (47.32)
– 1042 (41.02)* – 1210 (47.64)* – 578 (22.76)*

N
MEASUREMENT POINTS
BRM-239
BODY ALIGNMENT
JSKIA4429ZZ
: Vehicle front
Unit: mm (in)

Center back pillar main hole center φ7 (0.28) Back door striker installing hole center
BRM-240
A
B
Heat resisting
viation solvents
°C (°F)
C
ABS Acrylonitrile Butadiene Styrene 80 (176) Avoid gasoline and solvents. — D
E
EPDM polymer
F
when burned.
TPO Thermoplastic Olefine 80 (176) ↑ Flammable G
H
tery acid. I
UP Unsaturated Polyester 90 (194) ↑ Flammable J
BRM
PC Polycarbonate
L
Avoid immersing in wa- M
ter.
PAR Polyarylate 180 (356) ↑ — N
O
CAUTION:
P
BRM-241
JSKIA4713ZZ

PBT + PET +
Base Lens PMMA
Lens PMMA Lens PC
Side turn signal lamp License plate lamp
Rear fog lamp
Wind shield molding PVC Housing PC

Reflex reflector

Lens Glass Housing ASA
Glass fiber

Door outside handle
BRM-242
H
JSKIA4752ZZ

I

Personal lamp
Housing PP Lower side panel PP + EPM J

Switch finisher PP Manual A/C Switch PC BRM
Map lamp
Console PP Case ABS
L
Center ventilator grille PC + ABS Lens PC M

Skin TPO Body PP
Instrument panel Center console N
A/T console
finisher
BRM-243

Body Repair: Section

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BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY

SECTION BRM BODY REPAIR

PRECAUTIONS ................................................... 5 Inner Rear Wheelhouse ...........................................57

BODY CONSTRUCTION ....................................26 LOCATION OF PLASTIC PARTS .................... 80 O

REPLACEMENT OPERATIONS ..................... 107 BODY COMPONENT PARTS .......................... 172

Fillet molding Material color – – – – – – – –

Sill cover Material color – – – – – – – –

Side guard molding Material color – – – – – – – –

D4D engine : 20 minutes

Tensile strength Major applicable parts

Tensile strength Major applicable parts A

Read the following precautions when repairing HSS: H

• Spot welding on HSS panels is harder than that of an ordinary

2. Precautions in spot welding HSS

• The panel surfaces must fit flush to each other, leaving no

2. Fill procedures before installation of service part.

Refer to label for information on working times. D

Refer to parts catalogue for the replacement parts.

: Both sided anti-corrosive precoated steel sections

Spare tire clamp bracket Under 440 —

Rear floor side assembly (RH & LH) Under 440 ×

Rear floor front Under 440 —

Rear floor board reinforcement 590 ×

Rear floor front extension (Upper RH & LH) Under 440 ×

Rear seat crossmember assembly 590 ×

Center front floor 780 ×

Inner sill (RH & LH) 980MPacaution 590 ×

Upper dash assembly Under 440 ×

Lower dash complete d. 980MPacaution 590 ×

Lower dash crossmember 980MPacaution 440 ×

Upper hoodledge (RH & LH) Under 440 ×

Lower hoodledge (RH & LH) Under 440 ×

Hoodledge reinforcement (RH & LH) Under 440 ×

Front hoodledge reinforcement (RH & LH) Under 440 ×

Upper front fender bracket (RH & LH) Under 440 ×

Front fender bracket (RH & LH) Under 440 ×

Front bumper armature assembly 1500MPacaution — —

Hoodledge connector assembly (RH & LH) Under 440 ×

Front side member assembly (RH & LH) f. 980MPacaution 590 ×

Front suspension mounting bracket (RH & LH) 590 ×

Rear side member (RH & LH) 590 ×

Rear side member extension (RH & LH) 780 ×

Refer to parts catalogue for the replacement parts. G

Sunroof models Normal roof models Right side

: Both sided anti-corrosive precoated steel sections

Front roof rail Under 440 —

Roof bow No.4 Under 440 — C

Rear roof rail Under 440 — D

Roof bow No.2 Under 440 —

Upper inner front pillar (RH & LH) 590 —

Side body assembly (RH & LH) Refer to No. −

Lower front pillar hinge brace (RH & LH) 590 —

Outer sill reinforcement (RH & LH) 590 ×

Inner rear pillar (RH & LH) 590 —

Upper rear pillar reinforcement (RH & LH) Under 440 — M

Outer rear wheelhouse (RH & LH) Under 440 ×

Jack mounting bracket Under 440 — P

Front door assembly (RH & LH) 590 ×

Outer front door panel (RH & LH) Under 440 ×

Rear door assembly (RH & LH) 440 ×

Outer rear door panel (RH & LH) Under 440 ×

Outer back pillar (RH & LH) Under 440 —

Back pillar assembly (Outer RH & LH) Under 440 —