DAIHATSU

J100

TO CONTENTS

DAIHATSU MOTOR CO., LTD.

NO. 9093-JE
 FOREWORD

This body repair manual introduces to you fundamental knowledge nec-

essary for servicing the bodies of Daihatsu vehicles and basic opera-
tions thereof. Furthermore, this manual describes the replacement pro-
cedures for principal sheet panels of the TERIOS including their welding
methods as well as those seal applying points.
It is urged that every body repair technician be acquainted with accu-
rate operations by making the most of this body repair manual in order
that rationalized, efficient repairs and reliable body servicing operations
may be carried out.
This manual has been compiled based on the TERIOS as of April 1997.
Due to continuing improvements in design, the contents and specifica-
tions in this manual may be partly revised without advance notice and
without incurring any obligations to us.

July. 1997

DAIHATSU MOTOR CO., LTD.

BJE97-00001
 CONTENTS
1. FUNDAMENTALS OF BODY REPAIR
OPERATIONS
1. MAIN INSTRUCTIONS ON
OPERATION ......................................... 6
(1) SRS AIRBAG/SEAT BELT
PRETENSIONER .............................. 6
(2) SAFETY MEASURES ....................... 6
(3) PROTECTION OF MOTOR
VEHICLE .......................................... 6
(4) WEARING OF PROTECTIVE
EQUIPMENT .................................... 6
(5) REMOVAL OF DANGEROUS
ARTICLES ........................................ 6
2. REMOVAL OPERATION ...................... 7
(1) DIMENSION MEASUREMENT
PRIOR TO OPERATION ................... 7
(2) SELECTION OF CUT/PATCHING
SECTION ......................................... 7
(3) DRILLING AND CUTTING OPERATION
OF DAMAGED PANEL ..................... 7
(4) REMOVAL OF RELATED-PARTS ...... 7
3. PREPARATION OF INSTALLATION .... 8
(1) ROUGH CUTTING OF CUT/
PATCHING SECTION ....................... 8
(2) SPOT WELDING SECTION .............. 8
(3) HOW TO READ WELDING
INSTRUCTIONS IN THIS
MANUAL .......................................... 9
(4) SPOT SEALER APPLICATION ......... 9
(5) PLUG WELDING SECTION ............. 9
4. INSTALLATION OPERATION .............. 10
(1) INSTRUCTIONS DURING SPOT
WELDING ........................................ 10
(2) NONDESTRUCTIVE TEST ............... 10
(3) INSTRUCTIONS DURING
WELDING ........................................ 11
(4) DIMENSION MEASUREMENT PRIOR
TO WELDING .................................. 11
(5) FINISH AFTER WELDING ................ 11
5. RUST PREVENTIVE TREATMENT ...... 11
(1) BODY SEALER APPLICATION ........ 11
(2) UNDERCOAT APPLICATION ........... 11
(3) RUST PREVENTION OF ENCLOSED
CONSTRUCTION ............................ 11
2. BODY CONSTRUCTION
1. PRINCIPAL AREAS WHERE HIGH-TEN-
SILE STEEL SHEETS OR GALVANIZED
STEEL SHEETS ARE USED ............... 14
(1) PARTS WHERE HIGH-TENSILE
STEEL SHEETS ARE USED ............. 14
(2) PARTS WHERE GALVANIZED
STEEL SHEETS ARE USED ............. 15
3. REPLACEMENT PROCEDURE FOR
BODY PANELS
1. RADIATOR UPPER CENTER SUPPORT
(REPLACEMENT MODE:
ASSEMBLY) ......................................... 18
(1) SPARE PART .................................... 18
(2) REMOVAL ........................................ 18
(3) INSTALLATION ................................ 19
2. RADIATOR SIDE SUPPORT
(REPLACEMENT MODE:
ASSEMBLY) ......................................... 20
(1) SPARE PART .................................... 20
(2) REMOVAL ........................................ 20
(3) INSTALLATION ................................ 21
3. FRONT CROSS MEMBER
(REPLACEMENT MODE:
ASSEMBLY) ......................................... 22
(1) SPARE PART .................................... 22
(2) REMOVAL ........................................ 22
(3) INSTALLATION ................................ 23
4. FENDER APRON REINFORCEMENT
PLATE (REPLACEMENT MODE:
ASSEMBLY) ......................................... 24
(1) SPARE PART .................................... 24
(2) REMOVAL ........................................ 24
(3) INSTALLATION ................................ 25
 5. FRONT FENDER APRON .................... 26
(1) SPARE PART .................................... 26
(2) REMOVAL ........................................ 26
(3) INSTALLATION ................................ 27
6. FRONT SIDE MEMBER ....................... 28
(1) SPARE PART .................................... 28
(2) REMOVAL ........................................ 28
(3) INSTALLATION ................................ 29
7. FRONT BODY PILLAR (OUTER AND
INNER) (REPLACEMENT MODE:
CUTTING) ............................................. 30
(1) SPARE PART .................................... 30
(2) REMOVAL ........................................ 30
(3) INSTALLATION ................................ 31
8. CENTER BODY PILLAR
(REPLACEMENT MODE:
CUTTING) ............................................. 32
(1) SPARE PART .................................... 32
(2) REMOVAL ........................................ 32
(3) INSTALLATION ................................ 33
9. EAR QUARTER PANEL (5 Door)
(REPLACEMENT MODE:
CUTTING) ............................................. 34
(1) SPARE PART .................................... 34
(2) REMOVAL ........................................ 34
(3) INSTALLATION ................................ 35
10. BODY LOWER BACK PANEL
(REPLACEMENT MODE:
ASSEMBLY) ......................................... 36
(1) SPARE PART .................................... 36
(2) REMOVAL ........................................ 36
(3) INSTALLATION ................................ 37
11. ROOF PANEL
(REPLACEMENT MODE:
ASSEMBLY) ......................................... 38
(1) SPARE PART .................................... 38
(2) REMOVAL ........................................ 38
(3) INSTALLATION ................................ 39
4. RUST PREVENTIVE TREATMENT
1. BODY SEALING ................................... 42
2. UNDERCOATING ................................. 44
3. AFFIXING OF ASPHALT SHEETS ...... 45
5. ALIGNMENT CHECKS AND
ADJUSTMENTS
1. HOOD ................................................... 48
2. FRONT DOOR, REAR DOOR .............. 49
3. BACK DOOR ........................................ 50
6. SERVICE DATA
1. WHEEL ALIGNMENT ........................... 52
(1) CHECKS OF TIRE SIZE AND AIR
INFLATION PRESSURE ................... 52
(2) WHEEL ALIGNMENT CHECK ......... 52
(3) WHEEL ALIGNMENT ....................... 52
2. BODY COLOR INFORMATION &
COLOR COMBINATION ....................... 53
COLOR CODE IN THE WORLD ............ 53
3. BODY DIMENSIONAL DIAGRAM ........ 54
(1) INSTRUCTIONS ............................... 54
4. BODY DIMENSIONAL DIAGRAM
CHART NO. J–6–1 ................................ 56
CHART NO. J–6–2 ................................ 57
CHART NO. J–6–3 ................................ 58
 TO CONTENTS
1. FUNDAMENTALS OF BODY REPAIR
OPERATIONS
1. MAIN INSTRUCTIONS ON
OPERATION .........................................
(1) SRS AIRBAG/SEAT BELT
PRETENSIONER ..............................
(2) SAFETY MEASURES ........................
(3) PROTECTION OF MOTOR
VEHICLE ..........................................
(4) WEARING OF PROTECTIVE
EQUIPMENT ....................................
(5) REMOVAL OF DANGEROUS
ARTICLES ........................................
2. REMOVAL OPERATION .......................
(1) DIMENSION MEASUREMENT
PRIOR TO OPERATION ...................
(2) SELECTION OF CUT/PATCHING
SECTION .........................................
(3) DRILLING AND CUTTING
OPERATION OF DAMAGED
PANEL ..............................................
(4) REMOVAL OF RELATED-PARTS ......
1
3. PREPARATION OF
6 INSTALLATION .................................... 8
(1) ROUGH CUTTING OF CUT/
6 PATCHING SECTION ....................... 8
6 (2) SPOT WELDING SECTION .............. 8
(3) HOW TO READ WELDING
6 INSTRUCTIONS IN THIS
MANUAL .......................................... 9
6 (4) SPOT SEALER APPLICATION ......... 9
(5) PLUG WELDING SECTION ............. 9
6 4. INSTALLATION OPERATION ............... 10
7 (1) INSTRUCTIONS DURING SPOT
WELDING ........................................ 10
7 (2) NONDESTRUCTIVE TEST ............... 10
(3) INSTRUCTIONS DURING
7 WELDING ........................................ 11
(4) DIMENSION MEASUREMENT
PRIOR TO WELDING ....................... 11
7 (5) FINISH AFTER WELDING ................ 11
7 5. RUST PREVENTIVE TREATMENT ...... 11
(1) BODY SEALER APPLICATION ........ 11
(2) UNDERCOAT APPLICATION ........... 11
(3) RUST PREVENTION OF
ENCLOSED CONSTRUCTION ........ 11
BJE97-01001
6
1. MAIN INSTRUCTIONS ON Air bag warning light
Driver’s air bag and inflator
OPERATION
(1) SRS AIRBAG/SEAT BELT PRETENSIONER
On some types of TERIOS, the SRS (Supplement Restraint Front
passenger’s
System) airbag is provided as optional equipment. air bag and
Prior to the operation, be sure to read carefully the service inflator
manual so that the operations may be carried out in the cor-
rect servicing procedures with accurate knowledge. Control unit
Failure to do this may actuate such equipment unexpectedly BJE97-01002

or prevent such equipment from functioning properly after the

service when it should function.

(2) SAFETY MEASURES

When you perform such an operation during which a body frame straightener is employed, be sure not to
enter in the pulling direction.
Moreover, make sure to use protective wire or chain.
Ensure that all of fasteners, clamps and pullers are installed accurately.

(3) PROTECTION OF MOTOR VEHICLE

Be sure to use protective cover so that the motor vehicle may be protected from getting dirt.
Make certain to employ heat-resistant protective cover especially during welding operation so as to protect
glass, seat and so forth.
BJE97-01003

(4) WEARING OF PROTECTIVE EQUIPMENT

Make sure to wear long-sleeved working dress, safety shoes
and so forth. Also, correctly use protectors suitable to the op-
eration.

BJE97-01004

(5) REMOVAL OF DANGEROUS ARTICLES

When fire is used in the vicinity of the fuel tank during the op-
eration, e.g. welding operations, make sure to remove the fuel
tank.
Moreover, be sure to plug the disconnected pipes so as to
prevent any fuel leakage.

BJE97-01005
 7
2. REMOVAL OPERATION
WARNING:
• During the operation, make sure to wear protectors suitable to the operation.
• During the operation, utmost care must be exercised to ensure that your fingers or hands may not be
pinched.

TERIOS

DAIHATSU

BJE97-01006

(1) DIMENSION MEASUREMENT PRIOR TO OPERATION

Prior to operations such as removal and cutting, be sure to measure the related-sections in accordance
with the body dimensional diagrams so as to evaluate the extent of damage. Then, proceed to carry out
rough straightening by means of a body straightener.

(2) SELECTION OF CUT/PATCHING SECTION

As a cut/patching section of the panel, be sure to select areas where strain due to welding can be sup-
pressed and the operation procedures up to finish can be performed readily. (Select such area where the
welding length becomes the shortest and the shape of the panel is not complicated.)
NOTE:
• Make sure that no reinforcement, etc. is present inside.
• Or, confirm the relationship with the part to be replaced. For example, remove the section instead of
cutting it, as required.

(3) DRILLING AND CUTTING OPERATION OF DAMAGED PANEL

When you perform drilling or cutting operations, make sure that no wire harness or hose, etc. is located at
the back side.
NOTE:
• Be very careful not to damage any panel not to be replaced.

(4) REMOVAL OF RELATED-PARTS

Prior to removal of related-parts such as moulding, be sure to affix protective tape to the body and tools so
that no damage is made to the body and parts to be removed.
NOTE:
• If paint film is damaged, be sure to perform repairing painting.
BJE97-01007
8
3. PREPARATION OF INSTALLATION
WARNING:
• During the operation, make sure to wear protectors suitable to the operation.
• During the operation, utmost care must be exercised to ensure that your fingers or hands may not be
pinched.
• Never use fires, such as welding operations, at those places where dangerous articles are stored.

BJE97-01008

(1) ROUGH CUTTING OF CUT/PATCHING

SECTION
When performing rough cutting of the panel, be sure to take
into consideration the overlapping width (approx. 50 mm) for
the butting welding section.

BJE97-01009

(2) SPOT WELDING SECTION

If the sum of the sheet thickness at the welding section is less
than 3 mm, perform spot welding.

BJE97-01010
 9
(3) HOW TO READ WELDING INSTRUCTIONS IN
THIS MANUAL
7 × S: Spot welding at seven points
2 × P: Plug welding at two points
3 × E: MIG welding at three points

BJE97-01011

(4) SPOT SEALER APPLICATION

As for the mating surfaces of the spot welding points, be sure
to completely remove the paint films so as to assure better
flow of electricity. Also, apply spot sealer as a rust-preventive
treatment.

BJE97-01012

(5) PLUG WELDING SECTION

At areas where spot welding can not be performed, make 5 to
6 mm holes with a pin punch or a drill. Then, perform a plug
welding.
NOTE:
• As for the two steel sheets to be used at plug welding
sections, they must be contacted closely each other.
This is a rule to be observed to assure adequate weld-
ing strength.
BJE97-01013
10
4. INSTALLATION OPERATION
WARNING:
• During the operation, make sure to wear protectors suitable to the operation.
• Never use fires, such as welding operations, at those places where dangerous articles are stored.

BJE97-01014

(1) INSTRUCTIONS DURING SPOT WELDING

1. Be sure to keep the correct shape of the tip end of a spot
welder at all times, for this will affect the welding strength.
Install the arm and tip properly.
2. Prior to spot welding, perform trial run of spot welding on
a test piece having the same thickness as the sheet.
Confirm the strength of the test piece.
3. When selecting spot welding positions, avoid former spot
positions.
BJE97-01015

(2) NONDESTRUCTIVE TEST

In order to inspect the welding conditions, drive a wedge as
indicated in the right figure into the side of the nugget, ac-
cording to the procedure indicated in the figure.
When there is no separation and the diameter of the nugget
section is at least 3 mm, you can evaluate the welding is satis-
factory.

BJE97-01016
 11
(3) INSTRUCTIONS DURING WELDING
1. Perform welding at more points than performed by the
manufacturer.
NOTE: Number of welding positions
Spot welding: At least 1.3 times as many as number
performed by the manufacturer
Plug welding: At least the same number as that per-
formed by the manufacturer
The distance between spot welding points should be at
least 15 mm.
BJE97-01017

2. Do not employ gas welding or brazing for welding the

panels, except for the specified positions.

(4) DIMENSION MEASUREMENT PRIOR TO

WELDING
When installing the main components of the underbody and
engine compartment, perform the operations correctly, refer-
ring to the body dimensional diagram.

(5) FINISH AFTER WELDING BJE97-01018

1. Inspect the welded zone so as to ensure that the welding

has been carried out positively.
2. When you use a sander to finish the welded zone after
completion of the welding operation, be very careful not to
grind off excessively.

5. RUST PREVENTIVE TREATMENT

(1) BODY SEALER APPLICATION
Apply body sealer to those required areas. (See page 44.)
BJE97-01019
(2) UNDERCOAT APPLICATION
Perform rust preventive treatment to the inside of the wheel
house and the back side of the floor, using undercoat agent.

(3) RUST PREVENTION OF ENCLOSED

CONSTRUCTION
In the case where the welding section is of enclosed con-
struction, perform the rust preventive treatment, using an
aerosol rust preventive agent through machined holes, etc.
BJE97-01020

q Aerosol rust preventive agent

BJE97-01021
TO INDEX TO NEXT SECTION
 TO CONTENTS

2. BODY CONSTRUCTION
2

1. PRINCIPAL AREAS WHERE HIGH-TENSILE

STEEL SHEETS OR GALVANIZED STEEL
SHEETS ARE USED ..................................... 14
(1) PARTS WHERE HIGH-TENSILE STEEL
SHEETS ARE USED .................................. 14
(2) PARTS WHERE GALVANIZED STEEL
SHEETS ARE USED .................................. 15
BJE97-02001
14
1. PRINCIPAL AREAS WHERE HIGH-TENSILE STEEL SHEETS OR
GALVANIZED STEEL SHEETS ARE USED
(1) PARTS WHERE HIGH-TENSILE STEEL SHEETS ARE USED
High-tensile steel sheets have been employed at various sections of the vehicle body. These high-tensile
steel sheets feature light weight and remarkable dentability-resistance properties *1 capable of withstand-
ing local external pressures.

Back door outer panel

Hood panel

Front door beam

extension R/L
Rear door beam
extension R/L

Front door (rear door)

: High-tensile steel sheets outside right & left panels

BJE97-02002

* Dentability-resistance properties: Minutes dents that could be formed when local outer pressures (fin-
1

ger pressures which are applied to the doors when opening/closing them or flying grits) are applied to
automotive outer sheets are called “dentability.” And the properties capable of withstanding such dents
are called “dentability-resistance properties.”
 15
(2) PARTS WHERE GALVANIZED STEEL SHEETS ARE USED
For improved rust-preventive performance, rust-preventive steel sheets have been employed widely on
those areas which are very prone to rust-formation.

Back door outside panel

Hood panel & Hood inner panel

Back door inside panel

Cowl top outer (inner) panel

Fuel filler opening

Rear bumper extension
filler RH

Side outer panel R/L

Front fender apron R/L

Front door Rear door inside panel R/L

inside panel R/L

Rear door
outside panel R/L

Front fender panel R/L Rear door hinge

Front door hinge side panel R/L
side panel R/L
Front door outside panel R/L

Quarter wheel house

outer panel R/L

Floor side inner member R/L

As for those places where the rust-preventive steel sheets are employed, : Galvanized steel sheets
their nomenclatures only are posted.
BJE97-02003
TO INDEX TO NEXT SECTION
 TO CONTENTS
3. REPLACEMENT PROCEDURE FOR
BODY PANELS
1. RADIATOR UPPER CENTER
SUPPORT (Replacement Mode:
Assembly) ........................................... 18
(1) SPARE PART ................................... 18
(2) REMOVAL ....................................... 18
(3) INSTALLATION ............................... 19
2. RADIATOR SIDE SUPPORT
(Replacement Mode: Assembly) ...... 20
(1) SPARE PART ................................... 20
(2) REMOVAL ....................................... 20
(3) INSTALLATION ............................... 21
3. FRONT CROSS MEMBER
(Replacement Mode: Assembly) ....... 22
(1) SPARE PART ................................... 22
(2) REMOVAL ....................................... 22
(3) INSTALLATION ............................... 23
4. FENDER COWL SIDE UPPER
MEMBER) ............................................ 24
(1) SPARE PART ................................... 24
(2) REMOVAL ....................................... 24
(3) INSTALLATION ............................... 25
5. FRONT FENDER APRON ................... 26
(1) SPARE PART ................................... 26
(2) REMOVAL ....................................... 26
(3) INSTALLATION ............................... 27
6. FRONT SIDE MEMBER ...................... 28
(1) SPARE PART ................................... 28
(2) REMOVAL ....................................... 28
(3) INSTALLATION ............................... 29
3
7. FRONT BODY PILLAR (Outer
and Inner) (Replacement Mode:
Cutting) ............................................... 30
(1) SPARE PART ................................... 30
(2) REMOVAL ....................................... 30
(3) INSTALLATION ............................... 31
8. CENTER BODY PILLAR
(Replacement Mode: Cutting) .......... 32
(1) SPARE PART ................................... 32
(2) REMOVAL ....................................... 32
(3) INSTALLATION ............................... 33
9. REAR QUARTER PANEL (5 Door)
(Replacement Mode: Cutting) .......... 34
(1) SPARE PART ................................... 34
(2) REMOVAL ....................................... 34
(3) INSTALLATION ............................... 35
10. BODY LOWER BACK PANEL
(Replacement Mode: Assembly) ...... 36
(1) SPARE PART ................................... 36
(2) REMOVAL ....................................... 36
(3) INSTALLATION ............................... 37
11. ROOF PANEL
(Replacement Mode: Assembly) ...... 38
(1) SPARE PART ................................... 38
(2) REMOVAL ....................................... 38
(3) INSTALLATION ............................... 39
BJE97-03001
18
1. RADIATOR UPPER CENTER SUPPORT
(Replacement Mode: Assembly)
(1) SPARE PART

Radiator upper
center support,
subassembly

Hood lock brace

subassembly

BJE97-03002

(2) REMOVAL

BJE97-03003
 19
(3) INSTALLATION

BJE97-03004
20
2. RADIATOR SIDE SUPPORT
(Replacement Mode: Assembly)
(1) SPARE PART
q Items to be observed during operation
• This is the headlamp installing section. Radiator side support
Therefore, the installation of the radiator side sup-
port must be carried out accurately.

w Related preparatory operation

• Remove the radiator upper center support. BJE97-03005

(See page 18.)

(2) REMOVAL

3XS

5XS

5XS
5XS

2XS2XS

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03006
 21
(3) INSTALLATION
q Main points of operation
(1) Install the spare parts, referring to the body dimensional diagram. (See page 54.)
(2) After completion of temporal installation, check relationship with the radiator upper center sup-
port.

3XP

7XS

7XS
7XS

2XP 3XS

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03007
22
3. FRONT CROSS MEMBER
(Replacement Mode: Assembly)
(1) SPARE PART
q Related preparatory operation
Remove the Hood lock brace. (See page 18.) Front cross member subassembly
Front side member
reinforcement R/L
subassembly

BJE97-03008

(2) REMOVAL
6XS

6XS

2XS
2XS
2XS
4XS

6XS
5XS

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03009
 23
(3) INSTALLATION
q Main points of operation
(1) Install the spare parts, referring to the body dimensional diagram. (See page 54.)
(2) After performing tack welding, carry out confirmation by installing the radiator side support.

2XP

6XS
6XP

2XP
2XP

8XS

3XS

2XP
7XS

3XS

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03010
24
4. FENDER COWL SIDE UPPER MEMBER
(Replacement Mode: Assembly)
(1) SPARE PART

Front fender cowl side

upper member

BJE97-03011

(2) REMOVAL
q Main points of operation
Grind the MIG spot welding section by means of a cut grinder or the like.
NOTE:
• Be very careful not to grind off excessively.

3XS
3XS
9XS

6XS

9XS
10XS

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03012
 25
(3) INSTALLATION

4XS

4XS
12XS

6XP

9XP
13XS

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03013
26
5. FRONT FENDER APRON
(1) SPARE PART
q Items to be observed during operation
• The front fender apron is an important part that
bears close relationship with the front wheel align-
ment. Therefore, it is mandatory to accurately per- Front fender apron
subassembly
form the measurement and welding operations.
• Condition in which the rear sections of the apron
and front fender are remained.
BJE97-03014
w Related preparatory operation
Condition in which the radiator upper center support is
removed (See page 18.)
Condition in which the front crossmember is removed
(See page 22.)
Condition in which the radiator side support is re-
moved (See page 20.)
Condition in which the fender cowl side upper member
is removed (See page 24.)

(2) REMOVAL
q Main points of operation
For easier operation, perform rough cutting at the position indicated in the figure below when the
front fender apron assembly is removed.

As viewed from arrow A 3XS

5XS

9XS

Drawing as viewed from arrow A

12XS

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03015
 27
(3) INSTALLATION
q Main points of operation
(1) Install the spare parts, referring to the body dimensional diagram. (See page 54.)
(2) After performing tack welding, temporally install the radiator upper support, front cross-member
and radiator side support, fender cowl side upper member. Then, check the alignment.
(3) Install the fender cowl side upper member in the subsequent operation.

As viewed
from arrow A 4XS

7XS

9XP

Drawing as viewed from arrow A

16XP

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03016
28
6. FRONT SIDE MEMBER
(1) SPARE PART
q Related preparatory operation
Condition in which the radiator upper center support is
removed (See page 18.)
Condition in which the front crossmember is removed Front side member
(See page 22.) subassembly
Condition in which the radiator side support is re-
moved (See page 20.)
Condition in which the fender cowl side upper member BJE97-03017
is removed (See page 24.)
Condition in which the front fender apron is removed
(See page 26.)

(2) REMOVAL
q Main points of operation
For easier operation, perform rough cutting at the position indicated in the figure below.

3XS

m
180 m
5XS
4XS

4XS

As viewed
from arrow A

6XS

9XS 5XS

4XS
8XS
12XS
3XS
3XS

3XS

3XS
Drawing as viewed from arrow A

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03018
 29
(3) INSTALLATION
q Main points of operation
(1) Install the spare parts, referring to the body dimensional diagram (See page 54.)
(2) After performing tack welding, temporarily install the front fender apron, radiator side support,
front cross-member, and fender cowl side upper member. Then, check the alignment.
(3) Install the fender cowl side upper member in the subsequent operation.

3XP

5XP
4XP

4XP

As viewed from arrow A

6XP

9XP 5XP

4XP
8XP
16XS
3XP
3XP

4XS

4XS
Drawing as viewed from arrow A

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03019
30
7. FRONT BODY PILLAR (Outer and
Inner) (Replacement Mode: Cutting)
(1) SPARE PART
q Items to be observed during operation
• As for the front body pillar replacement, the outer Front body
outer pillar Front body
pillar should be replaced integral with the rein- subassembly inner pillar
forcement.
Front pillar
w Related preparatory operation reinforcement
• Condition in which the fender cowl upper member BJE97-03020

is removed

(2) REMOVAL
q Main points of operation
(1) When roughly cutting the panel, make sure that no wire harness or the like is present at the in-
side.
NOTE:
• The antenna is provided at the right pillar; the wire harness at the left pillar.
• The butting welding positions of the outer and inner pillars should be at least 50 mm apart from each
other.

150 mm
m
0m
m

8XS
0m

10
15

3XS

11XS 18XS
25XS

mm
300

7XS

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03021
 31
(3) INSTALLATION
q Main points of operation
(1) As for those parts which are not set in the spare parts, they should be reassembled prior to tem-
poral installation of panels.
(2) After completion of temporal installation, check the front door, front fender and windshield glass
for proper alignment.

120 mm

11XS

4XS

11XP 15XP

4XS
33XS
m
350 m

10XS

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03022
32
8. CENTER BODY PILLAR
(Replacement Mode: Cutting) Center body pillar
(1) SPARE PART reinforcement
subassembly
q Items to be observed during operation Root side inner rail
• As for the center body pillar replacement, the outer subassembly
pillar should be replaced integral with the rein- Center body Center body inner pillar
forcement. pillar subassembly

Center body inner lower

pillar
BJE97-03023

(2) REMOVAL
q Main points of operation
When roughly cutting the upper section of the center body pillar, it should be noted that an inner re-
inforcement is present inside the pillar.
NOTE:
• Be very careful not to cut the panel excessively, while paying attention to the size of the spare parts.

100 mm
250 mm 
70 mm 
70 mm  Do not cut in this area
Nut for seatbelt
Reinforcement

100 mm

23XS
22XS
4XS

3XS

As viewed
from arrow A 11XS
160 mm 300 mm Drawing as viewed
from arrow A
Rough cutting position
Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03024
 33
(3) INSTALLATION
q Main points of operation
(1) When performing the lap cutting, follow the procedure given in the figure below. Utmost care
must be exercised during the rough cutting at the spare part side.
NOTE:
• Be very careful not to damage the reinforcement at the inside.

(2) As for those parts which are not set in the spare parts, they should be reassembled prior to
temporal installation of panels.
(3) After completion of temporal installation, check the front door and rear door for proper align-
ment.

70 mm

220 mm

70 mm

30XS
29XS
4XP

3XP

15XS

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03025
34
9. REAR QUARTER PANEL (5 Door)
(Replacement Mode: Cutting)
(1) SPARE PART
q Items to be observed during operation
(1) As for the rear quarter panel replacement, perform Rear quarter panel
the cutting replacement and with the reinforcement
as a set.
Belt anchor reinforcement
subassembly
BJE97-03026

(2) REMOVAL
q Main points of operation
(1) When roughly cutting the panel, it should be noted that an inner reinforcement is present inside
the pillar. Hence, be sure to perform the cutting at a position indicated in the figure below.
(2) When roughly cutting the panel, make sure that no wire harness or washer hose or drain hose,
etc. is present at the inside.
NOTE:
• When roughly cutting the panel, be very careful not to cut excessively, while confirming the spare
parts.

6XS 3XS

3XS 6XS

2XS
180 mm 21XS

220 mm 7XS
As viewed from
arrow A
12XS

4XS

4XS
As viewed from
arrow B mm
140

4XS

Rough cutting position

Butting position
Spot welding (S)
Drawing as viewed from arrow B Drawing as viewed from arrow A MIG plug welding (P)

BJE97-03027
 35
(3) INSTALLATION
q Main points of operation
(1) As for those parts which are not set in the spare parts, they should be reassembled prior to tem-
poral installation of panels.
(2) Before temporarily installing the spare parts, apply body sealer to the wheel housing section.
(See page 42.)
(3) After completion of temporal installation, check the rear door and back door for proper align-
ment.

8XS 4XS

150 mm
4XS 6XP
250 mm

2XP
28XS

9XS
As viewd
from arrow A
16XS

4XP

6XS

mm
170

(Those parts which are not set in the spare parts) 4XP

Rear door rock striker

reinforcement
Drawing as viewed from arrow A
2XP
4XP

Fuel inlet box

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03028
36
10. BODY LOWER BACK PANEL
(Replacement Mode: Assembly)
(1) SPARE PART

Body lower back panel

subassembly

BJE97-03029

(2) REMOVAL

14XS

3XS

3XS

21XS

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03030
 37
(3) INSTALLATION
q Main points of operation
After completion of temporal installation of the spare parts, check the back door for proper align-
ment.

19XS

3XP

3XP

28XS

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03031
38
11. ROOF PANEL (Replacement Mode: Assembly)
(1) SPARE PART

Roof panel

BJE97-03032

(2) REMOVAL
q Main point of operation
As for the brazing points, heat them and eliminate the braze, using a wire brush.
NOTE:
• Care must be exercised as to overheating.

1XS

1XS

15XS Brazing

Brazing

38XS

38XS

16XS

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03033
 39
(3) INSTALLATION
q Main point of operation
(1) As for the mating sections with the rear pillar, perform brazing.
NOTE:
• Care must be exercised as to overheating.

1XP

1XP

20XS Brazing

Brazing

50XP

50XP

21XS

Rough cutting position

Butting position
Spot welding (S)
MIG plug welding (P)

BJE97-03034
TO INDEX TO NEXT SECTION
 TO CONTENTS

4. RUST PREVENTIVE TREATMENT

1. BODY SEALING ............................................ 42

2. UNDERCOATING .......................................... 44
3. AFFIXING OF ASPHALT SHEETS ............... 45
BJE97-04001
42
1. BODY SEALING
For the rust prevention and waterproofing, fill body sealer to
the joint section of the body panel and panel’s hemming sec-
tion.

Body Sealer

NOTE:
1. Clean the sections to which the body sealer is applied,
using a cloth dampened with white gasoline.
BJE97-04002
2. Remove any body sealer adhering to those sections
where such application is no required, using a cloth
dampened with white gasoline.

A
B

C
D E J

A
F A
G

I
K

BJE97-04003
 43

Spatula finish
(50 mm from forward and backward edges)
Section A–A Section A Section B

Overfender installation hole

Section C Section D Section E

200

Section F Section G Section H

As viewed from arrow I As viewed from arrow J As viewed from arrow L

Section H
BJE97-04004
44
2. UNDERCOATING
For soundproof and rust prevention, apply the undercoat agent to the back side of the floor and the inside
of the wheel house.

Undercoat Agent

NOTE:
1. Clean the sections to which the undercoat is applied, using a cloth dampened with white gasoline.
2. Do not apply the undercoat to those sections where such application is not required; e.g. the muffler.
3. If the back side of the floor has been welded, apply the undercoat for the purpose of rust prevention.

Specifications for destinations other than EU

Specifications for EU destination

BJE97-04005
 45
3. AFFIXING OF ASPHALT SHEETS
For soundproof treatment, affix the asphalt sheets to the floor, while heating the asphalt sheets by means of
a burner, etc.

i
o

u
y

o
!0
!1

No. Part name No. Part name

q Dash panel outer insulator
w Dash panel silencer board subassembly
e Front floor silencer left sheet
r Front floor silencer center sheet
t Front floor silencer right sheet
y Center floor silencer sheet
u Center floor silencer center sheet
i Rear floor silencer No.1 sheet
o Rear floor silencer No. 3 sheet
!0 Rear floor silencer No. 2 sheet
!1 Rear floor silencer No. 4 sheet

BJE97-04006
TO INDEX TO NEXT SECTION
 TO CONTENTS

5. ALIGNMENT CHECKS AND

ADJUSTMENTS

5
1. HOOD ............................................................. 48
2. FRONT DOOR, REAR DOOR ....................... 49
3. BACK DOOR ................................................. 50
BJE97-05001
48
1. HOOD

1 3
2

Difference in Difference between

No. Part name Gap Deviation
height right and left
q Hood × Fender 4.4 ± 1.5 0 ± 1.5 Not to exceed 1.5 Not to exceed 1.5
w Radiator grill × Hood 7.6 ± 1.5 2.9 ± 1.5 Not to exceed 2.0 —
e Headlamp × Hood 7.8 ± 1.5 5.2 ± 1.5 Not to exceed 2.0 —
Unit: mm
BJE97-05002
 49
2. FRONT DOOR, REAR DOOR

20 mm
400 mm
2 4

3
1

Difference in Difference between

No. Part name Gap Deviation
height right and left
q Fender × Front door panel 4.7 ± 1.5 0 ± 1.5 — Not to exceed 1.5
w Side outer panel × Front door panel 5.2 ± 1.5 5.9 ± 1.5 — Not to exceed 1.5
e Front door panel × Rear door panel 5.5 ± 1.5 0 ± 1.5 — Not to exceed 1.5
r Side outer panel × Rear door panel 5.2 ± 1.5 7.2 ± 1.5 — Not to exceed 1.5
t Quarter panel × Rear door panel 4.7 ± 1.5 0 ± 1.5 — Not to exceed 1.5

Unit: mm

BJE97-05003
50
3. BACK DOOR

1
100 mm

100 mm
2

3 4

Difference in Difference between

No. Part name Gap Deviation
height right and left
q Roof panel × Back door glass 10.4 ± 1.5 1.8 ± 1.5 — Not to exceed 1.5
w Back door panel × Back door glass 2.0 ± 1.5 1.5 ± 1.5 — Not to exceed 1.5
e Quarter panel × Back door panel 5.3 ± 1.5 0 ± 1.5 — Not to exceed 1.5
r Rear bumper pillar × Back door 5.3 ± 1.5 0 ± 1.5 — Not to exceed 1.5
panel
t Rear bumper × Back door panel 7.3 ± 2.0 — — Not to exceed 2.0
Unit: mm

BJE97-05004
TO INDEX TO NEXT SECTION
 TO CONTENTS

6. SERVICE DATA

1. WHEEL ALIGNMENT .................................... 52 6

(1) CHECKS OF TIRE SIZE AND AIR
INFLATION PRESSURE ............................. 52
(2) WHEEL ALIGNMENT CHECK ................... 52
(3) WHEEL ALIGNMENT ................................ 52
2. BODY COLOR INFORMATION & COLOR
COMBINATION .............................................. 53
COLOR CODE IN THE WORLD ..................... 53
3. BODY DIMENSIONAL DIAGRAM ................. 54
(1) INSTRUCTIONS ........................................ 54
4. BODY DIMENSIONAL DIAGRAM ................. 56
CHART NO. J–6–1 .......................................... 56
CHART NO. J–6–2 .......................................... 57
CHART NO. J–6–3 .......................................... 58
BJE97-06001
52
1. WHEEL ALIGNMENT
(1) CHECKS OF TIRE SIZE AND AIR INFLATION PRESSURE
Ensure that the correct tire size is employed and that both right and left tires exhibit no conspicuous wear.
(Refer to “Service Management Manual” page 39.)
BJE97-06002

(2) WHEEL ALIGNMENT CHECK

If the wheel alignment-related parts have excessive loose-
ness, it will cause errors in the alignment measured value.
Hence, be sure to perform the following checks for excessive
looseness. If excessive play exists, perform repairs before the
wheel alignment measurement is conducted.

q Runout of tire
Maximum Limit: 2 mm for Right-and-Left
1.4 mm for Up-and-Down
BJE97-06003

w Other related parts

• Ball joint for excessive play
• Steering linkage for excessive play and deformation
• Suspension-related parts for excessive play and deformation
• Front wheel bearing for excessive play

(3) WHEEL ALIGNMENT

Vehicle model
J100
Item
Toe-in 0 ± 1.5 mm
Camber 0°30′ ± 45′
Caster 2°35′ ± 1°
Front
Kingpin inclination angle 13°45′ ± 1°
+1°20′
Inner side (degree) 38°28′ –2°40′
Tire turning angle +1°30′
Outer side (degree) 33°24′ –2°30′
+3
Toe-in 5 –2
Rear
Camber –40′ ± 35′
BJE97-06004
 53
2. BODY COLOR INFORMATION & COLOR COMBINATION
Body color name Code

Silver metallic S07

Black metallic 6A5
Red mica metallic R24
Turquoise mica metallic B36
Purplish blue mica B38
Violet metallic P05
White W09
Two-tone color Silver metallic / Silver metallic NF7
Two-tone color Black metallic / Silver metallic NF2
Two-tone color Red mica metallic / Silver metallic NF0
Two-tone color Turquoise mica metallic / Silver metallic ND9
Two-tone color Purplish blue mica / Silver metallic NG1
Two-tone color Violet metallic / Silver metallic NG2
Two-tone color White/Silver metallic NC1
BJE97-06005

COLOR CODE IN THE WORLD

Color code
Color name SPIES
DAIHATSU AKZO DUPONT ICI STANDOX
HECKER
Silver metallic S07 DAHS07 L8842 B127B 97076 S07
Black metallic 6A5 DAH6A5 G8742 A403B 96326 6A5
Red mica metallic R24 DAHR24 F2213 FCN6B 33273 R24
Turquoise mica metallic B36 DAHB36 F2855 HMG7B 55174 B36
Purplish blue mica B38 DAHB38 F3425 JNE4B 55603 B38
Violet metallic P05 DAHP05 F3426 JNE5B 40868 P05
White W09 DAHW09 K9344 XM48 16461 W09
Two-tone color S07 DAHS07 L8824 B127B 97076 S07
NF7
Silver metallic / Silver metallic S07 DAHS07 L8842 B127B 97076 S07

Two-tone color 6A5 DAH6A5 G8742 A403B 96326 6A5

NF2
Black metallic / Silver metallic S07 DAHS07 L8842 B127B 97076 S07
Two-tone color R24 DAHR24 F2213 FCN6B 33273 R24
NF0
Red mica metallic / Silver metallic S07 DAHS07 L8842 B127B 97076 S07
Two-tone color B36 DAHB36 F2855 HMG7B 55174 B36
Turquoise mica metallic / Silver metallic ND9
S07 DAHS07 L8842 B127B 97076 S07
Two-tone color B38 DAHB38 F3425 JNE4B 55603 B38
NG1
Purplish blue mica / Silver metallic S07 DAHS07 L8842 B127B 97076 S07

Two-tone color P05 DAHP05 F3426 JNE5B 40868 P05

Violet metallic / Silver metallic NG2
S07 DAHS07 L8842 B127B 97076 S07
Two-tone color W09 DAHW09 K9344 XM48 16461 W09
White / Silver metallic NC1
S07 DAHS07 L8842 B127B 97076 S07
BJE97-06006
54
3. BODY DIMENSIONAL DIAGRAM
(1) INSTRUCTIONS
This body dimensional diagram is based on the measurement of the body dimensions by means of a track-
ing gauge for the body shell (condition where all pieces of equipment have been removed).

q How to read dimensional diagram

All dimensions have been posted in this diagram according to the following rules.

surface
Frame
lower

N,n
760
N

298
474

466
92
4

M,m
836 m
M

221
619
11
646

9 0

48
L,l
971
l
L
546

545

10
90

2,420
40
K,k
917
K

Wheel base
470
474

97
4
J,j
1

789
J

j
227

225

790
726
I,i
i
I

575

92
607

8
855

192

H,h

678
H

267
G 267

730
152

G,g

679
g
in a straight line

in a vertical
dimension

direction
q Distance

e Distance
w Plane

BJE97-06007
 55
(1) Distance in a straight line (q in figure) ... Indicated by
red dimension line
This indicates the distance in a straight line between
the centers of the measuring points.

BJE97-06008

(2) Plane dimension (w in figure) ... Indicated by black di-

mension line
This indicates the dimension measured when the mea-
suring points are projected on a plane.

BJE97-06009

(3) Distance in a vertical direction (e in figure) ...

Indicated by black dimension line
This indicates the distance in a vertical direction from
the imagined line at the lower surface of the rocker
panel or frame to the lower surface or center of the
measuring point.

BJE97-06010

w Instructions to be observed during measuring operation

The basic measuring method of the body dimensions is one which uses a tracking gauge.
(1) When performing the measurement by a tracking gauge, ensure that the gauge proper and pointer,
etc. exhibit no excessive looseness.
(2) When performing the measurement by a tape measure, ensure that it exhibits no deflection, twist,
bend and so forth.
Especially, as for the red dimension line, it indicates the distance in a straight line. Hence, if a tape
measure is interfered with the body during the measurement, use the tracking gauge to perform ac-
curate measurements.
(3) When the measuring points are covered with the undercoat, body sealer or the like, be sure to re-
move it completely and expose the measuring point. Then, proceed to the measurement.
BJE97-06011
 Applicable Model: Date: Chart No.
TERIOS
J100G 1997. 5 J–1–1

Point code Measuring point Hole diameter Point code Measuring point Hole diameter
A, a Front fender attaching nut, front side 12 mm dia. D, d Cowl top panel windshield cover attaching hole 7 mm dia.
B, b Front spring support hole, front side 9.5 mm dia. E, e Headlamp attaching nut (upper inner side) 7 mm dia.
C, c Cowl top side and front fender attaching hole, rear side 10 mm dia. Right 8 mm dia.
F, f Front bumper bracket attaching reference hole
NOTE: Left 8.5 mm dia.
As for points where dimensions are given only at one side, the right side is symmetric with the left side. Unit: mm

[Reference dimensions]

1232
1
48
A D c
1311

81
1208 1

a
B

E 894

928
A,a b
A,a
E,e e
E,e
891

B,b D
695

C,c F,f
F f
 Applicable Model: Date: Chart No.
TERIOS
J100G 1997. 5 J–1–2

Point code Measuring point Hole diameter Point code Measuring point Hole diameter
G, g Front side member front reference hole 15 mm dia. K, k Front side member reference hole 15 mm dia.
H, h Front suspension member attaching hole (Front side) 15 mm dia. L, l Rear floor side member reference hole 15 mm dia.
I, i Front suspension member attaching hole (Rear side) 16 mm dia. M, m Rear suspension bumper bracket attaching nut 9 mm dia.
J, j Front side member reference hole 15 mm dia. N, n Rear floor side member reference hole 15 mm dia.
NOTE: Unit: mm
As for points where dimensions are given only at one side, the right side is symmetric with the left side.

K 546 L
646 M
474 474
G 267 607 I 227 J N
H

09

760
789

90
8
679

730

4
971

836
678

726
790

917

11
92

97

92
10
g h 855
i n
j m
k l

G,g K,k

267 575 225 470 545 619 466

H,h L,l

221 298 Frame

152 192 1 lower
40 48 surface
G,g H,h I,i J,j K,k L,l M,m N,n
I,i J,j I,i M,m
J,j Wheel base 2,420 N,n M,m N,n
 Applicable Model: Date: Chart No.
TERIOS
J100G 1997. 5 J–1–3

Point code Measuring point Hole diameter Point code Measuring point Hole diameter
A, a Mating section of roof panel with quarter panel (side outer side) — N, n Center pillar cutout section (Upper side) —
B, b Mating section of cowl panel with front lower quarter panel — O, o Center pillar cutout section (Lower side) —
C, c Front door hinge attaching hole (Upper hinge) 11 mm dia. P, p Rocker panel cutout section (Lower side) —
D, d Front door hinge attaching hole (Lower hinge) 11 mm dia. Q, q Roof side rail cutout section (Upper side) —
E, e Front body pillar cutout section — R, r Quarter panel cutout section (Rear upper side) —
F, f Rocker panel cutout section (Front side) — S, s Quarter panel cutout section (Rear lower side) —
G, g Front body pillar cutout section (Upper side) — T, t Courtesy lamp attaching reference hole 12 mm dia.
H, h Roof side rail cutout section (Upper side) — U, u Rear combination lamp attaching hole 7 mm dia.
I, i Center pillar cutout section (Upper side) — V, v Courtesy lamp switch attaching section 11 mm dia.
J, j Center pillar cutout section (Lower side) — W, w Rear bumper attaching hole 7 mm dia.
K, k Rocker panel cutout section (Lower front side) — X, x Back door hinge attaching reference hole (Upper hinge) 10 mm dia.
L, l Rear door hinge attaching hole (Upper hinge) 13 mm dia. Y, y Back door hinge attaching reference hole (Lower hinge) 10 mm dia.
M, m Rear door hinge attaching hole (Lower hinge) 13 mm dia. Unit: mm

929 Q u
A a H 881
R U
G N 658
592 I

1101
123

106

108 985
64
4 5
3

988
B

2
953
1191

33
S

12

90
a 12 846 X

12
11 L
1007 1
806 108

799
C O T
E
1061
60
11
7
116

J 6
96 1061
V Y
M P w
1002
974
D K
F
W

[Width dimensions]
E–e F–f G–g H–h I–i J–j
1227 1236 1076 1018 1098 1233

K–k N–n O–o P–p Q–q R–r S–s

1242 1199 1235 1238 1002 1078 1232

TO INDEX TO NEXT SECTION