Mitsubishi Lancer 2006 Body Repair Manual

LANCER/ GROUP INDEX
LANCER WAGON GENERAL . . . . . . . . . . . . . . . . . . . . . 0

BODY BODY CONSTRUCTION . . . . . . . . . . 1
REPAIR MANUAL BODY DIMENSIONS . . . . . . . . . . . . . 2
FOREWORD
WELDED PANEL REPLACEMENT . 3
This manual has been prepared for the use of all CORROSION PROTECTION . . . . . . . 4
service mechanics engaged in the body repair
service. Body dimensions, welded panel replacement SYNTHETIC-RESIN PARTS . . . . . . . 5
procedures, body sealing application instructions, and
all the other information required to provide quick and BODY COLOUR. . . . . . . . . . . . . . . . . 6
accurate body repair service are contained herein.
One especially important point is the welding method. REFERENCE MATERIAL . . . . . . . . . 8
All of the vehicle’s original strength and durability can
be maintained by following the welding procedures
contained in this manual.
Note that, in order to maximize the efficiency of the
repair work, first, both the extent of the damage and
the replacement parts that are needed must be
calculated accurately, and then the actual work must
be performed accurately and efficiently.
The publications shown below are also available, and
should be used in conjunction with this manual.
TECHINICAL INFORMATION MANUAL

IJTE04E1CD
IJTE05E1CD
IJTE06E1CD
WORKSHOP MANUAL
CHASSIS GROUP CJTX04E1CD
CJTE05E1CD
CJTE06E1CD
(PASSENGER CARS & LIGHT

COMMERCIAL VEHICLES) PBAE9216
PARTS CATALOGUE B606K006A_
Mitsubishi Motors Corporation reserves the right to

make changes in design and specifications and/or to
make additions to or improvements in its products
without imposing any obligation upon itself to install
them on its products previously manufactured.
©0LWVXELVKL0RWRUV(XURSH%9 6HSW
Manual description.fm Page 1 Friday, September 2, 2005 10:16 AM
MANUAL DESCRIPTION
CONTENTS
The first page of this manual contains a table of contents which lists the name of vehicle models and
groups within each model.
TEXT
The vehicles to which the information in the text pertains are generally designated according to their
body classification. In some cases, other limiting designations such as model name, type of drive
system, etc., are given. If there are no such limiting designations, the information can be assumed to
cover all models.
PAGE NUMBERS
All pages are numbered consecutively within each model. The page number can be found on the upper
left or right of each page.
SECTION TITLES
The group titles and section titles can be found at the upper center of each page.
Page number Group title

Group number Section title
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7
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8
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AB100844 AB
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0-1
GROUP 0
GENERAL
CONTENTS
VEHICLE IDENTIFICATION . . . . . . . 0-2 MAJOR SPECIFICATIONS . . . . . . . . 0-3

0-2 GENERAL
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION
M4000001000736
MODELS
<SEDAN>
Model code Engine model Price class Transmission Fuel supply
model system
CS1A SNJEL6 4G13-SOHC (1,298 Invite F5M41 MPI
SNJER6 mL) <2WD, 5M/T>
CS3A SNJEL6 4G18-SOHC (1,584
SRJEL6 mL) F4A4A
<2WD, 4A/T>
SNJER6 F5M41
<2WD, 5M/T>
SRJER6 F4A4A
<2WD, 4A/T>
CS9A SNHML6 4G63-DOHC (1,997 Intense F5M42
mL) <2WD, 5M/T>
SRHML6 F4A4A
<2WD, 4A/T>
SNHMR6 F5M42
<2WD, 5M/T>
<WAGON>
Model code Engine model Price class Transmission Fuel supply
model system
CS3W LNJEL6 4G18-SOHC (1,584 Invite F5M41 MPI
mL) <2WD, 5M/T>
LRJEL6 F4A4A
<2WD, 4A/T>
LNJER6 F5M41
<2WD, 5M/T>
LRJER6 F4A4A
<2WD, 4A/T>
LNHEL6 Intense F5M41
LNHER6 <2WD, 5M/T>
CS9W LNJML6 4G63-DOHC (1,997 Invite F5M42
LNHML6 mL) Intense <2WD, 5M/T>
LNHMR6
GENERAL
MAJOR SPECIFICATIONS
0-3
M4000003000594
<SEDAN>
Items CS1A CS3A CS9A
SNJEL6/R6 SNJEL6/R6, SNHML6/R6,
SRJEL6/R6 SRHML6
Vehicle Overall length 4,535
dimension mm Overall width 1,715
Overall height (unladen) 1,445 1,415
1,435*1
Wheelbase 2,600
Track Front 1,470
Rear 1,470
Front overhang 965
Rear overhang 970
Ground clearance 165 135
(unladen) 155*1
Vehicle Front Toe-in (at the centre of tyre 1±2
wheel tread) mm
alignment Toe angle (per wheel) 0°03' ± 0°06
Toe-out angle on turns (inner 21°42' ± 1° 30'
wheel outer wheel at 20°)
Camber 0°05' ± 0°30'*2 -0°05' ± 0°30'*2
Caster 2°45' ± 0°30'*2 2°55' ± 0°30'*2
Kingpin inclination angle 12°30' ± 1°30' 12°40' ± 1°30'
Rear Toe-in (at the centre of tyre 3±2
tread) mm
Toe angle (per wheel) 0°08' ± 0°05'
Camber -0°40' ± 0°30'*2
Wheels and tyres Tyre size 195/60 R15 88H 195/50 R16 84V
Wheel size 15 × 6JJ 16 × 6JJ
Offset mm 46
NOTE: .
*1
• : Vehicles with high ground clearance suspension.
• *2: Difference between right and left wheels must be less than 30'
0-4 GENERAL
<WAGON>
Items CS3W CS9W
LNJEL6/R6, LNHEL6/R6 LNJML6 LNHML6/R6
LRJEL6/R6
Vehicle Overall length 4,540
dimension mm Overall width 1,715
Overall height 1,480 1,450 1,480 1,450
(unladen) 1,470*1 1,470*1
Wheelbase 2,600
Track Front 1,470
Rear 1,470
Front overhang 965
Rear overhang 975
Ground clearance 165 135 165 135
(unladen) 155*1 155*1
Vehicle Front Toe-in (at the centre 1 ± 2
wheel of tyre tread) mm
alignment Toe angle (per wheel) 0°03' ± 0°06'
Toe-out angle on 21°42' ± 1°30'
turns (inner wheel
when outer wheel at
20°)
Camber 0°05' ± 0°30'*2 -0°05' ± 0°30'*2 0°05' ± 0°30'*2 -0°05' ± 0°30'*2
Caster 2°45' ± 0°30'*2 2°55' ± 0°30'*2 2°45' ± 0°30'*2 2°55' ± 0°30'*2
Kingpin inclination 12°30' ± 1°30' 12°40' ± 1°30' 12°30' ± 1°30' 12°40' ± 1°30'
angle
Rear Toe-in (at the centre 3±2
of tyre tread) mm
Toe (per wheel) angle 0°08' ± 0°05'
Camber -0°40' ± 0°30'*2
Wheels and Tyre size 195/60 R15 195/50 R16 195/60 R15 195/50 R16
tyres 88H 84V 88H 84V
Wheel size 15 × 6JJ 16 × 6JJ 15 × 6JJ 16 × 6JJ
Offset mm 46
NOTE: .
*1
• : Vehicles with high ground clearance suspension.
• *2: Difference between right and left wheels must be less than 30'
1-1
GROUP 1
BODY
CONSTRUCTION
CONTENTS
BODY COMPONENTS. . . . . . . . . . . . 1-2 REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 1-22

ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
BODY MAIN CROSS-SECTIONAL UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 1-25
VIEWS . . . . . . . . . . . . . . . . . . . . . . . . 1-6 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
MAINTENANCE, SERVICEABILITY . 1-10 SILENCER APPLICATION LOCATIONS 1-31
BODY CONSTRUCTION LOCATIONS USING URETHANE FOAM

CHARACTERISTICS . . . . . . . . . . . . . 1-13 AND FOAM MATERIAL . . . . . . . . . . . 1-32
FRONT BODY. . . . . . . . . . . . . . . . . . . . . . . 1-13
SIDE BODY. . . . . . . . . . . . . . . . . . . . . . . . . 1-18 STIFFENER AND DAMP SHEET
APPLICATION LOCATIONS . . . . . . . 1-37
1-2 BODY CONSTRUCTION
BODY COMPONENTS
BODY COMPONENTS
M4010001000146
<Sedan> 29 30
27 28
26 31
25 32
33 34
35
21
23 24
22 36
37
42 38
40
19 43 41 46
20 39
15 45
14 47
13 44
49
18 50 48
11 55
17
16
52
10 51
9 71
56 59
8 53
12 57 54
7 67 60
68 58
6 72
5
66
4
69
75 74 73
2 3 77 76
65 61
62
70 63
64
1
: Anti-corrosion steel panels
: High-tensile steel panels AB300927AC
BODY CONSTRUCTION
BODY COMPONENTS
1-3
1. Front bumper reinforcement 40. Rear wheel house inner panel
2. Front end crossmember 41. Centre pillar inner
3. Hood lock stay 42. Front pillar inner upper
4. Headlamp support side panel 43. Front pillar inner lower
5. Front end upper bar 44. Side outer panel
6. Headlamp support panel side 45. Spare tyre bracket
7. Front upper frame inner 46. Rear end panel inner
8. Upper frame bulkhead front 47. Rear end panel outer
9. Upper frame bulkhead 48. Towing hook reinforcement
10. Dash panel 49. Jack bracket
11. Dash silencer panel 50. Rear seatback reinforcement
12. Dash panel reinforcement 51. Rear floor sidemember extension
13. Cowl top lower panel 52. Rear floor crossmember
14. Cowl top inner panel 53. Rear floor sidemember
15. Cowl top upper panel 54. Upper arm crossmember
16. Upper frame to front pillar brace 55. Rear floor pan
17. Upper frame outer extension 56. Child anchor bracket lower
18. Front upper frame extension inner 57. Rear floor seat belt reinforcement
19. Front deck crossmember 58. Rear floor panel extension
20. Hood inner panel 59. Rear door panel inner
21. Hood outer panel 60. Rear door panel outer
22. Roof rail front 61. Rear door side door beam upper
23. Roof bow front 62. Rear door side door beam
24. Rear roof bow 63. Front door panel outer
25. Roof side rail inner 64. Front door side door beam
26. Roof rail rear 65. Front door panel inner
27. Roof panel 66. Front floor side sill inner
28. Rear shelf panel 67. Front floor crossmember rear
29. Trunk lid inner panel 68. Front floor crossmember front
30. Trunk lid outer panel 69. Front floor sidemember
31. Rear shelf brace 70. Front fender
32. Trunk lid hinge 71. Instrument panel centre reinforcement bracket
33. Quarter panel inner 72. Front floor pan
34. Quarter corner panel 73. Backbone reinforcement
35. Rear combination lamp housing 74. Sidemember inner
36. Rear floor side brace 75. Spring house panel
37. Quarter outer panel lower extension 76. Front fender shield
38. Fuel filler lid 77. Sidemember outer
39. Side sill end plate
BODY COMPONENTS
<Wagon> 31
32
23
22 33 37
30 34
35
21 28 29
27
26
25
36
24 38
20 39
43 41
15 19
42 40
14
44 46
13 45
48
47
11 53
18 54 49
55
10 17
16
50
51
52
9 12
59 58 56
8 71
61
7 57
70 60
6 72 69
5
68
4
78 77 76 73 67 62
2 79 74
3 64 63
65
75 66
1
: Anti-corrosion steel panels
: High-tensile steel panels AB300928AC
BODY CONSTRUCTION
BODY COMPONENTS
1-5
1. Front bumper reinforcement 41. Rear wheel house inner panel
2. Front end crossmember 42. Centre pillar inner
3. Hood lock stay 43. Front pillar inner upper
4. Headlamp support side panel 44. Front pillar inner lower
5. Front end upper bar 45. Side outer panel
6. Headlamp support panel side 46. Rear end crossmember inner
7. Front upper frame inner 47. Rear end crossmember outer
8. Upper frame bulkhead front 48. Spare tyre bracket
9. Upper frame bulkhead 49. Towing hook reinforcement
10. Dash panel 50. Rear floor crossmember brace
11. Dash silencer panel 51. Rear floor sidemember extension
12. Dash panel reinforcement 52. Rear floor crossmember
13. Cowl top lower panel 53. Jack bracket
14. Cowl top inner panel 54. Rear floor crossmember upper
15. Cowl top panel upper 55. Rear floor pan
16. Upper frame to front pillar brace 56. Rear floor sidemember
17. Upper outer frame extension 57. Upper arm crossmember
18. Upper frame extension inner 58. Child anchor bracket lower
19. Front deck crossmember 59. Rear floor seat belt reinforcement Large
20. Hood inner panel 60. Rear floor panel extension
21. Hood outer panel 61. Rear door panel inner
22. Roof rail front 62. Rear door panel outer
23. Roof panel 63. Rear door side door beam
24. Roof bow A 64. Rear door side door beam upper
25. Roof bow front reinforcement 65. Front door panel outer
26. Roof bow B 66. Front door side door beam
27. Roof bow C 67. Front door panel inner
28. Roof bow D 68. Front floor side sill inner
29. Roof bow E 69. Front floor crossmember front
30. Roof rail rear 70. Front floor crossmember rear
31. Tailgate panel inner 71. Instrument panel centre reinforcement bracket
32. Tailgate panel outer 72. Front floor pan
33. Rear gate pillar reinforcement 73. Backbone reinforcement
34. Quarter panel inner 74. Front floor sidemember
35. Rear pillar reinforcement upper 75. Front fender
36. Roof side rail inner 76. Sidemember inner
37. Rear lamp housing 77. Spring house panel
38. Quarter outer panel lower extension 78. Front fender shield
39. Fuel filler lid 79. Sidemember outer
40. Side sill end plate
BODY MAIN CROSS-SECTIONAL VIEWS

M4010002000149
<Sedan> A
C E
B
D
AB300698AB
A (Driver's side) C Front pillar Front pillar

Front pillar reinforcement lower inner lower
reinforcement upper
Side roof Front pillar

rail inner reinforcement
upper B
Front pillar inner Side outer panel

upper reinforcement Side outer panel
AB200024 AH
AB300950AB
A (Passenger's side) D Side sill outer

reinforcement centre
Front pillar
reinforcement
upper Side sill
reinforcement
support
Side roof rail inner Side outer panel

Side outer panel Front floor
AB301116AB side sill inner AB300934 AB
B Front end
crossmember outer E Side sill outer
Front end reinforcement rear
crossmember inner
Side sill
reinforcement
support
Front end crossmember Side outer panel

Rear floor
reinforcement AB200200AE side sill inner AB300934AC
BODY CONSTRUCTION
1-7
G
H
AB300748AB
F (Drive's side) Front pillar H Rear pillar

Front pillar inner upper inner upper inner
reinforcement
Front pillar
Side outer reinforcement
panel upper B
Front pillar Front pillar

reinforcement inner reinforcement Side outer
upper AB201887AD panel AB201988AC
F (Passenger's side) I
Front pillar
reinforcement
upper Rear wheel
house inner
panel
Front pillar Side outer

inner upper Quarter panel
panel Side outer inner
panel
AB301019AB
AB300932AB
G Centre pillar inner J

Centre pillar
seat belt
reinforcement
Side outer
Centre pillar reinforcement panel Rear end Rear end
panel inner panel outer
AB200262AC AB201989AB
<Wagon>
A
B E
C
D
AB300699 AB
A (Driver's side) C Front pillar Front pillar

Front pillar reinforcement lower inner lower
reinforcement upper
Side roof Front pillar

rail inner reinforcement
upper B
Front pillar inner Side outer panel

upper reinforcement Side outer panel
AB200024 AH
AB300950AB
A (Passenger's side) D Side sill outer

reinforcement centre
Front pillar
reinforcement
upper Side sill
reinforcement
support
Side roof rail inner Side outer panel

Side outer panel Front floor
AB301116AB side sill inner AB300934 AB
B Front end
crossmember outer E Side sill outer
Front end reinforcement rear
crossmember inner
Side sill
reinforcement
support
Front end crossmember Side outer panel

Rear floor
reinforcement AB200200AE side sill inner AB300934AC
BODY CONSTRUCTION
1-9
G
H
AB300749AB
F (Drive's side) Front pillar H Rear lamp

Quarter panel inner housing
Front pillar inner upper inner upper
reinforcement
Front pillar
Side outer reinforcement
panel upper B
Front pillar Front pillar

reinforcement inner reinforcement Rear gate pillar
upper AB201887AD Side outer panel reinforcement AB201058AC
F (Passenger's side) I
Front pillar
reinforcement
upper Rear wheel
house inner
panel
Front pillar Side outer Quarter panel

inner upper panel Side outer inner
panel
AB301019AB
AB300932AB
G J
Centre pillar inner panel Centre pillar
seat belt
reinforcement
Side outer Rear end Rear end

Centre pillar reinforcement crossmember inner crossmember outer
panel
AB200262AD AB300930AB
MAINTENANCE, SERVICEABILITY
M4010003000164
FENDER SHIELD
A positioning hole, marking and notch has been
added on the front fender shield, front upper frame
inner, front sidemember gusset rear and dash panel
to improve assembling workability when replacing
the panel.
AB300918AB
BODY CONSTRUCTION
1-11
SIDE STRUCTURE
A panel positioning notch has been added on the
door opening to improve assembling workability
when replacing the panel.
Panel positioning notch AB200202 AC
<Sedan>
<Wagon>
AB300922 AB
SIDE OUTER PANEL

The extra parts are supplied in 4 different cut forms
as a result of employing the integrated side-frame
side outer panel.
<Sedan>
Centre pillar outer
Quarter outer
Front pillar outer
Side sill outer
AB202026 AB
<Wagon>
Centre pillar outer
Quarter outer
Front pillar outer
Side sill outer
AB200271AB
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
1-13
FRONT BODY NOTE: *: A steel sheet of varying thickness that is
M4010010000133 welded into one steel sheet.
Headlamp Support
An uneven thickness steel sheet* in which the sheet
thickness is thicker on the shipping hook assembling
side was employed for the front end crossmember
outer to ensure rigidity of the shipping hook assem-
bling area and to provide lightweightness.
4
7
2 3
8
10
11
1 12
13 AB300775AB
1. Front bumper reinforcement 8. Headlamp support side panel

2. Shipping hook 9. Radiator bracket
3. Front end crossmember reinforcement 10. A/C condenser bracket
4. Hood lock stay 11. Front end crossmember inner
5. Front end crossmember inner reinforcement 12. Front end crossmember outer
6. Front end upper bar 13. Front bumper clip bracket
7. Front end upper bar reinforcement
Fender Shield NOTE: *: A steel sheet of varying thickness that is

The cross section of the front sidemember has been welded into one steel sheet.
increased and a steel sheet with variable thickness*
has been adopted for the front sidemember inner to
increase the thickness of the cabinet side in the aim
to improve safety in collision, body rigidity, and real-
ize lightweight.
Right side
7
6 A
5 8
4
3 9
6
7 5
2 8 4
Left side
12
A
13
9
1
11 2
10
1
14
10
AB300971AB
1. Headlamp support panel side

A
2. Front fender shield
3. Engine mount reinforcement plate
4. Front upper frame inner Cowl top
lower panel
5. Upper frame bulkhead front
6. Upper frame bulkhead
7. Spring house bracket reinforcement
8. Spring house bracket
9. Spring house panel
10. Front sidemember Spring house
Spring
bracket
11. Transmission mount reinforcement plate rear house panel AB300973AB
12. Spring house reinforcement The spring house panel has been designed to be
13. Fender shield reinforcement
directly installed with the cowl top lower panel, and
14. Transmission mount reinforcement plate
the body rigidity of the suspension attachment holder
has been increased to improve operational stability
and quietness.
BODY CONSTRUCTION
1-15
Front Sidemember Reinforcement
Right side 7 8
9 10
6
11
3 12
4 13
17 14
2
18
5 19
1 16 15
20 AB300776AB
3
2 8
9
4
A B 13
5
16
AB300783AB
1. Sidemember inner
A
2. Front sidemember bulkhead A
3. Front sidemember inner reinforcement lower 4
4. Front sidemember bulkhead
5. Front bumper stay bracket (LH drive vehicles)
6. Sidemember outer
7. Front sidemember gusset rear
8. Front sidemember inner reinforcement rear
9. Tie down reinforcement
10. Dash panel extension 6 1
11. Pipe support rear AB300781AB
12. Pipe nut
13. Front sidemember rear B 3
14. Dash crossmember extension
15. Suspension crossmember support bracket
16. Suspension crossmember bracket inner
17. Pipe support front
18. Retainer
19. Square head bolt
20. Pipe
1
6
AB200280AE
Left side 10 12
8 9 11
7 13
6 14
5 15 16
28 17
4 18
3 24 19
25
2 26 20
1
31 30 29 27 23 22 21 AB300777AB
15 16 18 19
8
10
14 9
3
20
B A
17
29
AB300784 AB
1. Suspension crossmember support bracket 28. Suspension crossmember bracket inner

2. Dash crossmember extension 29. Transmission mount reinforcement
3. Front sidemember rear 30. Transmission mount bracket
4. Pipe nut 31. Transmission mount reinforcement rear
5. Dash panel extension
6. Pipe support rear
A
7. Foot rest bracket (LH drive vehicles) 18
8. Front sidemember reinforcement inner (LH drive
vehicles)
9. Front sidemember outer reinforcement A (LH drive 13
vehicles)
10. Front sidemember outer reinforcement B (LH drive
vehicles)
21
11. Front sidemember inner reinforcement upper
16
12. Front sidemember gusset rear
13. Sidemember outer 17 AB200039 AE
14. Tie down reinforcement
15. Front sidemember bulkhead rear B
16. Front sidemember bulkhead front 19
17. Front sidemember inner reinforcement
18. Front sidemember outer reinforcement
19. Front sidemember bulkhead A
20. Front bumper stay bracket (LH drive vehicles)
21. Sidemember inner
22. Battery bracket front
23. Battery bracket rear 13
24. Pipe support front 21
AB200283AE
25. Retainer
26. Square head bolt
27. Pipe
BODY CONSTRUCTION
1-17
Front Deck
5 6 7 8
3
2
4 12 11 9
10
15
1 13
16
14
AB300780AB
1. Cowl top lower panel 15. Upper outer frame extension

2. Brake oil reservoir tank bracket 16. Upper frame to front pillar brace
3. Cowl top lower reinforcement
4. Cowl top lower reinforcement G
5. Cowl top upper reinforcement centre Dash Panel
6. Cowl top inner panel • A dash panel crossmember has been added and
7. Deck stay bracket the thickness of the dash panel lower has been
8. Cowl top upper panel increased to improve collision stability.
9. Clutch pedal support bracket
• A silencer (steel sheet binding type vibration
10. Cowl top upper reinforcement
11. Upper frame bulkhead rear
damping material) has been added between the
12. Wiper bracket centre dash panel and dash panel silencer to control the
13. Front upper frame extension inner penetrating sound and vibration from the engine.
14. Cowl top lower reinforcement F
4 5
3
7 9
8
10
2
1 AB300782 AB
1. Dash panel crossmember 6. Dash panel reinforcement

2. Dash panel 7. Dash silencer side
3. Dash silencer centre 8. Accelerator pedal stopper bracket
4. Dash silencer panel 9. Dash panel reinforcement lower
5. Accelerator pedal reinforcement 10. Dash panel lower
SIDE BODY
M4010011000136
SIDE STRUCTURE
<Sedan>
13 19
16
18 20
12
15 21
17 22
11
14 23
42
10
24
41
9 8 7 43 27
44
6 40 28
57 25
39
5 56 26
38 55 47 46 45
48
54 33
49
53 50 34
4 51
29
3 2 37 52
32
1 30
35
36 31
AB300787AB
1. Side sill bulkhead front (Driver’s side) 15. Side sill bulkhead F (Right side on RH drive
2. Front door hinge reinforcement lower vehicles)
3. Side sill to floor plate 16. Roof side rail inner
4. Front pillar inner lower 17. Roof side rail reinforcement centre
5. Deck crossmember bracket front 18. Rear seat back brace
6. Deck crossmember bracket rear 19. Rear shelf brace upper
7. Front pillar reinforcement upper B (Driver’s side) 20. Rear shelf brace lower
8. Front pillar inner reinforcement (Driver’s side) 21. Rear pillar inner
9. Front pillar inner upper reinforcement (Driver’s side) 22. Quarter panel inner
10. Front pillar inner upper 23. Rear floor side brace
11. Side sill outer reinforcement support extension 24. Fuel filler neck bracket (Excluding the right side on
(Right side on RH drive vehicles) RH drive vehicles)
12. Side sill reinforcement support (Right side on RH 25. Rear pillar reinforcement
drive vehicles) 26. Rear sensor reinforcement
13. Side sill reinforcement support rear (Right side on 27. Quarter corner panel
RH drive vehicles) 28. Rear combination lamp housing
14. Side sill bulkhead G (Right side on RH drive 29. Rear bumper bracket
vehicles) 30. Quarter outer panel lower extension
BODY CONSTRUCTION
1-19
31. Side outer panel 46. Spring house bracket
32. Striker reinforcement 47. Side sill end plate
33. Side sill reinforcement outer rear 48. Centre pillar reinforcement
34. Side sill reinforcement support rear (Excluding the 49. Side sill bulkhead E (Excluding the right side on RH
right side on RH drive vehicles) drive vehicles)
35. Side sill outer reinforcement centre 50. Side sill bulkhead D (Excluding the right side on RH
36. Side sill outer reinforcement front drive vehicles)
37. Front pillar reinforcement lower 51. Side sill bulkhead C (Excluding the right side on RH
38. Front door check reinforcement drive vehicles)
39. Front door hinge reinforcement upper 52. Side sill bulkhead B (Excluding the right side on RH
40. Front pillar reinforcement upper drive vehicles)
41. Centre pillar inner 53. Centre pillar inner lower
42. Spring house panel 54. Rear door hinge reinforcement lower
43. Spring house reinforcement 55. Rear door hinge reinforcement upper
44. Rear wheel house inner panel 56. Centre pillar plate inner
45. Spring house bracket plate 57. Centre pillar seat belt reinforcement
<Wagon>
13
16 19
18
12 21
15
11 17
14 20 22
42 43
23
24 26
10 44 27
41 28
9 45
8 46 25
6 7 40 59 47
5
39 38
58 49 48 33
57 50
56 34
55 52 51
4 53
29
3 37 54
2 32
30
1
35
36
31
AB300789 AB
1. Side sill front bulkhead (Driver’s side) 18. Quarter panel inner
2. Front door hinge reinforcement lower 19. Quarter inner extension upper
3. Side sill to floor plate 20. Seatbelt reinforcement upper
4. Front pillar inner lower 21. Speaker bracket
5. Deck crossmember bracket front 22. Quarter inner extension lower
6. Deck crossmember bracket rear 23. Rear pillar reinforcement upper
7. Front pillar reinforcement upper B (Driver’s side) 24. Fuel filler neck bracket (Excluding the right side on
8. Front pillar inner reinforcement (Driver’s side) RH drive vehicles)
9. Front pillar inner upper reinforcement (Driver’s side) 25. Seatbelt reinforcement
10. Front pillar inner upper 26. Quarter outer extension upper
11. Side sill outer reinforcement support extension 27. Rear lamp housing
(Right side) 28. Gas spring reinforcement
12. Side sill reinforcement support (Right side on RH 29. Rear gate pillar reinforcement
drive vehicles) 30. Quarter outer panel lower extension
13. Side sill reinforcement support rear (Right side on 31. Side outer panel
RH drive vehicles) 32. Striker reinforcement
14. Side sill bulkhead G (Right side on RH drive 33. Side sill outer reinforcement rear
vehicles) 34. Side sill reinforcement support rear (Excluding the
15. Side sill bulkhead F (Right side on RH drive right side on RH drive vehicles)
vehicles) 35. Side sill outer reinforcement centre
16. Roof side rail inner 36. Side sill outer reinforcement front
17. Roof side rail reinforcement centre 37. Front pillar reinforcement lower
BODY CONSTRUCTION
1-21
38. Front door check reinforcement 51. Side sill bulkhead E (Excluding the right side on RH
39. Front door hinge reinforcement upper drive vehicles)
40. Front pillar reinforcement upper 52. Side sill bulkhead D (Excluding the right side on RH
41. Centre pillar inner drive vehicles)
42. Rear wheel house reinforcement 53. Side sill bulkhead C (Excluding the right side on RH
43. Spring house panel drive vehicles)
44. Wheel house extension inner 54. Side sill bulkhead B (Excluding the right side on RH
45. Spring house reinforcement drive vehicles)
46. Rear wheel house inner panel 55. Centre pillar inner lower
47. Spring house bracket plate 56. Rear door hinge reinforcement lower
48. Spring house bracket 57. Rear door hinge reinforcement upper
49. Side sill end plate 58. Centre pillar plate inner
50. Centre pillar reinforcement 59. Centre pillar seatbelt reinforcement
SIDE STRUCTURE REINFORCEMENT

1. The thickness of the reinforcements of the front 4. The cross section of the side sill outer reinforce-
pillar and centre pillar has been increased to ment has been made large to improve safety in
improve collision safety. collision and body rigidity.
2. The front pillar reinforcement upper, side outer 5. A rear pillar reinforcement has been added, and
panel, and front roof rail have been joined to the rear shelf and rear wheel house have been
improve twisting rigidity. joined to improve the twisting rigidity of the sus-
3. The side sill has been made thin by employing a pension attaching portion.
variable thickness steel sheet* for the centre pil- NOTE: *: A steel sheet of varying thickness that is
lar reinforcement to improve safety in collision welded into one steel sheet.
and realize lightweight.
<Sedan>
5
<Wagon>
1,3
2
4
1,3
1 4
AB300951AB
REAR BODY
M4010012000128
Rear Deck (Sedan)

Twisting rigidity has been improved by adding a rear
shelf extension to realize a closed cross section
structure.
6
2
1 7 AB300792 AB
1. Rear seatback reinforcement 6. Trunk lid hinge reinforcement

2. Rear shelf extension 7. Seat belt reinforcement
3. Rear shelf panel
4. Rear shelf reinforcement
5. Rear shelf child-seat belt reinforcement
Rear End Panel (Sedan)
4
AB300793AB
1. Rear end panel inner 3. Rear end panel outer

2. Trunk lid striker reinforcement 4. Rear bumper bracket
BODY CONSTRUCTION
1-23
Rear End Crossmember (Wagon)
3
2
4
1
AB300794 AB
1. Rear end crossmember inner

2. Tailgate striker reinforcement
3. Rear end crossmember outer
4. Rear bumper bracket
ROOF
M4010013000132
The roof bow has large cross-section and the roof
bow front reinforcement is used to improve collision
safety.
<Sedan>
3
4
2
5
6
7 8
1
<Wagon> 9
2
10
12
13 11
14
16
6 15
17
1 19 18
20 AB300969AB
1. Roof rail front 12. Roof bow E

2. Map lamp bracket 13. Roof bow D
3. Roof panel 14. Roof bow F
4. Roof rail rear 15. Roof rack reinforcement centre (Vehicles with roof
5. Roof bow rear rail)
6. Roof bow front reinforcement 16. Roof bow C
7. Roof bow front 17. Roof bow B
8. Roof rail rear outer 18. Roof rack reinforcement front (Vehicles with roof rail)
9. Tailgate hinge reinforcement 19. Roof bow A
10. Roof rail rear inner 20. Sunvisor bracket
11. Roof rack reinforcement rear (Vehicles with roof rail)
BODY CONSTRUCTION
1-25
UNDER BODY
M4010014000135
Front Floor
The cross section of the front floor sidemember has
been made large to improve safety in collision.
1
5
7
6
10
11 8
12 9
AB300846AB
1. Front floor pan 9. Front floor sidemember reinforcement front (Driver’s

2. Instrument panel centre reinforcement bracket side)
3. Front floor crossmember front 10. Backbone crossmember rear
4. Front floor crossmember rear 11. Backbone reinforcement
5. Front floor side sill inner 12. Backbone crossmember front
6. Front floor sidemember reinforcement
7. Front floor sidemember reinforcement rear (Driver’s
side)
8. Front floor sidemember
Rear Floor
The cross section of the rear floor sidemember has
been made large to improve safety in collision.
<Sedan> 3
4
5
2
25 7
6
1 24 8
9
16 11 10
15
20 12
17 14 13
23 26
19
21 18
22 AB300847AB
1. Rear floor pan 14. Toe control link bracket

2. Child anchor bracket lower 15. Fuel tank bracket rear
3. Rear seatback reinforcement 16. Fuel tank bracket rear centre
4. Spare tyre bracket 17. Toe control link bracket support
5. Towing hook reinforcement 18. Tie down reinforcement
6. Rear floor crossmember 19. Rear seat crossmember side
7. Upper arm crossmember reinforcement 20. Rear seat crossmember centre
8. Lower arm bracket rear 21. Rear seat crossmember bulkhead side
9. Lower arm bulkhead 22. Front floor sidemember extension
10. Lower arm bracket front 23. Rear floor extension
11. Upper arm support bracket 24. Rear floor seat belt reinforcement
12. Upper arm bracket reinforcement 25. Upper arm crossmember
13. Toe control link reinforcement 26. Rear floor sidemember
BODY CONSTRUCTION
1-27
<Wagon>
4
3
7
2 25 5
24
6
1
8
9
11 10
17
12
16
21
13
15
14 26
18
22 20 19
23 AB300848 AB
1. Rear floor pan 14. Toe control link bracket

2. Child anchor bracket lower 15. Toe control link bracket support
3. Rear floor crossmember upper 16. Fuel tank bracket rear
4. Spare tyre bracket 17. Fuel tank bracket rear centre
5. Towing hook reinforcement 18. Tie down reinforcement
6. Rear floor crossmember 19. Rear seat crossmember side
7. Upper arm crossmember reinforcement 20. Rear seat crossmember bulkhead side
8. Lower arm bracket rear 21. Rear seat crossmember centre
9. Lower arm bulkhead 22. Rear floor extension
10. Lower arm bracket front 23. Front floor sidemember extension
11. Upper arm support bracket 24. Rear floor seat belt reinforcement Large
12. Upper arm bracket reinforcement 25. Upper arm crossmember
13. Toe control link reinforcement 26. Rear floor sidemember
Rear Floor Sidemember Reinforcement

<Sedan> 11
8 10
9
7
6
5
12
4
13
14
3
2
1 15 AB300852AB
5 6 8 9
A
4
AB300850 AB
1. Rear floor sidemember support A

2. Trailing arm bracket 4
3. Rear floor sidemember
4. Rear floor sidemember bulkhead
5. Rear seat belt bracket
6. Rear seatback bracket side
7. Rear floor crossmember extension 3
8. Stabilizer reinforcement
9. Muffler hanger front A (Right side)
10. Rear sidemember trailer reinforcement 15
11. Muffler hanger rear (Right side)
2 AB300940AC
12. Rear floor sidemember extension
13. Rear spring house bracket support rear
B
14. Rear spring house bracket support front
15. Rear floor side sill inner
8 3
AB300941AB
BODY CONSTRUCTION
1-29
<Wagon> 11
9 10
7 8
4
12
13
14
3
2 1 15 AB300853 AB
A 6 13
4
8
5
AB300849 AB
1. Rear floor sidemember support

A 4
2. Trailing arm bracket
3. Rear floor sidemember
4. Rear floor sidemember bulkhead
5. Rear floor sidemember reinforcement front
6. Rear seatback bracket side
7. Rear floor crossmember extension
3
8. Rear floor sidemember reinforcement rear
9. Muffler hanger front A (Right side)
10. Rear sidemember trailer reinforcement 15
11. Muffler hanger rear (Right side) 2 AB300940AB
12. Rear floor sidemember extension
13. Rear spring house bracket support rear B
14. Rear spring house bracket support front
15. Rear floor side sill inner
8 3
AB300941AB
DOOR
M4010015000127
The front and back of the side door beam has been
made large to cope with the force from the front and
sides during collision.
Front door 5 6
7
4 8
9
3 2
Rear door 1 10
15 15 17
<Sedan> 16 17 <Wagon> 16
14 14
18 18
19
19
13 12 13 12
20 20
11 11
AB300949AB
1. Front door hinge panel 11. Rear door hinge panel

2. Front door hinge reinforcement upper 12. Rear door side door beam
3. Front door side door beam 13. Rear door side door beam upper
4. Front door panel outer 14. Rear door panel outer
5. Front door outside handle reinforcement 15. Rear door belt line reinforcement outer
6. Front door belt line reinforcement outer 16. Rear door belt line bracket
7. Front door window sash 17. Rear door window sash
8. Front door belt line reinforcement inner 18. Rear door belt line reinforcement inner
9. Front door latch reinforcement 19. Rear door latch reinforcement
10. Front door panel inner 20. Rear door panel inner
BODY CONSTRUCTION
SILENCER APPLICATION LOCATIONS
1-31
SILENCER APPLICATION LOCATIONS
M4010005000160
A silencer (MD-12, RSS and melting sheet) has been NOTE: .
adhered on the top part of the floor to improve • MD-12 is a high performance sheet composed of
anti-vibration performance and to shut-out exhaust asphalt applied with mica and thermosetting resin
gas heat. for improving anti-vibration performance.
• RSS (Rubber Special Sheet) is a product name
of Nihon Tokushu Toryo Co., Ltd. The product
features the same performance as a steel sheet
sandwich type and refers to a heat cured resin
sheet that is moulded into a sheet with a uniform
;;;;;;
thickness. It contains degenerating resin and filler
with asphalt and rubber as the main contents.
<Sedan>
;;;;;;;
;;;
;;;
;;;
;;; ;;;
;;;
;;;
;;;
;;; ;
;;; ;;;
<Wagon>
;;;
;;; ;;;
;;;
;;; ;;; ;;;
;;; ;;;
;; ;
: 1.6 mm (0.063 in) thick melting sheet
;;; ;;;
;;;
: 3.2 mm (0.126 in) thick melting sheet [Place two 1.6 mm (0.063 in) melting sheet one on top of another.]
: 1.6 mm (0.063 in) thick MD-12 [Place a 1.6 mm (0.063 in) melting sheet.]
: 6.0 mm (0.236 in) thick MD-12 [Place four 1.6 mm (0.063 in) melting sheet one on top of the next.]
: 1.6 mm (0.063 in) thick melting sheet and 1.5 mm (0.059 in) thick RSS
[Place two 1.6 mm (0.063 in) melting sheet one on top of another.]
: 1.6 mm (0.063 in) thick melting sheet and 2.0 mm (0.079 in) thick RSS
[Place three 1.6 mm (0.063 in) melting sheet one on top of the next.]
NOTE: When you use melting sheet(s) in place of MD-12 or RSS during serving, follow the instructions enclosed by [ ].
AB500777AB
LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL
LOCATIONS USING URETHANE FOAM AND FOAM

MATERIAL
M4010007000122
• Introduction of noise was prevented by inserting CAUTION
urethane foam inside the centre pillar and quarter The foam materials may burn when heated.
inner (Wagon). Always observe the following instructions.
• By filling the top of the front pillar, bottom of the
• Never use a gas burner or burn the areas
front pillar, centre pillar, rear pillar and inside the
using foam materials.
wheel house arch with acoustic foam materials,
• When cutting the parts using foam materials,
penetration of noise is prevented.
ensure to use tools (air saw, etc.) that do not
• High-rigidity foam materials were added inside
generate fire.
the front sidemember (left side on LH drive vehi-
cles), rear floor sidemember, side sill and side • If there are residual foam materials at body
roof rail to heighten panel rigidity. side then weld after removing the foam mate-
rials from periphery of the welding area.
BODY CONSTRUCTION
1-33
<Sedan> A
F
B
D E
E
C
AB300701AB
A Front pillar
D Front pillar
Front pillar inner lower Acoustic foam
reinforcement upper B
reinforcement (Driver's side)
upper
Side roof
rail inner
Acoustic foam Front pillar Side outer panel

Front pillar inner reinforcement lower
reinforcement (Driver's side) AB201973AC AB300096AC
B Front pillar
inner lower E
Side sill High-rigidity foam
reinforce- Side sill
ment outer
support reinforcement
front front
Side sill
outer
Acoustic foam reinforce-
ment front
AB300944 AB Side outer panel
AB201975AC
C F Side outer
panel
Front sidemember
outer Sidemember Acoustic foam
reinforcement outer
rear B
Quarter panel
inner
High-rigidity
foam AB300943AB AB201976 AC
J I
AB300745AB
AB100698 AB201057
G J Front pillar
inner lower
High-rigidity foam
Front pillar
reinforcement
upper
Acoustic foam
Centre pillar Front pillar
Side outer panel reinforcement reinforcement lower
AB201977AC AB202038AB
H
Rear pillar inner K
Urethane foam
Side sill outer

reinforcement
Acoustic foam
Centre pillar
Side outer panel AB201981AC reinforcement
AB300946AD
I Centre pillar inner L

Rear floor pan
Rear floor
Acoustic foam side sill inner High-rigidity
Centre pillar reinforcement foam
Rear floor sidemember
AB201982 AC AB300945AC
BODY CONSTRUCTION
1-35
<Wagon> A
D
E
E
C
AB300702 AB
A Front pillar
D Front pillar
Front pillar inner lower Acoustic foam
reinforcement upper B
reinforcement (Driver's side)
upper
Side roof
rail inner
Acoustic foam Front pillar Side outer panel

Front pillar inner reinforcement lower
reinforcement (Driver's side) AB201973AC AB300096AC
B Front pillar
inner lower E
Side sill High-rigidity foam
reinforce- Side sill
ment outer
support reinforcement
front front
Side sill
outer
Acoustic foam reinforce-
ment front
AB300944 AB Side outer panel
AB201975AC
C F Side outer
panel
Front sidemember
outer Sidemember Acoustic foam
reinforcement outer
rear B
Quarter panel
inner
High-rigidity
foam AB300943AB AB201976 AC
I H
J
K
L
AB300746AB
AB100698
G J
Urethane foam
High-rigidity foam
Side sill outer
reinforcement
Front pillar
reinforcement
upper
Centre pillar Centre pillar
Side outer panel reinforcement reinforcement
AB201977AC AB300946AC
H Centre pillar inner

K
Rear floor pan
Acoustic foam Rear floor

Centre pillar reinforcement side sill inner High-rigidity
foam
AB201982 AC Rear floor sidemember
AB300945AB
AB201057
I Front pillar L Urethane foam
inner lower
Side outer
panel
Acoustic foam
Quarter panel inner
Front pillar
reinforcement lower Quarter outer panel
AB202038 AD lower extension AB300947AB
BODY CONSTRUCTION
STIFFENER AND DAMP SHEET APPLICATION LOCATIONS
1-37
STIFFENER AND DAMP SHEET APPLICATION LOCATIONS
M4010008000147
Sound insulation was improved with anti-vibration NOTE: The main contents of a stiffener are epoxy
effects and heightening surface rigidity with a stiff- resin. It comes in a sheet form and contains a mix-
ener applied on the inner side of the side outer panel, ture of glass fiber and filler, and cures (stiffens) when
and a damping sheet adhered to the quarter inner heated. It is used to improve the rigidity of the outer
panel and the inner side of the front door. panel.
Stiffener
Stiffener
Damp sheet
<Front door>
Damp sheet AB300942 AB

NOTES
2-1
GROUP 2
BODY DIMENSIONS
CONTENTS
BODY DIMENSIONS AND TYPE A (PROJECTED DIMENSIONS) 2-22

MEASUREMENT METHODS. . . . . . . 2-2 UNDER BODY <WAGON> . . . . . . . . . . . . . 2-22
SUSPENSION INSTALLATION DIMENSIONS
TYPE A (PROJECTED DIMENSIONS) 2-4 <WAGON> . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
UNDER BODY <SEDAN>. . . . . . . . . . . . . . 2-4
SUSPENSION INSTALLATION DIMENSIONS TYPE B (ACTUAL-MEASUREMENT
<SEDAN> . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 DIMENSIONS). . . . . . . . . . . . . . . . . . . 2-26
UNDER BODY <WAGON> . . . . . . . . . . . . . 2-26
TYPE B (ACTUAL-MEASUREMENT SUSPENSION INSTALLATION DIMENSIONS
DIMENSIONS) . . . . . . . . . . . . . . . . . . 2-8 <WAGON> . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
UNDER BODY <SEDAN>. . . . . . . . . . . . . . 2-8 FRONT BODY <WAGON> . . . . . . . . . . . . . 2-30
SUSPENSION INSTALLATION DIMENSIONS SIDE BODY <WAGON> . . . . . . . . . . . . . . . 2-32
<SEDAN> . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 REAR BODY <WAGON> . . . . . . . . . . . . . . 2-34
FRONT BODY <SEDAN> . . . . . . . . . . . . . . 2-12 INTERIOR <WAGON> . . . . . . . . . . . . . . . . 2-36
SIDE BODY <SEDAN> . . . . . . . . . . . . . . . . 2-14
REAR BODY <SEDAN> . . . . . . . . . . . . . . . 2-16
INTERIOR <SEDAN> . . . . . . . . . . . . . . . . . 2-18
2-2 BODY DIMENSIONS
BODY DIMENSIONS AND MEASUREMENT METHODS

M4020001000147
• •
Projected dimension
Centre of hole
Height
Probe
AB100778 AB AB100780AB
AB100780
Type A (projected dimensions) is the dimension Insert the tracking gauge probes securely into the
when a measurement location is projected onto measurement holes.
the plane. • When the standard dimensions in the illustration
NOTE: The height indicates a distance from the are enclosed by rectangle, this indicates that the
assumed standard line established 100 mm symmetrical left and right positions have the
below the lowest measurement point. same dimensions.
•
•
Ac
tua
l-m
ea
su
red
dim
A en
sio
n
A'
AB100779AB AB100781AB
Type B (actual-measurement dimensions) is the When using a notch for dimension measurement, set
actual distance between the measurement the measuring point at the centre of the notch.
•
points. Measure using a tracking gauge or a Bolt

measuring tape, etc.
NOTE: .
• Make the lengths of the tracking gauge
probes the same (A=A’).
• Do not bend or twist the measuring tape.
Measurement point
AB100782AB
When measuring the suspension mounting arm, or

link mounting position, use the suspension
mounting bolt, etc. (Type B only)
• The body centre points are shown for the pur-
pose of checking the position of the left and right
symmetry location.
BODY DIMENSIONS
2-3
NOTES
2-4 BODY DIMENSIONS
TYPE A (PROJECTED DIMENSIONS)

UNDER BODY <SEDAN>
M4020005000279
mm
(Centre line of the vehicle)
1,364
982
1,010 714 926
750 713 1,220 963
1 786
3 795
4 582
2
6 7
247
5
AB300566AB
1,157 1,212
905 909
1,225 1,462 1,742 1,234
1
4
3
2
6 7
5
AB300567AB
No. Standard measurement point Hole shape Size mm

1* Centre of under cover mounting hole Round 8
2 Front sidemember inner notch − −
3* Centre of front crossmember mounting hole Round 18
4* Centre of front floor sidemember positioning hole Round 25
5* Centre of rear seat crossmember side water draining hole Oblong 22 × 38
6 Centre of rear floor sidemember water draining hole Round 16
7* Centre of trailer bar mounting hole Round 15
NOTE: The * mark indicates the mounting position for the frame centering gauge.
BODY DIMENSIONS
2-5
mm
(Standard Line)
2 6 7
4 5
1 3
339 345 345

185 162 100 185
563 1,097 563
1,335 1,358
1,545
AB300618 AB
NOTE: The assumed standard line is established 100 mm below the measurement point No.4.
1 2 3
AB201728AF AB200319AC AB201817AD
4 5 6
AB201808AD AB200322AC AB300839AB

2-6 BODY DIMENSIONS
SUSPENSION INSTALLATION
DIMENSIONS <SEDAN>
M4020013000263
mm
372 (Centre line of the vehicle)
514
290
11
373
713 880
1,111 906 713 1,201 650 350
16 1,110
86
154 219
3
10
288 15
12
368
8 14 9
13
370
AB300568AB
11 977
1,092
857 882
525
851 888 772

16
1,022 669
15
3 12
10
14
13 AB300569AB

3 Centre of front crossmember mounting hole Round 18
4 Centre of front floor sidemember positioning hole Round 25
8 Centre of front shock absorber mounting hole Round 114
9 Centre of rear shock absorber mounting hole Round 64
10 Tip of front crossmember mounting bolt (left) − −
11 Tip of front crossmember mounting bolt (right) − −
13 Centre of trailing arm mounting position − −
14 Centre of control link mounting hole − −
15 Centre of upper arm mounting position − −
16 Centre of lower arm mounting position − −
BODY DIMENSIONS
2-7
A Vehicle centre
4˚24´
AB300840AB
mm
3 12´ 850 551
8
A
(Standard Line)
0 9
10 11 14 15
3 12 13 16
749 4
440
232 321
217 162 104 100 175 133
477 1,256 331
563 434
835 594
AB300619AB
3,12 8 9
12
AB201819 AE AB200328AC AB300841AB

2-8 BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

UNDER BODY <SEDAN>
M4020005000280
mm
1,373
982
1,010 1,220
750 713 714 926 963
1 806
3 4 603 795
2 6
7
291
5
AB300570 AB
1,170
1,222
918
911 1,750
1,225 1,465
1,234
1
3 4
2
6 7
5
AB300571AB

1 Centre of under cover mounting hole Round 8
5 Centre of rear seat crossmember side water draining hole Oblong 22 × 38
7 Centre of trailer bar mounting hole Round 15
BODY DIMENSIONS
2-9
1 2 3
AB201728AF AB200319AC AB201817AD
4 5 6
AB201808AD AB200322AC AB300839AB
7 (Left side) 7 (Right side)
AB300837AB AB300838 AB
2-10 BODY DIMENSIONS
DIMENSIONS <SEDAN>
M4020013000274
mm
389
534
11 295
386
906 713 713 1,201 350 880

650
104 16
178 289
3
10 293 12 15
372
14
13
387
AB300572AB
11 978
859 890 1,093
558
777
853 895 16
1,033 676
15
3 12
10 14
13
AB300573AB

13 Centre of trailing arm mounting position Round 11
14 Centre of control link mounting position − −
BODY DIMENSIONS
2-11
3,12 10 11
12
AB201819 AE AB200334AC AB201822AD
13 14 15
AB200336AC AB300842AB AB300843AB
16
AB300844AB
FRONT BODY <SEDAN>

M4020006000131
mm
1,091
870 26
1,508
23 Body centre point

1,390
1,437
576
1,502
25
730
813 540
1,040 24
318
758
734 22
873 1,340
20 951 872
21
600 894
19
17

AB300750AB
704 29
889
328 542
1,050 28
775
894
700
27 AB300751AB
BODY DIMENSIONS
2-13

17 Centre of front bumper mounting hole Round 6.6
18 Centre of front end upper bar water draining hole (Body centre point) Round 8
19 Centre of harness mounting hole Oblong 7 × 12
20 Centre of intercooler pipe mounting hole Round 9
21 Centre of front fender mounting hole Round 6.6
22 Centre of front strut mounting hole Round 11.5
23 Front deck notch (Body centre point) − −
25 Centre of hood hinge mounting hole Round 9
26 Corner of roof panel − −
27 Centre of front end crossmember outer positioning hole Round 20
28 Centre of front bumper beam mounting hole Round 10
29 Centre of headlamp mounting hole Round 6.6
30 Centre of front end upper bar positioning hole (Body centre point) Round 8
17,29 18,30 19
18
29
17
30
AB300752 AB AB300753 AB AB200346 AC
20 21 22
AB200347AC AB200348AC AB201830 AD
23 24,25 26
25
24
AB200350AC AB200351AC AB201833AD

SIDE BODY <SEDAN>

M4020007000134
mm
33 37
31 35 39
688 828
808 875
463
716 581
1,174 1,127
902
1,084 40
863 960
32 36
34 38 AB300623AB
33 37
41 1,100 731
43
1,067 837
1,094 1,124 45
338 355
901
1,041
42 44
AB300622AB

31 Front pillar positioning notch (upper) − −
32 Front pillar positioning notch (lower) − −
33 Side roof rail positioning notch (front) − −
34 Side sill positioning notch (front) − −
35 Centre pillar positioning notch (upper) − −
36 Centre pillar positioning notch (lower) − −
37 Side roof rail positioning notch (rear) − −
38 Side sill positioning notch (rear) − −
BODY DIMENSIONS
2-15
39 Quarter panel positioning notch (upper) − −
40 Quarter panel positioning notch (lower) − −
41 Centre of front door hinge mounting hole (upper) Round 11
42 Centre of front door hinge mounting hole (lower) Round 11
43 Centre of rear door hinge mounting hole (upper) Round 11
44 Centre of rear door hinge mounting hole (lower) Round 11
45 Centre of rear door switch mounting hole Round 5
32,42 36,44 40,45
32 36 40
42 45
44
AB201836AD AB202191AD AB201838AD
REAR BODY <SEDAN>

M4020008000148
mm
46
990
48 Body centre point 653

1,271
1,200
47
1,268 521
703 567
1,114
49
1,460
463
1,025
51
50
750
52 AB300587AB

46 Coner of roof panel − −
47 Centre of rear glass moulding mounting hole Oblong 7 × 11
48 Centre of rear shelf body − −
49 Corner of side outer panel − −
50 Centre of rear combination lamp mounting hole (lower) Round 10
51 Centre of rear end trim mounting hole Round 8.5
52 Centre of rear end panel positioning hole Round 16
BODY DIMENSIONS
2-17
46 47 48
AB201839AD AB201840AD AB201841AD
49,50 51 52
49
50
AB201842AD AB300586AB AB300585 AB

INTERIOR <SEDAN>
M4020009000141
mm
33 37
1,145 1,112
1,297 1,235 39
1,289 35
31
1,379
1,395 40
36
1,368
1,407
32 1,388
38
34
AB300628AB
33 37
35 39
31 1,054
1,100
1,016 1,084
1,136
36 40
856
683
706
1,041
32 809 53
38
34
AB300629AB
1,110 825
1,151
55 580
51
AB300588 AB
BODY DIMENSIONS
2-19

53 Centre of front seat rail mounting hole Round 14
54 Centre of floor carpet mounting hole (Body centre point) Round 6
51 53 54
AB300586AB AB201845AD AB200385AC
55
AB300845AB
<L.H. drive mm
vehicles>
664 678 662 660
57 1,283 59
1,279 1,290
58 1,283 60
AB301011AB
<R.H. drive 56 Body centre point

vehicles>
660 662 678 664
57 1,283 59
1,290 1,279
58 1,283 60
AB301010AB

56 Instrument panel bracket centre tip (Body centre point) − −
57 Centre of deck crossmember mounting hole (upper) Round 11
58 Centre of deck crossmember mounting hole (lower) Round 11
56 57,58 59,60
57 59
58 60
AB200388AC AB200389AC AB301012 AB

BODY DIMENSIONS
2-21
NOTES

UNDER BODY <WAGON>
M4020005000310
mm
Centre line of the vehicle
1,364
982
1,010 714 926
750 713 1,220 963
1 786
3 795
4 582
2
6 7
247
5
AB300574 AB
1,157 1,212
905 909
1,225 1,462 1,742 1,234
1
4
3
2 6 7
5
AB300575AB

1* Centre of under cover mounting hole Round 8
3* Centre of front crossmember mounting hole Round 18
4* Centre of front floor sidemember positioning hole Round 25
5* Centre of rear seat crossmember side water draining hole Oblong 22 × 38
7* Centre of trailer bar mounting hole Round 15
NOTE: The * mark indicates the mounting position for the frame centering gauge.
BODY DIMENSIONS
2-23
mm
Standard Line
6 7
2 5
4
1 3
339 345 345

185 162 185
100
563 1,097 563
1,335 1,358
1,545
AB300621AB
1 2 3
AB201728AF AB200319AC AB201817AD
4 5 6
AB201808AD AB200322AC AB300839AB

DIMENSIONS <WAGON>
M4020013000304
mm
372 Centre line of the vehicle
514
290
11
373
713 880
1,111 906 713 1,201 650 350
16 1,110
86
154 219
3
10
288 15
12
368
8 14 9
13
370 AB300576 AB
11 977
1,092
857 882
525
851 888 772

16
1,022 669
15
3 12
10
14
13 AB300577AB

8 Centre of front shock absorber mounting hole Round 114
10 Tip of crossmember mounting bolt (left) − −
13 Centre of trailing arm mounting position − −
14 Centre of control link mounting hole − −
BODY DIMENSIONS
2-25
A Vehicle centre
4˚24´
AB300840AB
mm
3 12´ 850 551
8
A
Standard Line 0 9
10 11 14 15
3 12 13 16
749 4
440
232 321
217 162 104 100 175 133
477 1,256 331
563 434
835 594
AB300620AB
3,12 8 9
12
AB201819 AE AB200328AC AB300887AB


UNDER BODY <WAGON>
M4020005000321
mm
1,373
982
1,010 1,220
750 713 714 926 963
1 806
3 4 603 795
2 6
7
291
5
AB300578 AB
1,170
1,222
918
911 1,750
1,225 1,465
1,234
1
3 4
2
6 7
5
AB300579AB

1 Centre of under cover mounting hole Round 8
5 Centre of rear seat crossmember side water draining hole Oblong 22 × 38
7 Centre of trailer bar mounting hole Round 15
BODY DIMENSIONS
2-27
1 2 3
AB201728AF AB200319AC AB201817AD
4 5 6
AB201808AD AB200322AC AB300839AB
7 (Left side) 7 (Right side)
AB300837AB AB300838 AB
DIMENSIONS <WAGON>
M4020013000315
mm
389
534
11 295
386
906 713 713 1,201 350 880

650
104 16
178 289
3
293 12 15
10
372
14
13
387
AB300580AB
11 978
859 890 1,093
558
777
853 895
16
1,033 676
15
3 12
10 14
13
AB300581AB

13 Centre of trailing arm mounting position Round 11
14 Centre of control link mounting position − −
BODY DIMENSIONS
2-29
3,12 10 11
12
AB201819 AE AB200334AC AB201822AD
13 14 15
AB200336AC AB300842AB AB300843AB
16
AB300844AB
FRONT BODY <WAGON>

M4020006000153
mm
1,091
870 26
1,508

1,390
1,437
576
1,502
25
730
813 540
1,040 24
318
758
734 22
873 1,340
20 951 872
21
600 894
19
17

AB300750AB
704 29
889
328 542
1,050 28
775
894
700
27 AB300751AB
BODY DIMENSIONS
2-31

17 Centre of front bumper mounting hole Round 6.6
18 Centre of front end upper bar water draining hole (Body centre point) Round 8
19 Centre of harness mounting hole Oblong 7 × 12
20 Centre of intercooler pipe mounting hole Round 9
22 Centre of front strut mounting hole Round 11.5
23 Front deck notch (Body centre point) − −
25 Centre of hood hinge mounting hole Round 9
26 Corner of roof panel − −
27 Centre of front end cross-member outer positioning hole Round 20
28 Centre of front bumper beam mounting hole Round 10
29 Centre of headlamp mounting hole Round 6.6
30 Centre of front end upper bar positioning hole (Body centre point) Round 8
17,29 18,30 19
18
29
17
30
AB300752 AB AB300753 AB AB200346 AC
20 21 22
AB200347AC AB200348AC AB201830 AD
23 24,25 26
25
24
AB200350AC AB200351AC AB201833AD

SIDE BODY <WAGON>

M4020007000156
mm
33 37
31 35
688
39
897
808 875
445
716 581
1,174 1,170
902
1,084 40
863
969
32 36
34 38
AB300625AB
33 37
1,100 709
41 43
1,067 837
1,094 1,124
45
338 355
901
1,041
42
44
AB300624AB

BODY DIMENSIONS
2-33
41 Centre of front door hinge mounting hole (upper) Round 11
42 Centre of front door hinge mounting hole (lower) Round 11
43 Centre of rear door hinge mounting hole (upper) Round 11
44 Centre of rear door hinge mounting hole (lower) Round 11
45 Centre of rear door switch mounting hole Round 5
32,42 36,44 40,45
32 36 40
42 45
44
AB201836AD AB202191AD AB201838AD
REAR BODY <WAGON>

M4020008000160
mm
46
700
896
1,079 562
880
1,205
703
1,213 361
47
1,169
668
1,020
48
750
49
50
AB300589AB

46 Centre of tailgate hinge mounting hole Round 12
47 Centre of tailgate gas spring mounting hole Round 11
48 Centre of tailgate striker mounting hole Round 13
49 Centre of rear bumper mounting hole Oblong 11 × 12
50 Centre of rear end crossmember positioning hole Round 16
46 47 48
AB200377AC AB300888AB AB300590AB
49,50
49
50
AB300608AB
BODY DIMENSIONS
2-35
NOTES
INTERIOR <WAGON>
M4020009000163
mm
33 37
1,121
1,145
1,281 39
1,289 1,297 35
31
1,379
1,395 40
36
1,407
1,368
1,388
38
32
34
AB300630AB
33 37
35 39
31
1,100 1,064
1,108
1,136 1,016
40
36
856
683
706
1,041 51
809 38
32
34
AB300631AB
53 1,110 760
1,269
930
54
AB300609AB
BODY DIMENSIONS
2-37

51 Centre of front seat rail mounting hole Round 14
52 Centre of floor carpet mounting hole (Body centre point) Round 6
51 52 53
AB201845AE AB200385AD AB300889AB
54
AB300890AB
<L.H. drive mm
vehicles>
664 678 662 660
56 1,283 58
1,279 1,290
57 1,283 59
AB301011AC
<R.H. drive 55 Body centre point

vehicles>
660 662 678 664
56 1,283 58
1,290 1,279
57 1,283 59
AB301010AC

55 Instrument panel bracket centre tip (Body centre point) − −
55 56,57 58,59
56 58
57 59
AB200388AD AB200389AD AB301012 AC

3-1
GROUP 3
WELDED PANEL
REPLACEMENT
CONTENTS
HEADLAMP SUPPORT . . . . . . . . . . . 3-2 REAR FLOOR <WAGON> . . . . . . . . . 3-36
FENDER SHIELD. . . . . . . . . . . . . . . . 3-4 REAR END PANEL <SEDAN>. . . . . . 3-38
FRONT SIDEMEMBER (PARTIAL REAR END CROSSMEMBER

REPLACEMENT) . . . . . . . . . . . . . . . . 3-8 WAGON> . . . . . . . . . . . . . . . . . . . . . . 3-39
FRONT PILLAR . . . . . . . . . . . . . . . . . 3-10 QUARTER, INNER <SEDAN> . . . . . . 3-40
CENTRE PILLAR . . . . . . . . . . . . . . . . 3-16 QUARTER, INNER <WAGON> . . . . . 3-42
SIDE SILL. . . . . . . . . . . . . . . . . . . . . . 3-20 FRONT DOOR OUTER PANEL

(ADHESION TYPE). . . . . . . . . . . . . . . 3-44
QUARTER, OUTER <SEDAN> . . . . . 3-24
FRONT DOOR OUTER PANEL
QUARTER, OUTER <WAGON> . . . . 3-28 (WELDED TYPE) . . . . . . . . . . . . . . . . 3-45
ROOF <SEDAN> . . . . . . . . . . . . . . . . 3-31 REAR DOOR OUTER PANEL

(ADHESION TYPE). . . . . . . . . . . . . . . 3-46
ROOF <WAGON> . . . . . . . . . . . . . . . 3-32
REAR DOOR OUTER PANEL
REAR FLOOR <SEDAN> . . . . . . . . . 3-34 (WELDED TYPE) . . . . . . . . . . . . . . . . 3-47
3-2 WELDED PANEL REPLACEMENT
HEADLAMP SUPPORT
HEADLAMP SUPPORT
M4030003000188
Symbol Operation description

Spot welding
MIG plug welding : indicates two panels to be welded
( : indicates three panels to be welded )
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
AB300990AB
REPAIR WELDS
B
B
(Right side)
AB301035AB
WELDED PANEL REPLACEMENT
HEADLAMP SUPPORT
3-3
NOTES
FENDER SHIELD
FENDER SHIELD
M4030004000170

Spot welding
MIG spot welding
Braze welding
AB300991AB
REPAIR WELDS
2 points, RHD only
A
AB301036
NOTE: Refer to the Headlamp Support section on P.3-2 for the welding points with headlamp support.
FENDER SHIELD
3-5
B C
C (With the upper frame to

G front pillar brace removed)
B
E D
D AB301037 AB
FENDER SHIELD
Y0189AV
2 points right side only
F
High-rigidity foam
(LHD left side)
G H
(With the upper frame extension outer removed)
4 points, passenger's side only
I
(Right side)
I
AB301042AB
FENDER SHIELD
3-7
NOTES
FRONT SIDEMEMBER (PARTIAL REPLACEMENT)

M4030000100119

Spot welding
MIG spot welding
Braze welding
AB300992AB
Centre of
under cover
mounting hole 105 mm 40 mm
Centre of front sidemember
A B inner positioning hole
AB301044
NOTE: Refer to the Headlamp Support section on P.3-2 for the welding points with headlamp support.
3-9
45 mm
Centre of under cover Centre of front
mounting hole sidemember inner positioning hole
105 mm
D
C
AB301045 AB
NOTE ON REPAIR WORK 2. As shown in the figure of the instructions, bend

REMOVAL the front fender shield on the cut area in advance,
when cutting the front sidemember outer.
<Left side>
1. Reuse the parts other than the sidemember outer
and sidemember inner.
Cut position
AB201857AB
Front
fender
shield 3. Remove the battery bracket front on the cut area
AB300835AB in advance when cutting the front sidemember
inner.
FRONT PILLAR
FRONT PILLAR
M4030005000548

Spot welding
MIG spot welding
Braze welding
AB300993AB
REPAIR WELDS
3 points
Right side
180 mm
A A
Acoustic foam C
50 mm
B B
<Driver's side> <Passenger's side>
High-rigidity foam
(With the upper frame extension outer removed)
C
AB301047AB
FRONT PILLAR
3-11
CAUTION
When repairing the area using foam materials do not use firing tools since the foaming materials may
burn.
NOTE: Refer to the Fender Shield section on P.3-4 for the welding points with the upper frame extension
outer.
NOTE ON REPAIR WORK 3. Divide the new front pillar inner upper parts into A
INSTALLATION <DRIVER’S SIDE> (front pillar inner reinforcement and front pillar
inner upper) and B (front pillar reinforcement
Front pillar upper and front pillar reinforcement upper B).
reinforcement
upper
A
80 mm
Side outer
panel
120 mm
Front pillar 160 mm

reinforcement upper B AB301054 AB
1. To reinforce the strength of the front pillar cut AB202039 AC
area, cut the side outer panel 160 mm above the

4. When assembling Part A, weld the areas shown
front pillar cut area, 120 mm above the front pillar
in the figure of the instructions from the outside
reinforcement upper and 80 mm above the front
and inside.
pillar reinforcement upper B.
CAUTION
Side sill outer
145 mm reinforcement Front pillar
centre 40 mm reinforcement
60 mm upper B
Cover
Front pillar
Side outer panel reinforcement
AB301055AB upper 80 mm
AB301056AB
2. To reinforce the strength in the side sill cut area,
Weld and repair the front pillar reinforcement
cut the side outer panel 145 mm behind the side
upper B if it is damaged.
sill cut area, then cut the side sill outer
reinforcement centre 60 mm behind the side sill 5. Cut Part B in alignment with the front pillar
cut area. reinforcement upper on the body-side. Next, cut
only the front pillar reinforcement upper 80 mm
from the cut area to create a cover, then cut the
front pillar reinforcement upper B 40 mm above
A
the front pillar reinforcement upper cut area.
AB200369AB
FRONT PILLAR
Cover
Front pillar
silencer protector
AB200372AB
6. To assemble Part B, weld the front pillar

reinforcement upper B then weld the cover of the
front pillar reinforcement upper.
CAUTION
Side sill reinforcement
support
40 mm
: Adhesive AB200375AB
AB200375
Cover
8. When assembling a new front pillar outer parts,
Side sill outer
reinforcement centre apply a front pillar silencer protector in advance,
100 mm
bury the clearance with butyl tape then apply
AB301057AB
structural adhesives in the areas shown in the
Weld and repair if the side sill reinforcement sup- figure of the instructions.
port is damaged. Adhesive: Epoxyayresin adhesive
7. Remove the side outer panel from the new front Brand: 3M ATD Part No.8115 or equivalent
pillar outer parts. Cut the front pillar outer by
aligning it with the side sill outer reinforcement
centre on the body-side. Next, cut only the side sill Cover
outer reinforcement centre 100 mm forward from
the cut area to create a cover, then cut the side sill
reinforcement support 40 mm behind the cut area
of the side sill outer reinforcement centre.
AB200374AB
9. Weld the side sill reinforcement support then weld

the cover of the side sill outer reinforcement
centre.
FRONT PILLAR
3-13
INSTALLATION <PASSENGER’S SIDE>

Side outer panel
50 mm
Front pillar
: Body sealant AB200475AB inner upper
100 mm
10.Apply in advance body sealant in the areas
AB301021AB
shown in the figure of the instructions when
assembling the side outer panel. 1. To reinforce the strength of the front pillar cut
area, cut the side outer panel 50 mm above the
A front pillar cut area, 100 mm above the front pillar
inner upper.
Side sill outer 145 mm

reinforcement
centre
B 60 mm
AB202041AC
11.Assemble the side outer panel, then cover the

hole and flange with bolt and aluminium tape and Side outer panel
fill the hole with foam materials as shown in the AB301022 AB
figure of the instructions.

2. To reinforce the strength in the side sill cut area,
• FOAM (Hole A): 3M ATD ULTRAPRO cut the side outer panel 145 mm behind the side
Panel foam-Yellow sill cut area, then cut the side sill outer
• FOAM (Hole B): 3M ATD Super panel filler reinforcement centre 60 mm behind the side sill
cut area.
Front pillar
inner upper
Front pillar
AB100787
reinforcement upper
AB301023AB
12.Wait 2 hours after filling the foam materials to
remove the bolt and aluminium tape, then melt the 3. Divide the new front pillar inner upper parts into
foam materials with a soldering gun so a clip, etc. the front pillar inner upper and the front pillar
can thoroughly be inserted in the hole filled with reinforcement upper.
foam materials.
FRONT PILLAR
CAUTION Adhesive: Epoxyayresin adhesive

Brand: 3M ATD Part No.8115 or equivalent
Side sill reinforcement
support
Cover
40 mm
Cover
Side sill outer

reinforcement
centre
100 mm
AB201024AB
AB301118AB
Weld and repair if the side sill reinforcement sup-
port is damaged. 6. Weld the side sill reinforcement support then weld
4. Remove the side outer panel from the new front the cover of the side sill outer reinforcement
pillar outer parts. Cut the front pillar outer by centre.
aligning it with the side sill outer reinforcement
centre 100 mm forward from the cut area to create
a cover, then cut the side sill reinforcement
support 40 mm behind the cut area of the side sill
outer reinforcement centre.
: Body sealant AB301119AB
7. Apply in advance body sealant in the areas shown

Front pillar in the figure of the instructions when assembling
silencer protector the side outer panel.
AB301120AB
: Adhesive AB301117AB
AB301117
8. Assemble the side outer panel, then cover the
hole and flange with bolt and aluminium tape and
5. When assembling a new front pillar outer parts, fill the hole with foam materials as shown in the
apply a front pillar silencer protector in advance, figure of the instructions.
bury the clearance with butyl tape then apply • FOAM (Hole A): 3M ATD ULTRAPRO
structural adhesives in the areas shown in the Panel foam-Yellow
figure of the instructions. • FOAM (Hole B): 3M ATD Super panel filler
FRONT PILLAR
3-15
9. Wait 2 hours after filling the foam materials to
remove the bolt and aluminium tape, then melt the
foam materials with a soldering gun so a clip, etc.
can thoroughly be inserted in the hole filled with
foam materials.
AB100787
CENTRE PILLAR
CENTRE PILLAR
M4030006000176

Spot welding
MIG spot welding
Braze welding
AB300994AB
REPAIR WELDS
125 ± 10 mm
B
Acoustic foam
A
C
125 ± 10 mm
290 ± 10 mm
High-rigidity foam
D E
C D E AB301062AB
CENTRE PILLAR
3-17
CAUTION
Do not use heat at areas using foam material as the foam material may burn.
NOTE ON REPAIR WORK 1. Remove the side outer panel, side sill outer
REMOVAL reinforcement centre, side sill bulkhead, and side
sill reinforcement support from the new centre
Centre pillar Adhesive points pillar.
reinforcement
2. To ensure the strength of the cut area at the top of
the centre pillar, cut the side outer panel 30 mm
above the cut area.
Cut the new centre pillar at the same positions.
CAUTION
Side sill outer Centre pillar seat
reinforcement centre belt reinforcement
Adhesive points AB201265AD
1. Since the centre pillar reinforcement and side sill

outer reinforcement centre of the side sill is
adhered together, cut the side outer panel in a
place where the reinforcement joint is visible, as Centre pillar
shown in the figure of the instructions, to remove reinforcement
the centre pillar reinforcement.
AB301067AB
If the centre pillar seat belt reinforcement has

been damaged, repair by welding.
3. Cut only the centre pillar reinforcement, aligned
with the body-side, of the new centre pillar
reinforcement parts so the centre pillar seat belt
reinforcement is not damaged.
Centre pillar (A)
seat belt
reinforcement AB301065AB
2. To detach the welding of the centre pillar seat belt

reinforcement and centre pillar reinforcement, cut
the lower part of the side roof rail inner as shown
in the figure of the instructions.
NOTE: Hold the side roof rail inner (A) that was
cut since it will be re-used.
: Adhesive AB300021 AB
INSTALLATION 4. When assembling the centre pillar reinforcement,

apply adhesives in the areas shown in the figure
of the instructions.
Adhesive: Epoxyayresin adhesive
30 mm
AB200422AB
CENTRE PILLAR
6. Assemble the side outer panel, then cover the

hole and flange with bolt and aluminium tape and
fill the hole with foam materials A and B as shown
Centre pillar in the figure of the instructions.
silencer protector • FOAM (Hole A): 3M ATD ULTRAPRO
Panel foam-Yellow
• FOAM (Hole B): 3M ATD Super panel filler
AB301068AB
5. When attaching the centre pillar inner, attach the

centre pillar silencer protector to the centre pillar
inner, and seal the holes of the centre pillar
silencer protector with butyl tape.
AB301070AB
A 7. Wait 2 hours after filling the foam materials to

foam materials.
AB301069AB
CENTRE PILLAR
3-19
NOTES
SIDE SILL
SIDE SILL
M4030007000191

Spot welding
MIG spot welding
Braze welding
AB300995AB
REPAIR WELDS
290 mm
E F Acoustic
foam
70 mm 70 mm
B G
A
C
High-rigidity foam
A B
D E F G
(Right side) AB301072 AB
SIDE SILL
3-21
CAUTION
NOTE ON REPAIR WORK

REMOVAL 50 mm
60 mm
Notch
Side sill reinforcement support
AB200601AC
Side sill outer reinforcement centre 3. Cut the side sill reinforcement support 50 mm
AB200598 AE forward of the cut area of the side sill outer
To remove the side sill outer reinforcement, cut it 60 reinforcement centre.
mm behind the notch.
INSTALLATION
50 mm
: Adhesive AB200626 AC
4. Adhere in advance adhesives in the areas shown

Side sill outer reinforcement centre in the figure of the instructions when assembling
AB200599AC the side sill outer reinforcement.
1. Cut only the side sill outer reinforcement centre Adhesive: Epoxyayresin adhesive
on the body-side, 50 mm forward of the cut area Brand: 3M ATD Part No.8115 or equivalent
and then remove.
110 mm
10 mm
Notch
AB200602AD
AB200600 AE
5. After assembling the new parts to the body, weld
2. Cut only the side sill outer reinforcement centre of the side sill reinforcement support, then weld the
the new side sill outer reinforcement parts from part cut from the side sill outer reinforcement
110 mm behind the notch, then cut from another centre.
10 mm behind the notch and remove. Re-use the
parts removed.
SIDE SILL
• FOAM (Hole A): 3M ATD ULTRAPRO

Panel foam-Yellow
: Body sealant AB301075AB
6. Apply in advance body sealant in the areas shown

in the figure of the instructions when assembling
AB301077AB
the side outer panel.
Wheel house
8. Wait 2 hours after filling the foam materials to
A foam materials.
Side sill
B
B
: Cuttable range AB301078 AB
9. Reference
Depending on the damaged range, it is advisable
to replace the side outer panel and side sill outer
reinforcement parts.
AB301076AB
CAUTION
7. Assemble the side outer panel, then cover the Cut the side sill outer reinforcement 50 mm away
hole and flange with bolt and aluminium tape and from the cut area of the side outer panel.
fill the hole with foam materials A and B as shown
in the figure of the instructions.
SIDE SILL
3-23
NOTES
QUARTER, OUTER <SEDAN>

M4030008000161
AB300748
Spot welding
MIG spot welding
Braze welding
AC300820AB
REPAIR WELDS
A
Foam acoustic material
D
500 ± 50 mm 3 points left side
A
160 ± 50 mm
C
Foam acoustic material
C
AB301081AB
CAUTION
3-25
AB301082 AB
NOTE ON REPAIR WORK 2. Assemble the quarter outer, then cover the hole
INSTALLATION and flange with bolt and aluminium tape and fill
the hole with foam materials A and B as shown in
the figure of the instructions.
• FOAM (Hole A): 3M ATD ULTRAPRO
Panel foam-Yellow
Rear pillar
silencer protector
AB301077AB
3. Wait 2 hours after filling the foam material to

foam materials.
: Body sealant AB301083 AB
1. When attaching the quarter outer, apply sealant to

the areas indicated in the illustration.
Attach the rear pillar silencer protector, and fill the
gaps with butyl tape.
: Cuttable range AB300903AB

A
4. Reference
A
Parts replacement is advised. depending on the
damaged range.
CAUTION
Avoid the fuel filler bracket (left side).
AB301084 AB
3-27
NOTES
QUARTER, OUTER <WAGON>

M4030008000172
AB300749
Spot welding
MIG spot welding
Braze welding
AB300821AB
REPAIR WELDS
140 ± 70 mm
C
3 points
B
left side
Acoustic foam
A D
160 ± 50 mm
A B C
AB301086AB
3-29
CAUTION
200 ± 30 mm
D
AB301087
NOTE ON REPAIR WORK

INSTALLATION Urethane foam
50 mm
: Body sealant AB300904 AB
2. To prevent the foam materials from dripping, apply

AB301090AB urethane foam to bury the inside of the
wheelhouse arch.
1. To reinforce the strength of the rear gate pillar cut
3. When assembling the quarter outer panel, apply
area, cut only the side outer panel from 50 mm
in advance body sealant to the areas shown in the
above the cut area of the gate pillar.
figure of the instructions.
AB300905AB AB301077AB
4. Assemble the quarter outer panel, cover the hole 5. Wait 2 hours after filling the foam materials to
and flange with bolt and aluminium tape, then fill remove the bolt and aluminium tape. Then melt
the hole with foam materials as shown in the the foam materials with a soldering gun so a clip,
figure of the instructions. etc. can thoroughly be inserted in the hole that
Foam: 3M ATD ULTRAPRO Panel foam-Yel- was clogged with foam materials, to bore open
low the hole.
ROOF <SEDAN>
3-31
ROOF <SEDAN>
M4030011000161

Spot welding
MIG spot welding
Braze welding
AB300996AB
Repair welds
A D
B
C
D
: Adhesive
AB301091AB
Adhesive: Urethane body sealer Brand: 3M ATD Part No.8542 or equivalent

ROOF <WAGON>
ROOF <WAGON>
M4030011000172

Spot welding
MIG spot welding
Braze welding
AB300997AB
Repair welds
A D
C
B B
Vehicles with roof rail Vehicles with roof rail

Vehicles without roof rail
: Adhesive
AB500781AB

ROOF <WAGON>
3-33
C
D
E AB301092 AB
NOTE ON REPAIR WORK The welding point is at the bottom of the roof rack
bracket rear. Thus, remove the roof rack bracket rear
<VEHICLE WITH ROOF RAIL>
and detach the welding point.
REMOVAL INSTALLATION
Remove the roof rack reinforcement rear. Weld the
Roof rack
reinforcement rear roof panel and then assemble the roof rack reinforce-
ment rear.
Weld points
AB300906 AB
REAR FLOOR <SEDAN>
REAR FLOOR <SEDAN>

M4030010000168
SYMBOL OPERATION DESCRIPTION

Spot welding
MIG spot welding
Braze welding
AB300824 AB
REPAIR WELDS
B
C
AB301005 AB
NOTE: Refer to the Rear End Panel <SEDAN> section on P.3-38 for the welding points with the rear end
panel.
REAR FLOOR <SEDAN>
3-35
B C
AB100144
Right
side
only
Right
side
only
D E AB301008 AB
NOTE ON REPAIR WORK When cutting the rear floor pan, cut it from 320 ± 10
mm behind the back of the rear seat back reinforce-
REMOVAL
ment.
Rear seat back
reinforcement
320 ± 10 mm
AB301009AB
REAR FLOOR <WAGON>
REAR FLOOR <WAGON>

M4030010000179
AB300749
Spot welding
MIG spot welding
Braze welding
AB300825AB
REPAIR WELDS
A
AB301013AB
NOTE: Refer to the Rear End Crossmember <WAGON> section on P.3-39 for the welding points with the
rear end crossmember.
REAR FLOOR <WAGON>
3-37
AB100144
Right
side
only
Right
side
only
C AB301008AB
NOTE ON REPAIR WORK When cutting the rear floor pan, cut it from 400 ± 10
mm behind the rear seat back assembling hole.
REMOVAL
400 ± 10 mm
AB300907AB
REAR END PANEL <SEDAN>
REAR END PANEL <SEDAN>

M4030009000089

Spot welding
MIG plug welding ( : indicates two panels to be welded
: indicates three panels to be welded)
MIG spot welding
Braze welding
AB300822 AB
REPAIR WELDS
AB300760AB
REAR END CROSSMEMBER <WAGON>
3-39
REAR END CROSSMEMBER <WAGON>
M4030015000130

Spot welding
MIG spot welding
Braze welding
AB300823AB
REPAIR WELDS
A AB301002 AB
NOTE ON REPAIR WORK 1. Cut the welding points of the rear end
REMOVAL crossmember. Then remove the quarter inner
extension lower as it will interfere with the rear
end crossmember removal.
2. Pull out the rear end crossmember.
AB301002 AB
QUARTER, INNER <SEDAN>

M4030012000164

Spot welding
MIG spot welding
Braze welding
AB300826AB
REPAIR WELDS
9 points
F on left side
E
6 points
on right
side
G
A
B
(With the quarter outer removed)
A B
AB301015 AB
NOTE: Refer to the Quarter, Outer <SEDAN> section on P.3-24 for the welding points with the quarter outer.
3-41
E F
G
(With the sill outer reinforcement rear removed)
AB301016AB
QUARTER, INNER <WAGON>

M4030012000175
AB300749
Spot welding
MIG spot welding
Braze welding
AC300827AB
REPAIR WELDS
9 points
on left side
6 points
on right side
A
B
(With the quarter outer removed)
A B
AB301017AB
NOTE: Refer to the Quarter, Outer <WAGON> section on P.3-28 for the welding points with the quarter
outer.
3-43
(With the side sill outer reinforcement rear removed)
AB301018AB
FRONT DOOR OUTER PANEL (ADHESION TYPE)
FRONT DOOR OUTER PANEL (ADHESION TYPE)

M4030001700073

Spot welding
MIG spot welding
Braze welding
AB300891AB
REPAIR WELDS
A
B C
C
: Adhesive 1 B
: Adhesive 2 AB500773AB
• Adhesive 1: Urethane body sealer NOTE ON REPAIR WORK

INSTALLATION
• Adhesive 2: Epoxyayresin adhesive
Brand: 3M ATD Part No.8115 or equivalent 1. When installing the front door outer panel, grind
the bonding surface and remove the paint to
improve adhesion. Then, degrease the front door
outer panel.
2. Install the front door outer panel and hem it. Then,
wipe off the adhesive that squeezed out.
FRONT DOOR OUTER PANEL (WELDED TYPE)
3-45
FRONT DOOR OUTER PANEL (WELDED TYPE)
M4030001500079

Spot welding
MIG spot welding
Braze welding
AB300891AB
REPAIR WELDS
50 mm
B C
B
: Adhesive 1
: Adhesive 2
AB202233AF
• Adhesive 1: Urethane body sealer • Adhesive 2: Epoxyayresin adhesive

Brand: Brand:
3M ATD Part No.8542 or equivalent 3M ATD Part No.8115 or equivalent
NOTE: After hemming the front door outer panel, MIG spot weld the flange overlap section at a pitch of 50
mm.
REAR DOOR OUTER PANEL (ADHESION TYPE)
REAR DOOR OUTER PANEL (ADHESION TYPE)

M4030001800047

Spot welding
MIG spot welding
Braze welding
AB300892 AB
REPAIR WELDS
A
B
B C
: Adhesive 1 C
: Adhesive 2 AB500774AB
• Adhesive 1: Urethane body sealer NOTE ON REPAIR WORK

INSTALLATION
• Adhesive 2: Epoxyayresin adhesive
Brand: 3M ATD Part No.8115 or equivalent 1. When installing the rear door outer panel, grind
the bonding surface and remove the paint to
improve adhesion. Then, degrease the rear door
outer panel.
2. Install the rear door outer panel and hem it. Then,
wipe off the adhesive that squeezed out.
REAR DOOR OUTER PANEL (WELDED TYPE)
3-47
REAR DOOR OUTER PANEL (WELDED TYPE)
M4030001600043

Spot welding
MIG spot welding
Braze welding
AB300892 AB
REPAIR WELDS
50 mm
A
A
C
C
: Adhesive
AB202234AB

NOTE: After hemming the rear door outer panel, MIG spot weld the flange overlap section at a pitch of 50
mm.
NOTES
4-1
GROUP 4
CORROSION
PROTECTION
CONTENTS
BODY SEALING LOCATIONS . . . . . 4-2 UNDERCOAT APPLICATION

LOCATIONS . . . . . . . . . . . . . . . . . . . . 4-16
WAX INJECTION LOCATIONS . . . . . 4-8
UNDERBODY ANTICORROSION
ROCKER PANEL PRIMER AGENT LOCATIONS . . . . . . . . . . . . . 4-17
APPLICATION LOCATIONS . . . . . . . 4-15
4-2 CORROSION PROTECTION
BODY SEALING LOCATIONS

M4040001000547
If the sealant application is directly visible on the NOTE: The bold dotted line indicates the application
outer plate and requires appearance quality of the area on the underside.
application in areas such as the drip rail, pillar, clinch
and so on, then apply the sealant so that it is flat, or
wipe off any excess mounding after the application.
Be careful not to obstruct the water draining hole.
<SEDAN>
FLOOR
1 2 3
14
AB500704AB
UPPER BODY
6
AB500705AB
SIDE BODY
12
8 10
9 11 13 AB500706AB
CORROSION PROTECTION
4-3
1 5
AB500699 AB AB300686AB
2 6
AB500703AB
AB300687AB
3 7
AB300684AB
AB300688AB
4 8
AB500697AB
AB300689AB
9 13
AB300685AB AB400093AC
10 14
AB300690AB AB500747AC
11 Hood
AB300691AB AB300556AB
Y0121AV
12 Front door
AB300584AB AB300610 AB
4-5
Rear door Trunk lid
AB300611AB AB300557AB
<WAGON>
FLOOR
1 2
3
14
AB500738AB
UPPER BODY
6
5
AB500739 AB
SIDE BODY
12
8 10
9 11 13 AB500740AB
1 4
AB500699 AB AB500697AB
2 5
AB500703AB AB300693AB
3 6
AB300692AB AB300696AB
4-7
7 11
AB300694AB AB300691AB
8 12
AB300689AB AB300695AB
9 13
AB300685AB AB400026AC
10 14
AB300690AB AB500747AC
WAX INJECTION LOCATIONS
Hood Rear door
AB300556AB AB300612 AB
Front door Tailgate
AB300610 AB AB300613AB

M4040008000054
In order to provide greater corrosion resistance, wax NOTES REGARDING WAX INJECTION
injection has been performed for the lower areas of WORK
the vehicle, such as the frame, the side sill, and other
• Be careful that the wax does not get onto other
panels which are a hollow-construction. If any of
parts. Especially if wax is to be injected into the
these panels are replaced, wax injection must be
lower part of the centre pillar and into the side sill,
performed for the new parts.
first remove the seat belt retractor and the door
Recommended wax:
switch.
• Tectyl 506, 506T or ML
• For wax injection locations which have a rubber
• Waxoyl
plug, do not forget to reinstall the rubber plug
• Dinitrol 3122 or 3654-1
after the wax injection is completed.
• Mercasol 831-ML
• Terotex
• HV200PLUS or HV300
4-9
<Sedan>
11
C
7
G
4
9
3 6
D
12
B
1
10
E
2 10
E
A
AB300732
AB300893 AB
<Wagon>
15
I
14
13
G
4
9
3 6 D
12
B
1
10
2 E
10
A E
AB300894 AB
4-11
: Nozzle insertion openings Application surfaces
1 A
AB301031AB
AB301109AB
AB301110 AB
3 B
AB301032AB
AB301111AB
AB301112 AB
5 B
AB301033AB
AB301113 AB
AB301114 AB
7 C
AB300915AC
AB300703AB
AB301053AB
4-13
9 D
AB301058 AB
AB301115AB
10 Front door Rear door E
AB301059AB
AB300913 AB
11 F
AB300914AB
AB300744AB
12 G
AB301060AB
AB300697AB
13 H
AB300915AB
AB300703AC
14
AB301049 AB
15 I
AB300916AB
AB300700 AB
ROCKER PANEL PRIMER APPLICATION LOCATIONS
4-15
ROCKER PANEL PRIMER APPLICATION LOCATIONS
M4040002000142
To prevent rusting from chipping (flying rock), a prim- The priming panel primer is applied between the
ing panel primer has been applied to the areas indi- under and middle coat. It improves anti-corrosive
cated in the figure. performance by preventing flying rock to damage the
body panel with the primer application, according to
the thickness and elasticity of the primer. Apply the
primer before the middle coat when replacing the
panel complete with a priming panel primer applica-
tion.
AB300549
<Sedan>
A AB300551AB
<Wagon> AB300550
A
AB300552 AB
35 mm
AB300582AB
: Rocker panel primer A

UNDERCOAT APPLICATION LOCATIONS
UNDERCOAT APPLICATION LOCATIONS

M4040003000167
The under parts of the body is undercoated for Tape the areas marked with an asterisks to protect
anti-corrosive, anti-rust, anti-chipping, and anti-vibra- those areas from getting any undercoating on those
tion performance. areas.
After correcting the body, restore as shown in the
instructions of the figure, if necessary.
* * *
* *
: Undercoat [Film thickness is at least 0.8 mm] AB400024AB
UNDERBODY ANTICORROSION AGENT LOCATIONS
4-17
UNDERBODY ANTICORROSION AGENT LOCATIONS
M4040009000068
In order to provide a greater corrosion resistance, NOTE: .
underbody corrosion prevention treatment should be • Take care not to permit the anticorrosion agent to
performed after undercoat application. After complet- come in contact with body painting, brake parts,
ing body repairs, restore this underbody corrosion exhaust pipes, bearing seals for rear axle and
prevention treatment as indicated in the illustration if rubber parts (such as tires and drive shaft boots).
necessary. Recommend wax: • If anticorrosion agent gets onto the oxygen sen-
• Tectyl 506T, 506 or S sor, it will cause a drop in the performance of the
• Waxoyl sensor. Cover the oxygen sensor with a protec-
tive material when applying anti-corrosion agents
and undercoats.
: 0.1 mm or more AB300559AB

NOTES
5-1
GROUP 5
SYNTHETIC-RESIN
PARTS
CONTENTS
LOCATION OF SYNTHETIC-RESIN ................................. 5-2

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

M4050001000634
The location and material of each of the principal

synthetic-resin parts are shown below.
<Sedan> 40 8 17
3
5, 6
38
4
9
12
10 34
2
42
11
13
14
33
7 35
1 41
30 29 36
32 AB500732AB
20 21 37 22 23
31
19
18
24
16
26
27 25
15
28
39 AB300875AD
SYNTHETIC-RESIN PARTS
5-3
No. Part name Material Abbreviation Heat-resistant

of material temperature
(°C)
1 Radiator grille Acrylonitrile butadiene styrene ABS 80
2 Radiator centre grille
3 Rear spoiler
4 Licence plate garnish
5 Door mirror (body colour)
6 Door mirror (black) Acrylonitrile styrene acrylate ASA (AAS) 80
7 Front bumper garnish
8 Roof antenna Acrylonitrile ethylene styrene AES 90
9 Headlamp Polycarbonate PC 120
10 Rear door outside handle Polycarbonate+Acrylonitrile PC+ABS 120 − 125
11 Rear door moulding butadiene styrene (PC/ABS)
12 Front door outside handle
13 Front door moulding
14 Front fender moulding
15 Front splash shield Polyethylene PE 100
16 Rear splash shield
17 Rear wiper arm Polyethylene terephthalate PET 115
18 Instrument panel Polypropylene PP 80
19 Front pillar trim
20 Inside rear view mirror
21 Centre pillar trim upper
22 Rear door trim
23 Rear pillar trim
24 Rear end trim
25 Rear scuff plate
26 Front scuff plate
27 Cowl side trim
28 Floor console box
29 Fog lamp bezel Rubber denatured polypropylene PP+E/P 80
30 Air intake bezel
31 Front door trim
32 Front bumper extension Talc filled rubber modified PP+E/P-TD 80 − 100
33 Front bumper face polypropylene (HMPP)
34 Rear bumper face
35 Rear bumper extension
36 Side air dam Talc filled rubber modified PP+E/P-TD20 110
polypropylene (20%)
37 Centre pillar trim lower Talc filled polypropylene (10%) PP-TD10 (PPF) 100 − 120
38 Front deck garnish Talc filled polypropylene (20%) PP-TD20 (PPF) 120 − 130

(°C)
39 Floor console
40 Roof drip moulding Polyvinyl chloride PVC 80
41 Front mudguard Thermo plastic elastomer TPO (TEO) 80 − 100
42 Rear mudguard
NOTE: .
• If the material symbols designated by the ISO differ from the old symbols, both are given, with the old
symboling enclosed in brackets.
ISO: International Standardization Organization.
• A slash (/) in the material symbol indicates that two different materials make two-layer construction. A plus
sign (+) indicates that the two different materials mix each other.
• The indicated heat-resistant temperature for parts which are composed of two or more types of material is
the value for the material with the lowest heat-resistant temperature.
• The material symbols for synthetic-resin parts are embossed on the parts in hidden places.
<Wagon> 44 7
3
4, 5
16
41
8
11 9 35
2
10 46
12
13
34
6
1 45 37 36
32 31
33 AB500733AB
SYNTHETIC-RESIN PARTS
5-5
39 40 20 42 22
19 21
23
18
38
17
24
25
15
28 27
29
14
26
30
43 AB300874AF

(°C)
1 Radiator grille Acrylonitrile butadiene styrene ABS 80
2 Radiator centre grille
3 Rear spoiler
4 Door mirror (body colour)
5 Door mirror (black) Acrylonitrile styrene acrylate ASA (AAS) 80
6 Front bumper garnish
7 Roof antenna Acrylonitrile ethylene styrene AES 90
8 Headlamp Polycarbonate PC 120
9 Rear door outside handle Polycarbonate+Acrylonitrile PC+ABS 120 − 125
10 Rear door moulding butadiene styrene (PC/ABS)
11 Front door outside handle
12 Front door moulding
13 Front fender moulding
14 Front splash shield Polyethylene PE 100
15 Rear splash shield
16 Rear wiper arm Polyethylene terephthalate PET 115
17 Instrument panel Polypropylene PP 80
18 Front door trim
19 Inside rear view mirror
20 Rear door trim
21 Quarter trim lower
22 Tailgate upper trim

(°C)
23 Tailgate side trim Polypropylene PP 80
24 Tailgate lower trim
25 Rear end trim
26 Luggage floor box
27 Rear scuff plate
28 Front scuff plate
29 Cowl side trim
30 Floor console box
31 Fog lamp bezel Rubber denatured polypropylene PP+E/P 80
32 Air intake bezel
33 Front bumper extension Talc filled rubber modified PP+E/P-TD 80 − 100
34 Front bumper face polypropylene (HMPP)
35 Rear bumper face
36 Rear bumper extension
37 Side air dam Talc filled rubber modified PP+E/P-TD20 110
polypropylene (20%)
38 Front pillar trim Talc filled polypropylene (10%) PP-TD10 (PPF) 100 − 120
39 Centre pillar trim upper
40 Centre pillar trim lower
41 Front deck garnish Talc filled polypropylene (20%) PP-TD20 (PPF) 120 − 130
42 Quarter trim upper
43 Floor console
44 Roof drip moulding Polyvinyl chloride PVC 80
45 Front mudguard Thermo plastic elastomer TPO (TEO) 80 − 100
46 Rear mudguard
NOTE: .
• If the material symbols designated by the ISO differ from the old symbols, both are given, with the old
symboling enclosed in brackets.
ISO: International Standardization Organization.
• A slash (/) in the material symbol indicates that two different materials make two-layer construction. A plus
sign (+) indicates that the two different materials mix each other.
• The indicated heat-resistant temperature for parts which are composed of two or more types of material is
the value for the material with the lowest heat-resistant temperature.
• The material symbols for synthetic-resin parts are embossed on the parts in hidden places.
6-1
GROUP 6
BODY COLOUR
CONTENTS
BODY COLOUR CODE . . . . . . . . . . . 6-2 BODY COLOURING . . . . . . . . . . . . . . 6-3

FRONT END . . . . . . . . . . . . . . . . . . . . . . . . 6-3
BODY COLOUR CHARTS. . . . . . . . . 6-2 RADIATOR GRILLE . . . . . . . . . . . . . . . . . . 6-3
FRONT BUMPER . . . . . . . . . . . . . . . . . . . . 6-4
6-2 BODY COLOUR
BODY COLOUR CODE
BODY COLOUR CODE

M4060001000163
Body colour code

AB300544AB AB202021AE
1. The body colour code is imprinted on the vehicle 2. The information is contained in the body colour
information code plate, which is mounted on the charts.
front deck.
BODY COLOUR CHARTS

M4060002000843
Check the vehicle’s body colour code, and then use
this body colour chart to determine the refinishing
paint supplier from which the colour can be pur-
chased.
Colour Colour Colour number Colour name Composition of film
code (Previous name)
SILVER A31 CMA10031 Cool Silver Metallic Metallic
(Cool Silver)
MEDIUM PURPLISH A39 CMA10039 Medium Purplish Grey Mica Metallic + Interferenced
GREY Pearl
GREENISH SILVER A86 CMA10086 Greenish Silver Metallic Metallic
RED R20 CMR10020 Wine Red Metallic Metallic
(Rose Red)
DARK BLUE T54 CMT10054 Deep Blue Mica Pearl
(Flop Blue)
WHITE W37 CMW10037 White Solid Solid
BLACK X42 AC11342 Black Pearl Interferenced Pearl
(Amethyst Black)
NOTE: .
• It is a solid, but clear coating is applied.
• For painting, inner panel colours should be similar to the outer panel colours.
BODY COLOUR
BODY COLOURING
6-3
BODY COLOURING
FRONT END
M4060015000144
(Except colour code A39, X42)
: BLACK (AC10657) AB500786AB
RADIATOR GRILLE
M4060007000279
1 2
A
1
3
1 Body colour A
2 Black (AC10085)
3 Dark Argent (AC10340) AB500788AB
6-4 BODY COLOUR
BODY COLOURING
FRONT BUMPER
M4060000500013
1
2
1 Body colour
A 2 A
2 Material colour AB500787AB
8-1
GROUP 8
REFERENCE
MATERIAL
CONTENTS
BOLTED PANEL FIT AND ADJUSTMENT OF OTHER PARTS . . 8-9

ADJUSTMENT . . . . . . . . . . . . . . . . . . 8-2 FRONT WHEEL ALIGNMENT . . . . . . . . . . 8-9
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 REAR WHEEL ALIGNMENT . . . . . . . . . . . . 8-10
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 HEADLAMP AIMING . . . . . . . . . . . . . . . . . . 8-11
TRUNK LID . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 FRONT FOG LAMP AIMING CHECK . . . . . 8-12
TAILGATE. . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
FUEL FILLER LID . . . . . . . . . . . . . . . . . . . . 8-5 SUPPLEMENTAL RESTRAINT SYSTEM
(SRS) - AIR BAG . . . . . . . . . . . . . . . . 8-14
INSTALLATION AND REMOVAL OF
ADHESIVE COMPONENTS. . . . . . . . 8-5
MOULDING. . . . . . . . . . . . . . . . . . . . . . . . . 8-5
SIDE AIR DAM . . . . . . . . . . . . . . . . . . . . . . 8-7
8-2 REFERENCE MATERIAL
BOLTED PANEL FIT AND ADJUSTMENT

HOOD
M4080005000123
HOOD FIT ADJUSTMENT
AC005947AF
3. If the hood is not flush with the surrounding

panels, or the hood locking and/or unlocking is
AC005945
heavy, check the routing of the release cable. If
1. If the clearance between the hood and body panel the cable is properly routed, loosen the hood latch
is uneven, loosen the hood mounting bolts and mounting bolts to move the hood latch so that it
adjust the clearance by moving the hood. can be engaged with the hood striker properly.
Hood mounting bolt tightening torque: 11 ± 2 Hood latch mounting bolt tightening torque:
N⋅m 9.0 ± 2.0 N⋅m
DOOR
M4080006000159
A
DOOR FIT ADJUSTMENT
CAUTION
• Attach protection tape to the fender and door
A edges where the hinge is installed.
• Do not rotate special tool door adjusting
wrench (MB991164) with a torque of over 98
N⋅m.
Y0215AU
Section A – A
Hood
MB990900
or
MB991164
17 mm
AC000592 AB
Hood bumper X0424CA
AC005948AB
1. Use special tool door edges where (MB990900 or
2. Rotate the hood bumper by using the arrow mark MB991164) to loosen the hinge mounting bolts on
on the hood bumper as a guide to adjust the hood the body side, and then adjust the clearance
height. If the hood bumper is rotated just one turn, around the door so that it is uniform on all sides.
the hood height changes by approximately 3 mm. Door hinge mounting bolt tightening torque:
27 ± 5 N⋅m
2. If a door is not flush with its surrounding panels,
loosen the door-side door hinge mounting bolts
and obtain the flushness by moving the door.
Door hinge mounting bolt tightening torque:
21 ± 4 N⋅m
REFERENCE MATERIAL
8-3
NOTE: (2) Adjustment by using the striker (toward the
Weld point Washer outside of the vehicle).
Use special tools slide hammer (MB990211)
and body puller (MB990243) to pull the striker
toward the outside of the vehicle.
Bolts
Shim
Striker
Weld point Washer
Door hinge AC206498 AF
If the door hinge mounting bolts washers are

welded, grind off the welding according to the pro-
cedure below beforehand.
(1) Remove the door hinge. AC006111AB
(2) Use a chisel or grinder to release the door
hinge mounting bolt washers, which are (3) Adjustment by using shims (forward and
welded to the door hinge. rearward)
(3) On completion, paint the affected area with a Increase or decrease the number of shims so
suitable touch-in brush to prevent corrosion. that the striker engages with the door latch
properly.
(4) Install the door hinge.
Door striker mounting bolt tightening
3. When the door is stiff to lock and unlock.
torque: 11 ± 2 N⋅m
TRUNK LID
M4080017000023
ADJUSTMENT OF CLEARANCE AROUND

TRUNK LID
MB990939 Trunk lid hinge
Temporary Striker
bolts
AC006109AD
(1) Adjustment by using the striker (toward the

inside of the vehicle and vertical direction)
Install a temporary bolts instead of the striker Trunk lid panel
mounting bolts, and use special tool brass bar assembly
(MB990939) and a hammer to tap the bolts to AC202897 AB
the desired direction. Loosen the trunk lid panel assembly mounting bolts
and move the trunk lid panel assembly to make the
clearance around the trunk lid uniform.
MB990211
MB990243
Striker
AC006110 AB
TRUNK LID FIT ADJUSTMENT TAILGATE

M4080007000129
Trunk lid panel assembly TAILGATE FIT ADJUSTMENT
1. If the striker and latch mesh badly, replace the
striker and striker mounting bolts with
replacement parts (striker: MR523105, striker
mounting bolts: MU000474).
A
A
Trunk lid bumper

Section A - A
Trunk lid bumper
AC203659
14 mm
2. Move the replaced striker forward and backward
or to the left and right to adjust, after bolt the
Trunk lid panel assembly striker temporarily.
3. After adjusting, tighten the bolts to the specified
torque.
AC305144 AB
Tailgate striker mounting bolt tightening
Turn each trunk lid bumper until the height shown in torque: 24 ± 4 N⋅m
the illustration is reached. If the trunk lid panel height NOTE:
on one side is different from that on the other side
(even after the trunk lid bumpers have been adjusted Grind here
to the height indicated in the illustration), turn the
trunk lid bumper(s) slightly to make fine adjustments
to the trunk lid panel height.
NOTE: When the bumper is new, one full turn of the
trunk lid bumper changes the height approximately 3
mm. Turn it clockwise to reduce height. Turn it
anti-clockwise to increase height.
AC203660AB
TRUNK LID STRIKER ADJUSTMENT When the bolts head interferes with the rear end
trim, grind the interference area with a round file.
Trunk lid striker
AC202898 AB
After checking the trunk lid release cable for proper AC201556
routing, loosen the trunk lid striker mounting bolts. 4. If uneven clearance is present between tailgate
Change the position of the trunk lid striker relative to and body, reposition the hinge to adjust the
the trunk lid latch assembly so that trunk lid locking clearance.
and unlocking effort is correct.
Tailgate hinge mounting bolt tightening
Trunk lid mounting bolt tightening torque: torque: 9.0 ± 2.0 N⋅m
8.9 ± 1.9 N⋅m
REFERENCE MATERIAL
INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS
8-5
FUEL FILLER LID If the height and clearance of the fuel filler lid is une-
M4080019000085 ven, loosen the fuel filler lid mounting bolts, then
FUEL FILLER LID FIT ADJUSTMENT move and adjust the fuel filler lid.
Fuel filler lid mounting bolt tightening
torque: 5.0 ± 1.0 N⋅m
AB300142 AB
INSTALLATION AND REMOVAL OF ADHESIVE

COMPONENTS
MOULDING
M4080014000057
Rear door moulding
Front door moulding
Front fender moulding
AB400090AB
Adhesive tape position

Adhesive tape a Adhesive tape a
Front fender Rear door moulding

moulding Adhesive tape b Front door moulding
Adhesive tape b AC400840AC
Adhesive tape: Double-sided tape [ a: 6 mm width and 1.2 mm thickness ]

[ b: 20 mm width and 1.2 mm thickness ]
REMOVAL <Remove double-sided tape remaining on door

moulding and adhere double-sided tape (when
FRONT FENDER, FRONT AND REAR
re-using door moulding)>
DOOR MOULDINGS REMOVAL
Gently lift and remove the door moulding. If there is
any double-sided tape remaining on the door mould-
ing, remove according to the following instructions.
<Remove double-sided tape remaining on the body
surface>
Protection tape
AC313343
1. Scrape off the double-sided tape on the door

moulding with a resin spatula as possible.
2. Wipe the door moulding surface and clean it with
a rag moistened with isopropyl alcohol.
Double-sided tape AC000420 AB 3. Remove only a small portion of the residual
adhesive.
1. Attach protection tape all the way along the edges
of the double-sided tape which is still adhering to 4. Adhere the double-sided tape as specified on the
the body. door moulding.
INSTALLATION
Double-sided tape
FRONT FENDER, FRONT AND REAR
DOOR MOULDINGS INSTALLATION
AC000421 AB
Adhesive tape
2. Use a resin spatula to scrape off the double-sided
tape.
Backing paper
3. Peel off the protection tape.
AC313344 AB
4. Wipe the body surface and clean it with a rag
moistened with isopropyl alcohol. 1. Tear off the double-sided tape backing paper.
NOTE: If attach the adhesive tape to the edge of
the backing paper, it will be easy to tear off.
REFERENCE MATERIAL
8-7
2. Install the clips to the front and rear door NOTE: If the double-sided tape is difficult to affix
mouldings before installing them to the vehicle in cold temperature, etc., warm the bonding sur-
body. faces of the body and door mouldings to about
3. Install the door mouldings. 40− 60°C before affixing the tape.
4. Firmly press in the door mouldings onto the
respective body surfaces.
SIDE AIR DAM

M4080000200014
Side air dam
Adhesive tape position

Side air dam
Adhesive tape
Adhesive tape: Double-sided tape [ 4 mm width and 1.2 mm thickness ]
AB301080AB
REMOVAL
SIDE AIR DAM REMOVAL
Gently lift and remove the side air dam. If there is
any double-sided tape remaining on the side air dam,
remove according to the following instructions.
<Remove double-sided tape remaining on the
body surface>
Double-sided tape
AC103187
1. Scrape off the double-sided tape on the side air

dam with a resin spatula as possible.
2. Wipe the side sill garnish surface and clean it with
a rag moistened with isopropyl alcohol.
3. Remove only a small portion of the residual
Protection tape adhesive.
AC200049AB
4. Adhere the double-sided tape as specified on the
1. Attach protection tape all the way along the edges side air dam.
of the double-sided tape which is still adhering to
the body. INSTALLATION
Double-sided tape
SIDE AIR DAM INSTALLATION.
Backing paper
AC200050AB
Adhesive tape
2. Scrape off the double-sided tape with a resin AC103247 AC
spatula as possible.
1. Tear off the double-sided tape backing paper.
3. Peel off the protection tape.
NOTE: If you attach the adhesive tape to the edge
4. Wipe the body surface and clean it with a rag of the backing paper, it will be easy to tear off.
moistened with isopropyl alcohol.
2. Install the side air dam.
<Remove double-sided tape remaining on side NOTE: If the double-sided tape is difficult to affix
air dam and adhere double-sided tape (when in cold temperature, etc., warm the bonding sur-
re-using side air dam)> faces of the body and side sill garnish to about 40
− 60°C before affixing the tape.
3. Firmly press in the side air dam.
REFERENCE MATERIAL
ADJUSTMENT OF OTHER PARTS
8-9
FRONT WHEEL ALIGNMENT TOE-OUT ANGLE ON TURNS
M4080009000460
To check the steering linkage, especially after the
Measure wheel alignment with alignment equipment vehicle has been involved in an accident or if an acci-
on a level surface. The front suspension, steering dent is presumed, it is advisable to check the toe-out
system, wheels, and tyres should be serviced to nor- angle on turns in addition to the wheel alignment.
mal condition before measuring wheel alignment. Conduct this test on the left turn as well as on the
TOE-IN right turn.
Standard value: Standard value:
at the centre of tyre tread: 1 ± 2 mm
Toe angle (per wheel): 0°03' ± 0°06' Item Specification
Toe-out angle on turns (inner 21°42' ± 1°30'
Lock nut wheel when outer wheel at 20°)
Clip
CAMBER, CASTER AND KINGPIN
INCLINATION
Standard value:
Item Invite Intense
Camber 0°05' ± 0°30'* −0°05' ± 0°30'*
AC006074 AD
Caster 2°45' ± 0°30'* 2°55' ± 0°30'*
1. Adjust the toe-in by undoing the clip and lock nut,
Kingpin 12°30' ± 1°30' 12°40' ± 1°30'
and turning the left and right tie rod turnbuckles by
inclination
the same amount (in opposite directions).
NOTE: The toe will move out as the left turnbuckle NOTE: *: difference between right and left wheels
is turned toward the front of the vehicle and the must be less than 30'
right turnbuckle is turned toward the rear of the NOTE: Camber and caster are preset at the factory
vehicle. and cannot be adjusted.
2. Install the clip and tighten the lock nut to the CAUTION
specified torque. Never subject the wheel bearings to the vehicle
Tightening torque: 40 ± 5 N⋅m load when the driveshaft nuts are loosened.
3. Confirm that the toe-in is at the standard value. NOTE:
4. Use a turning radius gauge to check that the MB991004
steering angle is at the standard value.
STEERING ANGLE
Standard value:
Inner Invite 39°30' ± 1°30'
wheels Intense (LH 33°40' +1°00'/−2°00'
drive vehicles)
Intense (RH 37°00' +1°00'/−2°00' AC001079 AB
drive vehicles) For vehicles with aluminium wheels, attach the cam-
Outer Invite 32°30' ber/caster/kingpin gauge to the driveshaft by using
wheels Intense (LH 28°46' special tool wheel alignment gauge attachment
(reference) drive vehicles) (MB991004). Tighten the special tool to the same
torque 245 ± 29 N⋅m as the driveshaft nut.
Intense (RH 30°00'
drive vehicles)
REAR WHEEL ALIGNMENT NOTE: .

M4080010000129 • LH: Clockwise viewed from the front → (+)
Measure wheel alignment with an alignment equip- camber
ment on level earth. • RH: Clockwise viewed from the front → (−)
The rear suspension, wheels, and tyres should be camber
serviced to the normal condition prior to wheel align- • The scale has gradations of approximately 14'.
ment measurement.
CAUTION
CAMBER
Standard value: −0°40' ± 0°30' (Left/right
deviation within 30')
CAUTION
Never subject the wheel bearings to the vehicle
load when the rear wheel hub nuts (self-locking
nuts) or special tool wheel alignment gauge
Connecting bolt
attachment (MB991014) are loosened.
NOTE: AC006160 AC
<Vehicles with aluminium wheels>
MB991014 To prevent bushings from breakage, the connect-
ing bolt should be temporarily tightened, and
then fully tightened to 90 ± 10 N⋅m with the vehi-
cle on the earth in the unladen condition.
3. Tighten the control link to the trailing arm.
4. After adjusting the camber, the toe should be
adjusted.
AC001079 AG
TOE-IN
For vehicles with aluminium wheels, attach the cam-
Standard value:
ber/caster/kingpin gauge to the trailing arm spindle
At the centre of tyre tread: 3 ± 2 mm
by using special tool wheel alignment gauge attach-
Toe angle (per wheel): 0°08' ± 0°05'
ment (MB991014). Tighten the special tool to the
same torque 175 ± 25 N⋅m as the rear wheel hub nut If toe-in is not within the standard value, adjust by fol-
(self-locking nut). lowing procedures.
If camber is not within the standard value, adjust by CAUTION
following procedures. To prevent bushings from breakage, the control
1. Disconnect the conjunction of the control link and link mounting nut should be temporarily tight-
the trailing arm. ened, and then fully tightened to 120 ± 10 N⋅m
with the vehicle on the earth in the unladen con-
Camber adjusting bolt dition.
Lower arm
assembly <Control link front view> <Control link rear view>
Toe adjusting bolt Control link

mounting nut
AC006159 AC
Control link Control link
2. Carry out adjustment by turning the camber AC006145 AD
adjusting bolt (lower arm assembly mounting bolt
Carry out adjustment by turning the toe adjusting bolt
which is located on the inner side of the body).
(control link mounting bolt which is located on the
inner side of the body).
REFERENCE MATERIAL
8-11
NOTE: . 10.Four lines of adhesive tape (or equivalent
• LH: Clockwise viewed from the front → Toe-in markings) are required on screen or wall:
• RH: Clockwise viewed from the front → Toe-out (1) Position a vertical tape or mark so that it is
• Turning the toe adjusting bolt by one groove of aligned with the vehicle centre line.
the scale, toe can be changed approximately 2.6 (2) Measure the distance from the centre-marks
mm (single side toe angle equivalent to 16'). on the headlamp lens to the floor. Transfer the
measurement to the screen. Horizontal tape or
HEADLAMP AIMING mark on the screen is for reference of vertical
M4080011000133
PRE-AIMING INSTRUCTIONS adjustment.

1. Inspect for badly rusted or faulty headlamp NOTE: Height from the floor to the centre of
assemblies. the headlamps (Reference value): 840 mm
(3) Measure the distance from the centre line of
2. These conditions must be corrected before a
the vehicle to the centre of each headlamp.
satisfactory adjustment can be made.
Transfer the measurement to the screen.
3. Inspect tyre inflation, and adjust if it is necessary. Vertical tape or mark on the screen with
4. If the fuel tank is not full, place a weight in luggage reference to the centre line of each headlamp
room of the vehicle to simulate weight of a full bulb.
tank (0.8 kg per litre).
5. There should be no other load in the vehicle other HEADLAMP ADJUSTMENT
than driver or substituted weight of approximately
CAUTION
75 kg placed in driver's position.
• Do not cover a headlamp for more than three
6. Thoroughly clean the headlamp lenses. minutes to prevent the plastic headlamp lens
7. Place the vehicle on a level floor, perpendicular to deformation.
a flat screen 10 m away from the bulb • When adjusting one headlamp beam, make
centre-marks on the headlamp lens. sure that another headlamp is off by discon-
8. Rock vehicle sideways to allow vehicle to assume necting the connector from it. When recon-
its normal position. necting the connector, make sure that the
9. Bounce the front suspension through three headlamp beam is not disturbed accidentally.
oscillations by applying the body weight to hood 1. The low-beam headlamp should project on the
or bumper. screen upper edge of the beam (cut-off).
(1)
Screen
Screen Headlamp centre line
Vertical
(2) (3) direction
Vehicle crntre
centreline
line
(3)
Horizontal
10 m direction
AC300567AB
Horizontal
In the centre
direction
of headlamps
Vertical
direction AC300658AB
AC304804 AB
2. If not the case, turn the adjusting screws to CAUTION

achieve the specified low-beam cut-off location on For the fog lamp which is not being measured,
the aiming screen. disconnect that fog lamp’s connector if possible
(V)
so that it does not illuminate while carrying out
the adjustment. Furthermore, make sure that the
Distance of Headlamp
vertical direction centre light axis does not get shifted when re-connect-
[0.69˚] ing the connector.
15˚
(H)
High intensity
zone
AC305155AB
Standard value:
(Vertical direction) 0.69° below horizontal (H)
(Horizontal direction) Position at which the Screwdriver (+)
AC301337AE
stat up point of 15° is crossed with vertical
line (V) If the value is out of the standard value, insert the
Limit: screwdriver (+) through the aiming hole on the side
Vertical direction; ± 0.29° from the standard under cover to adjust by turning the adjusting gear
value for fog lamp aiming.
Horizontal direction; ± 0.5° from the standard NOTE: Horizontal adjustment is not possible.
value In addition, the method of checking the light axis on a
screen (simple check) is given below.
FRONT FOG LAMP AIMING CHECK
M4080013000106
After setting the vehicles to the following condition, In the centre
adjust the front fog lamp aiming. of front fog lamps
• Check that the tyre inflation pressure is at the
value indicated on the tyre pressure labels.
• Set the vehicle to the unladen condition and park
it on a level surface.
• Have a single person (approximately 75 kg) sit in
the driver’s seat.
• Run the engine at a speed of 2,000 r/min to fully
charge the battery. Screen
Turn on the front fog lamps and check that the illumi-
nation is within the standard value range.
Standard value: Illuminates to within 40
metres
3m
AC305200AB
1. Place the screen so that it is directly opposite the

centre of the fog lamp at a distance of 3 metres,
and turn on the fog lamps.
REFERENCE MATERIAL
8-13
CAUTION 2. Insert the screwdriver (+) through the aiming hole
For the front fog lamp which is not being meas- on the side under cover. By turning the adjusting
ured, disconnect that fog lamp’s connector if gear for fog lamp aiming, align the cutoff line
possible so that it does not illuminate while car- (border line of the shadow temperature) with the
rying out the adjustment. Furthermore, make specified position in the figure.
sure that the light axis does not get shifted when NOTE: Horizontal adjustment is not possible.
re-connecting the connector.
Screwdriver (+)
Centre of lamp V
H
Cut-off line Vertical direction
1.15˚ (6cm)
High-luminance
zone
AC305154 AB
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - AIR BAG
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - AIR BAG

M4080016000097
WARNING
• Improper service or maintenance of any
component of the SRS and any
SRS-related component, can lead to per-
sonal injury or death to service personnel
(from inadvertent firing of the air bag) or
to the driver and passenger (from render-
ing the SRS inoperative).
• The SRS components and seat belt with
pre-tensioner should not be subjected to
heat, so remove the SRS-ECU, driver’s
and front passenger’s air bag modules,
clock spring, side air bag modules, cur-
tain air bag modules, side impact sensors
and seat belt pre-tensioner before drying
or baking the vehicle after painting.
• SRS-ECU, air bag modules, side
impact sensors, clock spring: 93°C or
more
• Seat belt pre-tensioner 90°C or more
• Service or maintenance of any SRS com-
ponent and SRS-related component must
be performed only at an authorized MIT-
SUBISHI dealer.
• MITSUBISHI dealer personnel must thor-
oughly review the chassis workshop man-
ual, and especially its GROUP 52B -
Supplemental Restraint System (SRS),
before beginning any service or mainte-
nance of any component of the SRS and
any SRS-related component.

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Mitsubishi Lancer 2006 Body Repair Manual

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LANCER/ GROUP INDEX

LANCER WAGON GENERAL . . . . . . . . . . . . . . . . . . . . . 0

TECHINICAL INFORMATION MANUAL

(PASSENGER CARS & LIGHT

Mitsubishi Motors Corporation reserves the right to

Page number Group title

+($'/$036833257 127( $VWHHOVKHHWRIYDU\LQJWKLFNQHVVWKDWLV

VEHICLE IDENTIFICATION . . . . . . . 0-2 MAJOR SPECIFICATIONS . . . . . . . . 0-3

BODY COMPONENTS. . . . . . . . . . . . 1-2 REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 1-22

MAINTENANCE, SERVICEABILITY . 1-10 SILENCER APPLICATION LOCATIONS 1-31

BODY CONSTRUCTION LOCATIONS USING URETHANE FOAM

BODY MAIN CROSS-SECTIONAL VIEWS

A (Driver's side) C Front pillar Front pillar

Side roof Front pillar

Front pillar inner Side outer panel

A (Passenger's side) D Side sill outer

Side roof rail inner Side outer panel

Front end crossmember Side outer panel

F (Drive's side) Front pillar H Rear pillar

Front pillar Front pillar

Front pillar Side outer

G Centre pillar inner J

A (Driver's side) C Front pillar Front pillar

Side roof Front pillar

Front pillar inner Side outer panel

A (Passenger's side) D Side sill outer

Side roof rail inner Side outer panel

Front end crossmember Side outer panel

F (Drive's side) Front pillar H Rear lamp

Front pillar Front pillar

Front pillar Side outer Quarter panel

Side outer Rear end Rear end

Panel positioning notch AB200202 AC

SIDE OUTER PANEL

Centre pillar outer

Front pillar outer

Side sill outer

Centre pillar outer

Front pillar outer

Side sill outer

1. Front bumper reinforcement 8. Headlamp support side panel

Fender Shield NOTE: *: A steel sheet of varying thickness that is

1. Headlamp support panel side

1. Suspension crossmember support bracket 28. Suspension crossmember bracket inner

1. Cowl top lower panel 15. Upper outer frame extension

1. Dash panel crossmember 6. Dash panel reinforcement

SIDE STRUCTURE REINFORCEMENT

Rear Deck (Sedan)

1. Rear seatback reinforcement 6. Trunk lid hinge reinforcement

Rear End Panel (Sedan)

1. Rear end panel inner 3. Rear end panel outer

1. Rear end crossmember inner

1. Roof rail front 12. Roof bow E

1. Front floor pan 9. Front floor sidemember reinforcement front (Driver’s

1. Rear floor pan 14. Toe control link bracket

1. Rear floor pan 14. Toe control link bracket

Rear Floor Sidemember Reinforcement

1. Rear floor sidemember support A

1. Rear floor sidemember support

1. Front door hinge panel 11. Rear door hinge panel

LOCATIONS USING URETHANE FOAM AND FOAM

Acoustic foam Front pillar Side outer panel

Side sill outer

I Centre pillar inner L

+($'/$036833257 127( $VWHHOVKHHWRIYDU\LQJWKLFNQHVVWKDWLV