Ford 2006 Escape J87R Bodyshop Manual

WAR NI NG

Servicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury, property damage, and failure of servicing increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Ford-trained technicians in mind. This manual may be useful to non-Ford trained technicians, but a technician with our service-related training and experience will be at less risk when performing service operations. However, all users of this manual are expected to at least know general safety procedures.

This manual contains "Warnings" and "Cautions" applicable to risks not normally encountered in a general technician's experience. They should be followed to reduce the risk of injury and the risk that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that the "Warnings" and "Cautions" are not exhaustive. It is impossible to warn of all the hazardous consequences that might result from failure to follow the procedures.

The procedures recommended and described in this manual are effective methods of performing service and repair. Some require tools specifically designed for a specific purpose. Persons using procedures and tools which are not recommended by Ford Motor Company must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized.

The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and Ford Motor Company reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation.

Parts should be replaced with genuine Ford replacement parts or with parts which match the quality of genuine Ford replacement parts. Persons using replacement parts of lesser quality than that of genuine Ford replacement parts must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized.

Ford Motor Company is not responsible for any problems which may arise from the use of this manual. The cause of such problems includes but is not limited to insufficient service-related training, use of improper tools, use of replacement parts of lesser quality than that of genuine Ford replacement parts, or not being aware of any revision of this manual.

CONTENTS

ESCAPE Bodyshop Manual

FOREWORD

This bodyshop manual is intended for use by technicians of Authorized Ford Dealers to help them service and repair Ford vehicles. It can also be useful to owners and operators of Ford vehicles in performing limited repair and maintenance on Ford vehicles.

For proper repair and maintenance, a thorough familiarization with this manual is important, and should always be kept in a handy place for quick and easy reference.

All the contents of this manual, including drawings and specifications, are the latest available at the time of printing. As modifications affecting repair or maintenance occur, relevant information supplementary to this volume will be made available at Ford dealers. This manual should be kept up-to-date.

Ford Motor Company reserves the right to alter the specifications and contents of this manual without obligation or advance notice.

All rights reserved. No part of this book may be reproduced or used in any form or by any means, electronic or mechanical including photocopying and recording and the use of any kind of information storage and retrieval-system-without permission in writing.

Ford Motor Company

APPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN), shown on the following page.

MARCH 2006 F342–20–06C

Title

Section

GENERAL INFORMATION

DIMENSIONS

80A

CONSTRUCTION

80B

PANEL REPLACEMENT

80C

WATER-PROOF AND RUST PREVENTIVE TREATMENT

80D

PLASTIC BODY PARTS

80E

PRIMARY COLOR MIXTURE CHART FOR BODY COLORS

80F

00-00–1

GENERAL INFORMATION

SECTION

To c of S CT

GENERAL INFORMATION . . . 00-00

To c of S CT

00-00 GENERAL INFORMATION

VEHICLE IDENTIFICATION NUMBER

(VIN) CODE . . . . . . . . . . . . . . . . . . . . . . 00-00–1

VEHICLE IDENTIFICATION NUMBERS

(VIN). . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–1

HOW TO USE THIS MANUAL. . . . . . . . . 00-00–2

SERVICE PRECAUTIONS. . . . . . . . . . . . 00-00–6

EFFICIENT REMOVAL OF BODY

PANELS . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–7

INSTALLATION PREPARATIONS . . . . . . 00-00–9

EFFICIENT INSTALLATION OF

BODY PANELS. . . . . . . . . . . . . . . . . . . . 00-00–10

ANTICORROSION, SOUND INSULATION,

AND VIBRATION INSULATION . . . . . . . 00-00–13

ABBREVIATION . . . . . . . . . . . . . . . . . . . . 00-00–14

End of Toc

BM: GENERAL INFORMATION

VEHICLE IDENTIFICATION NUMBER (VIN) CODE

id000000600800

End Of Sie

VEHICLE IDENTIFICATION NUMBERS (VIN)

id000000600100

LFA CKZTNX*2 000001— LFA CLZTNX*2 000001— LFA CMZTVX*2 000001— LFA CNZTVX*2 000001— LFA YKZTNX*2 000001— LFA YLZTNX*2 000001— LFA YMZTVX*2 000001— LFA YNZTVX*2 000001—

End Of Sie

L F A C K Z T N X 7 2 1 2 3 4 5 6

Assemble Plant

Serial No.

2= FLH FAP2 Plant

Engine type

N= L3 (2.3L) V= AJ (3.0L Duratec)

Model

Gross vehicle weight and Air bags

LFA= Ford Lio Ho

World manufacturer identification

C= 4001—5000 lbs {1814—2268 kg}, with Driver, Passenger and Side air bag Y= 4001—5000 lbs {1814—2268 kg}, with Driver and Passenger air bag

Constant

Model year

6=2006, 7= 2007, 8= 2008

KZT= 4x4, Export 2.3L, 4WD, XLS, 4EAT, ABS LZT= 4x4, Export 2.3L, 4WD, XLT, 4EAT, ABS MZT= 4x4, Export 3.0L, 4WD, 4EAT, ABS NZT= 4x4, Export 3.0L, 4WD, 4EAT, ABS, S/R

aesffb00000001

00-00–2

GENERAL INFORMATION

HOW TO USE THIS MANUAL

id000000600900

Efficient Replacement of Body Panels

• This section contains information on the body panels in regard to the welding types, number of spot welds, and cut-and-join locations that are necessary for panel removal and installation.

• The type of weld and position are indicated by symbols.

• Some sections have notes concerning the operation being performed. Thoroughly read and understand the

notes before carrying out any procedures.

Example

Symbols of Panel Replacement

• The following 6 symbols are used to indicate the type of weld that is used when replacing body panels.

REAR FENDER PANEL REMOVAL

Shows operation section

Shows procedure, caution and note

BRAZE WELDING

CUT-AND-JOINT LOCATION

ROUGH CUT LOCATION

Shows number of weld

Shows welding region

Shows a cross

Shows a insulator

Shows a dimensions

Shows a cross location

Avoid cutting with a flame as the insulator (shaded) is flammable.

1.The rear fender panel and wheel house are joined with glue at the wheel arch line.

Drill the 24 weld locations indicated by (A), from the room side.

Caution

NOTE

BOTTOM SIDE 1

{9.84in}

250mm

(A)24

A-A

B-B

30mm

{1.18in}

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SYMBOL

MEANING

Spot welding

arc welding (plug welding)

spot welding

SYMBOL

MEANING

Continuous MIG welding (Cut-and-join location)

Braze welding

Rough cut location

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GENERAL INFORMATION

00-00–3

Body Dimensions (Flat-plane Dimensions)

• Flat-plane dimensions are the dimensions measured by projecting certain reference points onto a plane surface.

• When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle.

• The hypothetical lines may differ according to the vehicle model.

• The schematic diagram shows the vehicle as it is projected from the underbody.

810

{31.89}

FLAT-PLANE DIMENSIONS

FRONT FENDER INSTALLATION NUT

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00-00–4

GENERAL INFORMATION

Example

Shows vehicle section

When there are no specific indications, all of units are in millimeters (mm).

Shows outline drawing

Shows dimension

The dimensions on the left and right in regard to the center of the vehicle are different.

Shows hypothetical standard line

Shows point symbol

Point symbol

Designation

Hole diameter

or bolt or nut size mm {in}

Crossmember No,1 standard hole

Front side frame standard hole Front suspension mounting block surface hole center Front suspension mounting bolt Front frame rear standard hole

Front frame rear standard hole Rear side frame standard hole

Link bracket

Rear suspension housing

F G

I J K

Rear side frame standard hole

Shows bolt size

Shows hole diameter

Shows slot

mm {in}

UNDERBODY FLAT-PLANE DIMENSIONS

φ 16 {0.62}

M14 {0.55}

φ 80 {3.14}

Point symbol

Designation

Hole diameter

or bolt or nut

size mm {in}

φ 16 {0.62} φ 31 {1.22}

φ 12 {0.47}

Rear suspension housing

φ 12 {0.47}

φ 16 {0.62}

φ 18 {0.62}

17 × 29.5

{0.66×1.16}

ABCDE F G H I J KL

1,016

{40.00}

687

{27.05}

420

182 93 144 120

{7.17} {3.66} {5.67} {4.72}

1,030

140

760

{5.51} {2.68}

379

{16.54}

{40.55}

{29.92} {14.92}

{25.75}

654

1,084 {42.84}

579

{22.80}

479

{18.86}

436

{17.17}

445

512

660

1,043

666

{17.52}

{20.16}

{25.98}

{41.06}

{26.22}

1,106 {43.54}

1,164

543

485

484

{21.37}

{19.05}

478

1,073 {37.91}

455

{17.91}

469

{18.46}

760

605

650

{29.92}

{23.82}

{25.59}

650

{45.83}

{25.59}

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GENERAL INFORMATION

00-00–5

Body Dimensions (Straight-line Dimensions)

• Straight-line dimensions are the actual dimensions between two standard points.

• When there are no specific indications, the standard points and dimensions are symmetrical in regard to the

center of the vehicle.

Example

817

FRONT FENDER INSTALLATION NUT

STRAIGHT-LINE DIMENSIONS

{32.17}

acxuub00000035

ROOM STRAIGHT-LINE DIMENSIONS (2)

Shows vehicle section

Shows dimension location

Shows outline drawing

Shows point symbol

Shows point indication Without apostrophe:RH

With apostrophe:LH

Shows details of the standard point location

Shows position and shape of the points

Shows dimension

No indication are shown within the outline drawing.

Measured

location

Dimension mm {in}

1 2 3 4 5 6 7

1,184 {46.61} 1,064 {41.89}

919 {36.18} 690 {27.17}

1,185 {46.65}

901 {35,47} 607 {23.90}

Measured

location

Dimension mm {in}

9 10 11

B-B'

C-C'

D-D'

1,667 {65.63} 1,672 {65.83} 1,037 {40.83}

1,290 {50.79} 1,208 {47.56}

1,463 {57.60}

1,642 {64.65}

B-B

C-C

D-D

H-H

G-G

F-F

E-E

E. E

I - I

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00-00–6

GENERAL INFORMATION

Symbols of Body Dimensions

• The following 8 symbols are used to indicate the standard points.

End Of Sie

SERVICE PRECAUTIONS

id000000600200

Arrangement of Workshop

• Arrangement of the workshop is important for safe and efficient work.

Safety Precautions

• Protective head covering and safety shoes should always be worn. Depending upon the nature of the work, gloves, safety glasses, ear protectors, face shield, etc., should also be used.

Vehicle Protection

• Use seat covers and floor covers.

• Use heat-resistant protective covers to protect glass areas and seats from heat or sparks during welding.

• Protect items such as moldings, garnishes, and

ornaments with tape when welding.

Remove Dangerous Articles

• Remove the fuel tank before using an open flame in that area. Plug connection piping to prevent fuel leakage.

SYMBOL

MEANING

SYMBOL

MEANING

Center of circular hole

Center elliptical hole

Notch

Panel seam, bead, etc.

Bolt tip

(arrow only)

Center of rectangular-shaped hole

Edge of rectangular-shaped hole

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Welding glasses

Ear protectors

Weldlng gloves

Cotton gloves

Dust mask Safety glasses

Face shield

Safety shoes

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GENERAL INFORMATION

00-00–7

Use of Pulling Equipment

• When using pulling equipment, keep away from the pulling area and use safety wires to prevent accidents.

Prevent Short Circuits

• Turn the ignition switch to the LOCK position.

• Disconnect the battery cables.

• Securely connect the welding machine ground

near the welding area.

End Of Sie

EFFICIENT REMOVAL OF BODY PANELS

id000000600300

Body Measurements

• Before removal or rough-cutting, first measure the body at and around the damaged area against the standard reference dimension specifications. If there is deformation, use frame repair equipment to make a rough correction.

Safety wires

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Battery cable

acxuub00000042

Ground

acxuub00000043

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00-00–8

GENERAL INFORMATION

Prevention of Body Deformation

• Use a clamp or a jack for removal and reinforce at and around the rough-cutting location to prevent deforming of the body.

Selection of Cut-and-join Locations

• For parts where complete replacement is not feasible, careful cutting and joining operations should be followed. If the location to be cut is a flat area where there is no reinforcement, the selected cutting location should be where the welding distortion will be minimal.

Removal of Associated Parts

• Protect moldings, garnishes, and ornaments with tape when removing associated parts.

Rough Cutting of Damaged Panel

• Verify that there are no parts (such as pipes, hoses, and wiring harness) nearby or on the opposite side of a panel which could be damaged by heat.

• For cut-and-join areas, allow for an overlap of 30—50 mm {1.18—1.97 in} and then rough-cut the damaged panel.

End Of Sie

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Wiring harness

Rough cut location

Cut-and-join location

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GENERAL INFORMATION

00-00–9

INSTALLATION PREPARATIONS

id000000600400

Rough Cutting of New Parts

• For cut-and-join areas, allow for an overlap of 30—50 mm {1.18—1.97 in} with the remaining area on the body side and then rough-cut the new parts.

Determination of Welding Method

• If the total thickness at the area to be welded is 3 mm {0.12 in} or more, use a CO2 gas shielded-arc welder to make the plug welds.

Making Holes for CO

Arc Welding

• For places that cannot be spot welded, make a hole for CO

arc welding using a punch or drill as follows.

(mm {in})

• Grind the shaded section indicated in the diagram below and create a hole in the part where the 3— 4 plates are put together. Also, weld the plates together tightly so that gaps do not develop.

Over lap

Body side rough cut location

New part rough cut location

30-50mm{1.18-1.97in}

acxuub00000048

3mm {0.12in}or more

acxuub00000049

Panel thickness (ø) Hole diameter (ø)

0.60—0.90 {0.02—0.03} 5 {0.19}

0.91—1.20 {0.04—0.05} 6 {0.23}

1.21—1.80 {0.051—0.07} 8 {0.31}

1.81—4.50 {0.071—0.17} 10 {0.39}

10mm{0.39in}

Outer panel

Middle panel

Inner panel

30°

acxuub00000050

00-00–10

GENERAL INFORMATION

Application of Weld-through Primer

• For treatment against corrosion, remove the paint grease, and other material from the portion of new part and body to be welded, and apply weld-through primer.

End Of Sie

EFFICIENT INSTALLATION OF BODY PANELS

id000000600500

Checking Preweld Measurements And Watching

• Align to the standard reference dimensions, based upon the body dimensions illustration, so that new parts are installed in the correct position.

Welding Notes

• For the number of weld points, welding should be performed in accordance with the following reference standards.

acxuub00000068

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Spot welding Original weld

If 3mm {0.12in} or more

Original number of welds x 1.3 or more

CO2 arc welding Original spot weld

Repair weld

Original number of welds or more

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GENERAL INFORMATION

00-00–11

Spot Welding Notes

• The shape of the spot welder tip is D=(2×t)+3. If the upper panel thickness is different from that of the under panel, adjust to the thinner one.

• Because the weld strength is affected by the shape of the spot welder tip, the optimum condition of the tip should always be maintained.

• Spot welds should be made at points other than the originally welded points.

• Before spot welding, make a trial weld using the same material as the body panel to check the weld strength.

70 - 120°

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Test piece method

Nugget diameter :4/5 of tip

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00-00–12

GENERAL INFORMATION

Checking Weld Strength

• Installation locations of the engine, chassis, and seat belts are designated as important safety locations for weld strength. Check weld strength by driving a chisel between the panels at every fourth or fifth weld spot, and every tenth regular weld location.

• Drive the chisel between the panels according to the number of panels as shown below.

• To determine weld strength, drive the chisel between the panel and check whether the panels come apart. If the panels come apart, make another weld near the original weld.

• Restore the shape of the checked area.

End Of Sie

Chisel dimensions

25mm {0.98in}

8mm{0.31in}

{0.20in}

20°

Weld location

Within 5mm

acxuub00000057

Two panels

Weld location

Three panels

Weld location

One location

Two location

Four panels

Weld location

Three location

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GENERAL INFORMATION

00-00–13

ANTICORROSION, SOUND INSULATION, AND VIBRATION INSULATION

id000000600600

Body Sealing

• Apply body sealer where necessary.

• For locations where application of body sealer is

difficult after installation, apply it before installation.

Application of Undercoating

• Apply an undercoat to the required location of the body.

Application of Rust Inhibitor

• Apply rust inhibitor (wax, oil, etc.) to the back of the welded areas.

Application of Floor Silencer

• Apply floor silencer by heating with an infrared ray lamp.

End Of Sie

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00-00–14

GENERAL INFORMATION

ABBREVIATION

id000000600700

End Of Sie

CM Control module Ctr Center DSC Dynamic stability control Fr Fron t HU Hydraulic unit LH Left M Metallic MC Mica RH Right Rr Rear

09-80A–1

BODY & ACCESSORIES

SECTION

80A

To c of S CT

BODY STRUCTURE

[CONSTRUCTION] . . . . . . . . 09-80A

BODY STRUCTURE[PANEL

REPLACEMENT]. . . . . . . . . . 09-80B

BODY STRUCTURE

[WATER-PROOF AND RUST

PREVENTIVE] . . . . . . . . . . . . 09-80C

BODY STRUCTURE

[DIMENSIONS] . . . . . . . . . . . . 09-80D

BODY STRUCTURE

[PLASTIC BODY PARTS]. . . . 09-80E

BODY STRUCTURE

[PRIMARY COLOR MIXTURE CHART FOR

BODY COLOS] . . . . . . . . . . . . 09-80F

To c of S CT

09-80A BODY STRUCTURE [CONSTRUCTION]

BODY COMPONENTS CONSTRUCTION

[CONSTRUCTION] . . . . . . . . . . . . . . . . 09-80A–2

End of Toc

BM: CONSTRUCTION

09-80A–2

BODY STRUCTURE [CONSTRUCTION]

BODY COMPONENTS CONSTRUCTION[CONSTRUCTION]

id098007739700

R.H.D. MODELS

atraab00000004

BODY STRUCTURE [CONSTRUCTION]

09-80A–3

80A

x:Applied

-:Not applied

No. Part Name High- tension steel Rust proof steel

Thickness

(mm) {in}

1 Bonnet x x 0.70 {0.028} 2 Shroud upper panel - - 0.90 {0.035} 3 Lamp bracket - x 1.20 {0.047} 4 Shroud side stay x x 1.20 {0.047}

5 Front bumper bracket

RH x - 2.00 {0.079}

LH x - 2.30 {0.091} 6 Bonnet lock stay - x 1.00 {0.039} 7 Crossmember No.1 (front) - x 1.00 {0.039} 8 Crossmember No.1 (rear) - x 1.00 {0.039} 9 Cross side reinforcement x x 2.30 {0.091}

10 Hook reinforcement

RH x - 2.00 {0.079}

LH x - 1.40 {0.055}

11 Front side frame (outer) x x 1.60 {0.063} 12 Frame reinforcement - x 1.40 {0.055} 13 Front side frame (inner) x x 1.60 {0.063} 14 Apron reinforcement (front) - - 1.00 {0.039} 15 Wheel apron panel (front) - x 0.70 {0.028} 16 Apron reinforcement - - 0.80 {0.031} 17 Suspension housing (upper) x x 2.90 {0.114} 18 Torque box - x 1.20 {0.047} 19 Front frame (rear) - x 2.30 {0.091} 20 Dash lower panel - - 0.75 {0.030} 21 Cowl upper plate x x 1.20 {0.047} 22 Dash upper panel - - 0.70 {0.028} 23 Cowl panel - x 0.70 {0.028} 24 Torque box reinforcement - x 1.20 {0.047} 25 Cowl side reinforcement - x 1.40 {0.055} 26 Cowl side panel - x 0.70 {0.028} 27 Hinge pillar (inner) - - 1.00 {0.039} 28 Hinge pillar reinforcement x x 1.20 {0.047} 29 Front pillar (inner) x - 1.00 {0.039} 30 Side sill reinforcement - x 1.00 {0.039} 31 Center pillar reinforcement x - 1.60 {0.063} 32 Center pillar (inner) - - 1.20 {0.047}

33 Front pillar reinforcement

RH x - 2.00 {0.079}

LH x - 1.40 {0.055}

34 Roof rail (inner) x - 1.00 {0.039} 35 Rear pillar (inner) - x 0.65 {0.026} 36 C-pillar reinforcement x - 1.00 {0.039} 37 Corner plate - x 1.00 {0.039} 38 Rear pillar reinforcement - - 0.80 {0.031} 39 Rear end panel - - 0.70 {0.028} 40 Front header - - 0.70 {0.028} 41 Roof panel - - 0.75 {0.030} 42 Roof reinforcement - - 0.80 {0.031} 43 Rear header - - 0.70 {0.028} 44 Front fender panel x x 0.70 {0.028} 45 Side frame (outer) - x 0.70 {0.028} 46 Rear end side member - x 0.80 {0.031} 47 Rear pillar (outer) - x 0.80 {0.031} 48 Front door x x 49 Rear door x x -

09-80A–4

BODY STRUCTURE [CONSTRUCTION]

50 Side sill (inner) x x 2.00 {0.079} 51 Front B frame x x 1.40 {0.055} 52 Crossmember No.3 - - 2.00 {0.079} 53 Crossmember No.4 x x 1.40 {0.055} 54 Crossmember No.2 - - 0.80 {0.031} 55 Front floor pan - - 0.80 {0.031} 56 Crossmember No.2.5 - - 0.80 {0.031} 57 Crossmember No.3 (upper) - - 0.80 {0.031} 58 Seat bracket - - 0.70 {0.028} 59 Rear side frame x x 1.40 {0.055} 60 Hook bracket x x 1.20 {0.047} 61 Wheel house panel - x 0.70 {0.028} 62 Rear floor pan - - 0.65 {0.026} 63 Crossmember No.5 - - 0.65 {0.026} 64 Rear bumper bracket x x 1.40 {0.055} 65 Liftgate - x -

No. Part Name High- tension steel Rust proof steel

Thickness

(mm) {in}

BODY STRUCTURE [CONSTRUCTION]

09-80A–5

80A

L.H.D. MODELS

atraab00000005

09-80A–6

BODY STRUCTURE [CONSTRUCTION]

x:Applied

-:Not applied

No. Part Name High- tension steel Rust proof steel

Thickness

(mm) {in}

1 Bonnet x x 0.70 {0.028} 2 Shroud upper panel - x 0.90 {0.035} 3 Lamp bracket - x 1.20 {0.047} 4 Shroud side stay x x 1.20 {0.047} 5 Front bumper bracket x - 2.30 {0.091} 6 Bonnet lock stay - x 1.00 {0.039} 7 Crossmember No.1 (front) - x 1.00 {0.039} 8 Crossmember No.1 (rear) - x 1.00 {0.039}

9 Cross side reinforcement x - 2.30 {0.091} 10 Hook reinforcement x - 1.40 {0.055} 11 Front side frame (outer) x x 1.60 {0.063} 12 Frame reinforcement - x 1.40 {0.055} 13 Front side frame (inner) x x 1.60 {0.063} 14 Apron reinforcement (front) - x 1.00 {0.039} 15 Wheel apron panel (front) - x 0.70 {0.028} 16 Apron reinforcement - x 0.80 {0.031} 17 Suspension housing (upper) x x 2.60 {0.102} 18 Torque box - x 1.20 {0.047} 19 Front frame rear - x 2.30 {0.091} 20 Dash lower panel - x 0.75 {0.030} 21 Cowl upper plate x x 1.20 {0.047} 22 Dash upper panel - x 0.70 {0.028} 23 Cowl panel - x 0.70 {0.028} 24 Torque box reinforcement - x 1.20 {0.047} 25 Cowl side reinforcement - - 1.40 {0.055} 26 Cowl side panel - x 0.70 {0.028} 27 Hinge pillar (inner) - - 1.00 {0.039} 28 Hinge pillar reinforcement x x 1.20 {0.047} 29 Front pillar (inner) x - 1.00 {0.039} 30 Side sill reinforcement - x 1.00 {0.039} 31 Center pillar reinforcement x - 1.60 {0.063} 32 Center pillar (inner) - - 1.20 {0.047} 33 Front pillar reinforcement x - 1.40 {0.055} 34 Roof rail (inner) x - 1.00 {0.039} 35 Rear pillar (inner) - x 0.70 {0.028} 36 C-pillar reinforcement x - 1.00 {0.039} 37 Corner plate - x 1.00 {0.039} 38 Rear pillar reinforcement - - 0.80 {0.031} 39 Rear end panel - - 0.70 {0.028} 40 Front header - - 0.70 {0.028} 41 Roof panel - - 0.75 {0.030} 42 Roof reinforcement - - 0.80 {0.031} 43 Rear header - - 0.70 {0.028} 44 Front fender panel x x 0.70 {0.028} 45 Side frame (outer) - x 0.70 {0.028} 46 Rear end side member - x 0.80 {0.031} 47 Rear pillar (outer) - x 0.80 {0.031} 48 Front door x x 49 Rear door x x 50 Side sill (inner) x x 2.00 {0.079} 51 Front B frame x x 1.40 {0.055} 52 Crossmember No.3 - - 2.00 {0.079}

BODY STRUCTURE [CONSTRUCTION]

09-80A–7

80A

End Of Sie

53 Crossmember No.4 x x 1.40 {0.055} 54 Crossmember No.2 - - 0.80 {0.031} 55 Front floor pan - x 0.65 {0.026} 56 Crossmember No.2.5 - - 0.80 {0.031} 57 Crossmember No.3 (upper) - - 0.80 {0.031} 58 Seat bracket - - 0.70 {0.028} 59 Rear side frame x x 1.40 {0.055} 60 Hook bracket x x 1.20 {0.047} 61 Wheel house panel - x 0.70 {0.028} 62 Rear floor pan - x 0.65 {0.026} 63 Crossmember No.5 - x 0.65 {0.026} 64 Rear bumper bracket x - 1.40 {0.055} 65 Rain rail - x 0.70 {0.028} 66 Liftgate - x -

No. Part Name High- tension steel Rust proof steel

Thickness

(mm) {in}

BODY STRUCTURE [PANEL REPLACEMENT]

09-80B–1

80B

09-80B BODY STRUCTURE [PANEL REPLACEMENT]

RADIATOR SHROUD PANEL

COMPONENT REMOVAL

[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–2

RADIATOR SHROUD PANEL

COMPONENT INSTALLATION

[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–2

CROSSMEMBER No.1 REMOVAL

[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–3

CROSSMEMBER No.1 INSTALLATION

[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–3

APRON REINFORCEMENT AND COWL

SIDE REINFORCEMENT REMOVAL

[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–4

APRON REINFORCEMENT AND COWL

SIDE REINFORCEMENT INSTALLATION[PANEL

REPLACEMENT]. . . . . . . . . . . . . . . . . . 09-80B–5

WHEEL APRON PANEL

COMPONENT REMOVAL

[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–6

WHEEL APRON PANEL COMPONENT

INSTALLATION[PANEL

REPLACEMENT]. . . . . . . . . . . . . . . . . . 09-80B–7

FRONT SIDE FRAME COMPONENT

REMOVAL[PANEL

REPLACEMENT]. . . . . . . . . . . . . . . . . . 09-80B–8

FRONT SIDE FRAME COMPONENT

INSTALLATION[PANEL

REPLACEMENT]. . . . . . . . . . . . . . . . . . 09-80B–9

FRONT SIDE FRAME

(PARTIAL CUTTING) REMOVAL

[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–10

FRONT SIDE FRAME

(PARTIAL CUTTING) INSTALLATION

[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–11

FRONT FRAME (REAR) REMOVAL

[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–12

FRONT FRAME (REAR) INSTALLATION

[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B–13

FRONT PILLAR REMOVAL[PANEL

REPLACEMENT]. . . . . . . . . . . . . . . . . . 09-80B–14

FRONT PILLAR INSTALLATION

[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–16

CENTER PILLAR REMOVAL

[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–18

CENTER PILLAR INSTALLATION

[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–19

SIDE SILL PANEL REMOVAL

[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–20

SIDE SILL PANEL INSTALLATION

[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–21

REAR FENDER PANEL REMOVAL

[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–22

REAR FENDER PANEL INSTALLATION

[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–23

REAR END PANEL AND

CROSSMEMBER No.5 REMOVAL

[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–24

REAR END PANEL AND

CROSSMEMBER No.5 INSTALLATION

[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–25

REAR PILLAR (OUTER) AND REAR

PILLAR REINFORCEMENT REMOVAL

[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–26

REAR PILLAR (OUTER) AND REAR

PILLAR REINFORCEMENT INSTALLATION[PANEL

REPLACEMENT] . . . . . . . . . . . . . . . . . .09-80B–27

REAR FLOOR PAN REMOVAL

[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–28

REAR FLOOR PAN INSTALLATION

[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–29

REAR SIDE FRAME

(PARTIAL CUTTING) REMOVAL

[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–30

REAR SIDE FRAME

(PARTIAL CUTTING) INSTALLATION

[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–30

ROOF PANEL REMOVAL

[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B–31

ROOF PANEL INSTALLATION[PANEL

REPLACEMENT] . . . . . . . . . . . . . . . . . .09-80B–32

End of Toc

BM: RADIATOR SHROUD PANEL

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Specifications and Main Features

Frequently Asked Questions

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