Kia Carnival 2005 User Manual

Body Shop Manual

FOREWORD

This Body Shop Manual illustrates body structures and service procedures for the CARNIV AL/SEDONA.

This manual illustrates the replacement of major body panels, plastic parts, body dimensions, sealing treatment etc., in a systematic manner which is necessary for effective and lasting body repairs. You are encouraged to become familiar with this manual and understand each section in order to perform proper repair procedures. Keep this manual in a convenient location so that it is readily available.

All information in this manual including specifications, data and illustrations is made based on the vehicles built at the time the manual was printed.

Information regarding the removal/replacement of components not specifically covered in this manual can be found in the CARNIVAL/SEDONA Service Manual. Information regarding electrical harness routing/ connections, etc. can be found in the CARNIV AL/SEDONA Electrical T roubleshooting Manual.

The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. Kia Motors Corporation reserves the right to discontinue models at any time, or change specifications or design without notice and without incurring obligation.

CONTENTS

Title Group

General Information

Body Construction

Body Dimensions

Body Panel Repair Procedure

Body Sealing Locations

Corrosion Protection

Body Modification Tools

Plastic Parts

Kia Motors Corporation

SEOUL, KOREA

CAUTION : Severe engine and transaxle damage may result from the use of poor quality fuels and lubricants that do not meet Kia specifications. You must always use high quality fuels and lubricants that meet the specifications described on the specification section in the relevant group of the Workshop Manual.

All rights reserved. No part of this publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means without the prior written permission of Kia Motors Corporation.

IMPORTANT SAFETY NOTICE

Proper service methods and repair procedures are essential for safe, reliable operation of all motor vehicles as well as personal safety of the operator. The service procedures and descriptions in this shop manual provide general directions for a service and repair.

Procedure, techniques, tools, and parts for service including the skill of the technician vary. It is impossible to provide advice or caution as to each case in this manual. Accordingly, anyone who intends to use a replacement part, service procedure, or tool, which is not recommended by the vehicle manufacturer, must first assure thoroughly that neither their personal safety nor the safe operation of the vehicle will be first jeopardized by the replacement part, service procedure, or tool they select.

IN THIS MANUAL

WARNING :

CAUTION :

NOTE :

The following list contains some general WARNINGS that you should follow while working on a vehicle.

Always wear safety glasses for eye protection. Use safety stands whenever a procedure requires you to be under the vehicle. Make sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. Set the parking brake when working on the vehicle. If you have an automatic transaxle, set in park unless instructed otherwise for a specific operation Place supporters against the front and rear surfaces of the tires to help prevent the vehicle from moving Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide poisoning. Keep yourself and your clothing away from moving parts when the engine is running, especially the drive belts. To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. Do not smoke while working on a vehicle. To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle. When it is necessary to work under the hood, keep hands and other objects clear of the radiator fan blades! Your vehicle may be equipped with a cooling fan that may turn on, even though the ignition switch is in the OFF position. For this reason care should be taken to ensure that the radiator fan electric motor is completely disconnected when working under the hood and the engine is not running.

Remind you to be especially careful in those areas where carelessness can cause personal injury. To prevent you from making errors that could damage the vehicle as well as personal injury.

Gives you added information that will help you complete a particular procedure.

General

Information

FUNDAMENTAL PROCEDURES

VEHICLE PROTECTION..................................GI - 2

A WORD ABOUT SAFETY ...............................GI - 2

WELDING PROCEDURES ..............................GI - 3

BOD Y FRAME STRAIGHTENER.....................GI - 3

ELECTRICAL PROCEDURES ........................GI - 3

FOR BEST RESULTS

DISASSEMBLY.................................................GI - 4

PREPARATION OF ASSEMBLY .......................GI - 6

ASSEMBLY.......................................................GI - 7

RUSTPROOF TREA TMENT AFTER

ASSEMBLY.......................................................GI - 8

VEHICLE LIFT (2-SUPPORT TYPE) AND SAFETY STAND POSITIONS

...................GI - 9

JACK SUPPORT POSITIONS ..................GI - 10

BODY COLORS AND MAJOR SPECIFICATIONS

..........................................GI - 11

GI-2 GENERAL INFORMATION

FUNDAMENT AL PR OCEDURES

VEHICLE PROTECTION

1. Cover the seats before performing any procedure to keep them from getting dirty .

2. Cover all glasses, seats and mats with a heat resistant cover when welding.

BVQGI6001

3. Protect moldings, garnishes and ornaments.

A WORD ABOUT SAFETY

1. Wear the appropriate safety equipment that is necessary for the procedure being performed.

Safety glasses

Mask

Face shield

2. When welding or performing other procedures that require the use of an open flame near the fuel tank, disconnect and remove the tank and fuel pipe, and cap the pipe to prevent fuel leakage.

Ear protectors

Gloves

Safety shoes

BVQGI6002

BVQGI6003

GENERAL INFORMATION GI-3 WELDING PROCEDURES

Observe the following tips when welding.

1. Wear appropriate eye protection.

2. Carefully follow the manufacturers operating instructions for the welding machine you are using.

3. Do not weld, smoke or allow open flames around volatile chemicals, cleaners or solvents or in any area where they have just been used.

BODY FRAME STRAIGHTENER

When using a frame straightener, do not enter the area where the body is being straightened by the chain.

ELECTRICAL PROCEDURES

1. Disconnect the negative battery terminal.

2. Do not pull on wires when disconnecting electrical connectors. Be careful to hold the connector itself when disconnecting it.

3. Insert the connector until it "licks" when connecting the connector.

4. Handle all electrical components with care.

BVQGI6004

GI-4 GENERAL INFORMATION

FOR BEST RESUL TS

DISASSEMBLY

Measuring dimensions before beginning

Measure the dimensions of the damaged area according to the body dimension drawings before disassembling and repairing. Adjust dimensions with body frame adjuster if deformed.

Selecting cutting area

Select a cutting area that is easily accessible and that is prone to the least amount of distortion when welding. Select an area that would allow the new part to overlap repair area by 1.2~2.0 in (30~50 mm).

Protecting body from damage

Secure the body with clamps and jacks to prevent damage to the body when working on it.

BVQGI6005

GENERAL INFORMATION GI-5

Disassembling related parts

Use caution when removing body molding and trim from the area to be worked. Apply masking tape where needed to prevent damage to the part being removed or to the vehicle body. Before starting repairs, check if pipes, hoses or electrical components are present near damaged area.

Wire harness

Repair work area

Cutting area

BVQGI6006

GI-6 GENERAL INFORMATION PREPARATION OF ASSEMBLY

Applying spot sealer

Remove paint from the surf ace of new parts and body to be spot welded, and apply spot sealer for rustproofing.

Selecting a welding method

If the thickness of the area to be welded with the panels overlapped is greater than 0.1 in (3 mm), do plug welding using a carbon arc welding machine.

Protecting body from damage

Secure the body with clamps and jacks to prevent damage to the body when working on it.

Thicker than

0.1 in (3mm)

Machining holes for plug welding

Drill a hole of approximately 0.2~0.24 in (5~6 mm) in diameter in those areas which are not suitable for spot welding.

BVQGI6008

BVQGI6007

Adjusting a new part

The new part should be cut larger than the repair area, overlapping the repair area by 1.2~2.0 in (30~50 mm).

1.2~2.0 in

(30~50 mm)

Overlap

body side to modify

new part to modify

1.2~2.0 in

(30~50 mm)

Overlap

BVQGI6009

GENERAL INFORMATION GI-7 ASSEMBLY

Measuring dimensions before welding

When assembling a new part, assemble it according to the body dimensions given in Section 31, and start welding after checking the gaps with nearby parts.

Caution when welding

The number of welding points should be determined based on the criteria below:

Spot welding Plug welding

Increase the number of

spot welds by 30%.

Pitch:

2.0 in (50 mm)

Old part

Pitch:

1.4 in (35 mm)

Repair part

Pitch: Same number of welds as original part.

Repair part more than

0.1 in (3 mm)

BVQGI6010

Caution when spot welding

The tip of the spot welding machine should be maintained to a minimum of 0.1 in (3 mm) because it greatly affects welding strength. When possible , spot welding should be done between the existing spot welded points . Before and after spot welding, weld a test piece(test pin) of the same material as the body panel, and check the welding strength.

0.1 in

(3 mm)

Good

No good

Using a hammer and a chisel

Existing welded spots

New welded spots

0.1 in

(3 mm)

Center

diameter

Using a test piece(test pin)

Nugget diameter to be 4/5 of chip diameter

BVQGI6011

GI-8 GENERAL INFORMATION RUSTPROOF TREATMENT AFTER ASSEMBLY

Body sealing

Apply body sealer where necessary.

Applying rustproof material

Apply rustproofing material(wax, oil, etc.) behind welded area.

Applying undercoat

Apply undercoat on the body where necessary .

BVQGI6012

GENERAL INFORMATION GI-9 VEHICLE LIFT (2-SUPPORT TYPE) AND SAFETY STAND POSITIONS

1. Place the lift blocks under the support points as shown in the illustration

2. Raise the hoist a few inches and rock the v ehicle to be sure it is firmly supported.

3. Raise the hoist to full height to inspect the lift points for secure support.

Lift Block

[Front]

[Rear]

BVQGI6013

GI-10 GENERAL INFORMATION JACK SUPPORT POSITIONS

BVQGI6014

GENERAL INFORMATION GI-11 BODY COLORS AND MAJOR SPECIFICATIONS

KIA COLOR CODES

Kia code Paint color

7P J9 K5 K9 6C 7V 9B U4

PAINT MANUFACTURE CODES

Kia code

Color name Dupont

Spies

Hecker

Cherry Kiss Cocktail

Evening Sailing Gold

V elvet Indigo Blue

Crystal Blue

Clear Silver

Olive Gray

Midnight Black

White Pearl Clear White

Standox BASF

Akzo

Nobel

PPG

J9 K5 K9 6C 7V 9B U4

Cherry Kiss Cocktail

Evening Sailing Gold

V elvet Indigo Blue

Crystal Blue

Clear Silver

Olive Gray

Midnight Black

White Pearl Clear White

X3089 X3088 X3090 X3091 X1135 X2188 M0510 M7817 F2756

769042 769041 769043 769044 746556 760711

75343 744249 755719

J9 K5 K9 6C 7V 9B U4

7P J9 K5 K9 6C 7V 9B U4

KIA9322 KIA9106 KIA9546 KIA9545 KIA9742 KIA9741 KIA9411 KIA9405 KIA4004

J9 K5 K9 6C 7V 9B U4

Body

Construction

BODY COMPONENTS .................................BC - 2

ZINC-GALVANIZED STEEL PANELS ....BC - 4

HIGH STRENGTH STEEL PANELS .......BC - 6

BC-2 BODY CONSTRUCTION

BOD Y COMPONENTS

Body construction will sometimes differ depending on specifications and country of destination. Theref ore, please k eep in mind that the information contained herein is based on vehicles for general destination.

111

107

105

108

109

110

106

100

101

102

112

103

5153

104

BVQBC6001

BODY CONSTRUCTION BC-3

1. Radiator support side member assembly

2. Head lamp support panel

3. Fender mounting braket assembly

4. Radiator support side member assembly

5. Radiator support lower outer member assembly

6. Radiator upper center member assembly

7. Radiator center stay member assembly

8. Dash panel assembly

9. Dash rainforcement assembly

10. Dash lower member assembly

11. Dash lower outer member assembly

12. Dash lower outer center member assembly

13. Fender apron inner lower panel assembly

14. Fender apron inner upper panel assembly

15. Front shock absorber housing panel assembly

16. Front shock absorber housing upper panel

17. Fender apron inner front support

18. Engine mounting bracket assembly

19. Front side inner member assembly

20. Front side member inner reinforcement assembly

21. Front side member inner rear reinforcement assembly

22. Front side member outer member assembly

23. Side cross front member

24. Center floor panel

25. Front seat cross front member assembly

26. Front seat cross rear member assembly

27. Console mounting front bracket assembly

28. Console mounting rear bracket assembly

29. Center floor side member

30. Center floor side member reinforcement assembly

31. Center floor side member upper reinforcement

32. No.1 cross member reinforcement

33. No.1 cross member reinforcement

34. No.1 cross member support reinforcement

35. No.1 cross member assembly

36. No.3 cross member assembly

37. No.3 cross member assembly

38. No.3 cross member assembly

39. Side sill inner upper panel

40. Side sill inner lower panel

41. Side sill inner rear panel

42. Rail guide lower panel assembly

43. Rear floor panel

44. Rear floor extension assembly

45. Rear floor side reinforcement

46. Rear floor side panel assembly

47. Rear floor rear panel

48. Rear floor rear cross member assembly

49. Rear towing hook bracket assembly

50. Rear floor side member

51. Rear floor side member extension assembly

52. Rear floor side front reinforcement assembly

53. Rear floor side rear reinforcement assembly

54. No.4 cross member assembly

55. No.5 cross member assembly

56. No.6 cross member

57. No.6 cross gusset

58. Back panel

59. Rear transverse member

60. Rear transverse side member

61. Roof panel

62. Roof front lower rail assembly

63. Roof No.2 rail

64. Roof No.2 rail

65. Room lamp mounting bracket

66. Roof rear upper rail assembly 67 Roof rear lower rail

68. Sun roof rack front bracket assembly

69. Cowl top outer panel

70. Cowl top outer reinforcement

71. Cowl inner lower panel assembly

72. Fender panel

73. Hood outer panel

74. Hood inner panel

75. Front door outer panel

76. Front door inner panel

77. Front door quadrant channel

78. Front door reinforcement beam

79. Front door belt outer rail

80. Front door belt inner rail

81. Front door frame assembly

82. Rear door outer panel

83. Rear door inner panel

84. Rear door belt outer rail

85. Rear door belt inner rail assembly

86. Rear door outer rail

87. Rear door beam

88. Tail gate outer panel

89. Tail gate inner panel

90. Front inner upper pillar assembly

91. Side inner upper reinforcement assembly

92. Front inner lower pillar assembly

93. Center pillar inner panel assembly

94. Front seatbelt upper mounting bracket assembly

95. Front pillar inner lower reinforcement assembly

96. Sill side outer front reinforcement

97. Quarter inner front reinforcement

98. Rear side belt upper mounting reinforcement assembly

99. Quarter inner panel

100. Quarter inner belt reinforcement assembly

101. Wheel house outer panel

102. Rear wheel house inner panel assembly

103. Quarter inner rear lower extension assembly

104. D pillar reinforcement gusset assembly

105. Front side outer panel

106. Front side outer panel

107. Fender rear upper reinforcement

108. Front pillar outer upper reinforcement

109. Front pillar outer lower reinforcement

110. Front side outer panel

111. Quarter outer rear upper extension

112. Rear combination lamp housing panel

BC-4 BODY CONSTRUCTION

ZINC-GAL VANIZED STEEL PANELS

Becavanized steel panel has excellent resistance, it tis used in areas which have a high possibility of painting deficiency below.

111

112

107

106

103

101

105

108

109

110

102

BVQBC6002

BODY CONSTRUCTION BC-5

1. Radiator support side member assembly

2. Head lamp support panel

3. Fender mounting braket assembly

4. Radiator support side member assembly

5. Radiator support lower outer member assembly

6. Radiator upper center member assembly

7. Radiator center stay member assembly

8. Dash panel assembly

9. Dash rainforcement assembly

10. Dash lower member assembly

11. Dash lower outer member assembly

12. Dash lower outer center member assembly

13. Fender apron inner lower panel assembly

14. Fender apron inner upper panel assembly

15. Front shock absorber housing panel assembly

16. Front shock absorber housing upper panel

17. Fender apron inner front support

18. Engine mounting bracket assembly

19. Front side inner member assembly

20. Front side member inner reinforcement assembly

21. Front side member inner rear reinforcement assembly

22. Front side member outer member assembly

23. Side cross front member

24. Center floor panel

25. Front seat cross front member assembly

26. Front seat cross rear member assembly

27. Console mounting front bracket assembly

28. Console mounting rear bracket assembly

29. Center floor side member

30. Center floor side member reinforcement assembly

31. Center floor side member upper reinforcement

32. No.1 cross member reinforcement

33. No.1 cross member reinforcement

34. No.1 cross member support reinforcement

35. No.1 cross member assembly

36. No.3 cross member assembly

37. No.3 cross member assembly

38. No.3 cross member assembly

39. Side sill inner upper panel

40. Side sill inner lower panel

41. Side sill inner rear panel

42. Rail guide lower panel assembly

43. Rear floor panel

44. Rear floor extension assembly

45. Rear floor side reinforcement

46. Rear floor side panel assembly

47. Rear floor rear panel

48. Rear floor rear cross member assembly

49. Rear towing hook bracket assembly

50. Rear floor side member

51. Rear floor side member extension assembly

52. Rear floor side front reinforcement assembly

53. Rear floor side rear reinforcement assembly

54. No.4 cross member assembly

55. No.5 cross member assembly

56. No.6 cross member

57. No.6 cross gusset

58. Back panel

59. Rear transverse member

60. Rear transverse side member

61. Roof panel

62. Roof front lower rail assembly

63. Roof No.2 rail

64. Roof No.2 rail

65. Room lamp mounting bracket

66. Roof rear upper rail assembly 67 Roof rear lower rail

68. Sun roof rack front bracket assembly

69. Cowl top outer panel

70. Cowl top outer reinforcement

71. Cowl inner lower panel assembly

72. Fender panel

73. Hood outer panel

74. Hood inner panel

75. Front door outer panel

76. Front door inner panel

77. Front door quadrant channel

78. Front door reinforcement beam

79. Front door belt outer rail

80. Front door belt inner rail

81. Front door frame assembly

82. Rear door outer panel

83. Rear door inner panel

84. Rear door belt outer rail

85. Rear door belt inner rail assembly

86. Rear door outer rail

87. Rear door beam

88. Tail gate outer panel

89. Tail gate inner panel

90. Front inner upper pillar assembly

91. Side inner upper reinforcement assembly

92. Front inner lower pillar assembly

93. Center pillar inner panel assembly

94. Front seatbelt upper mounting bracket assembly

95. Front pillar inner lower reinforcement assembly

96. Sill side outer front reinforcement

97. Quarter inner front reinforcement

98. Rear side belt upper mounting reinforcement assembly

99. Quarter inner panel

100. Quarter inner belt reinforcement assembly

101. Wheel house outer panel

102. Rear wheel house inner panel assembly

103. Quarter inner rear lower extension assembly

104. D pillar reinforcement gusset assembly

105. Front side outer panel

106. Front side outer panel

107. Fender rear upper reinforcement

108. Front pillar outer upper reinforcement

109. Front pillar outer lower reinforcement

110. Front side outer panel

111. Quarter outer rear upper extension

112. Rear combination lamp housing panel

BC-6 BODY CONSTRUCTION

HIGH STRENGTH STEEL P ANELS

Because high strength steel panel has excellent resistance, it is used in areas which have a high posibility of painting deficiency below .

111

109

108

104

101

BVQBC6003

BODY CONSTRUCTION BC-7

1. Radiator support side member assembly

2. Head lamp support panel

3. Fender mounting braket assembly

4. Radiator support side member assembly

5. Radiator support lower outer member assembly

6. Radiator upper center member assembly

7. Radiator center stay member assembly

8. Dash panel assembly

9. Dash rainforcement assembly

10. Dash lower member assembly

11. Dash lower outer member assembly

12. Dash lower outer center member assembly

13. Fender apron inner lower panel assembly

14. Fender apron inner upper panel assembly

15. Front shock absorber housing panel assembly

16. Front shock absorber housing upper panel

17. Fender apron inner front support

18. Engine mounting bracket assembly

19. Front side inner member assembly

20. Front side member inner reinforcement assembly

21. Front side member inner rear reinforcement assembly

22. Front side member outer member assembly

23. Side cross front member

24. Center floor panel

25. Front seat cross front member assembly

26. Front seat cross rear member assembly

27. Console mounting front bracket assembly

28. Console mounting rear bracket assembly

29. Center floor side member

30. Center floor side member reinforcement assembly

31. Center floor side member upper reinforcement

32. No.1 cross member reinforcement

33. No.1 cross member reinforcement

34. No.1 cross member support reinforcement

35. No.1 cross member assembly

36. No.3 cross member assembly

37. No.3 cross member assembly

38. No.3 cross member assembly

39. Side sill inner upper panel

40. Side sill inner lower panel

41. Side sill inner rear panel

42. Rail guide lower panel assembly

43. Rear floor panel

44. Rear floor extension assembly

45. Rear floor side reinforcement

46. Rear floor side panel assembly

47. Rear floor rear panel

48. Rear floor rear cross member assembly

49. Rear towing hook bracket assembly

50. Rear floor side member

51. Rear floor side member extension assembly

52. Rear floor side front reinforcement assembly

53. Rear floor side rear reinforcement assembly

54. No.4 cross member assembly

55. No.5 cross member assembly

56. No.6 cross member

57. No.6 cross gusset

58. Back panel

59. Rear transverse member

60. Rear transverse side member

61. Roof panel

62. Roof front lower rail assembly

63. Roof No.2 rail

64. Roof No.2 rail

65. Room lamp mounting bracket

66. Roof rear upper rail assembly 67 Roof rear lower rail

68. Sun roof rack front bracket assembly

69. Cowl top outer panel

70. Cowl top outer reinforcement

71. Cowl inner lower panel assembly

72. Fender panel

73. Hood outer panel

74. Hood inner panel

75. Front door outer panel

76. Front door inner panel

77. Front door quadrant channel

78. Front door reinforcement beam

79. Front door belt outer rail

80. Front door belt inner rail

81. Front door frame assembly

82. Rear door outer panel

83. Rear door inner panel

84. Rear door belt outer rail

85. Rear door belt inner rail assembly

86. Rear door outer rail

87. Rear door beam

88. Tail gate outer panel

89. Tail gate inner panel

90. Front inner upper pillar assembly

91. Side inner upper reinforcement assembly

92. Front inner lower pillar assembly

93. Center pillar inner panel assembly

94. Front seatbelt upper mounting bracket assembly

95. Front pillar inner lower reinforcement assembly

96. Sill side outer front reinforcement

97. Quarter inner front reinforcement

98. Rear side belt upper mounting reinforcement assembly

99. Quarter inner panel

100. Quarter inner belt reinforcement assembly

101. Wheel house outer panel

102. Rear wheel house inner panel assembly

103. Quarter inner rear lower extension assembly

104. D pillar reinforcement gusset assembly

105. Front side outer panel

106. Front side outer panel

107. Fender rear upper reinforcement

108. Front pillar outer upper reinforcement

109. Front pillar outer lower reinforcement

110. Front side outer panel

111. Quarter outer rear upper extension

112. Rear combination lamp housing panel

Body

Dimensions

GENERAL

MEASUREMENT METHOD .......................BD - 2

PROJECTED DIMENSIONS ............................BD - 2

ACTUAL-MEASUREMENT DIMENSIONS......BD - 3

MEASUREMENT POINT..................................BD - 3

FRONT BODY .................................................BD - 4

SIDE BODY (FRONT) ...................................BD - 6

SIDE BODY (REAR) .....................................BD - 8

INTERIOR A .....................................................BD - 10

INTERIOR B .....................................................BD - 12

INTERIOR C .....................................................BD - 14

REAR BODY ....................................................BD - 16

UNDER BODY (PROJECTED DIMENSIONS)

UNDER BODY (STRAIGHT-LINE DIMENSIONS)

.........................................................BD - 2

...................BD - 18

............BD - 21

BD-2 BODY DIMENSIONS

GENERAL

1. Basically, all measurements in this manual are taken with a tracking gauge.

2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.

3. For measuring dimensions, both projected dimension and actual-measurement dimension are used in this manual.

MEASUREMENT METHOD

PROJECTED DIMENSIONS

1. These are the dimensions measured when the measurement points are projected into the reference plane, and are the reference dimensions used for body alterations.

2. If the length of the tracking gauge probes are adjustable, make the measurement by lengthening one probe by the amount equivalent to the difference in height of the two surfaces.

Height

Projected Dimension

BMCBD6001

BODY DIMENSIONS BD-3

ACTUAL-MEASUREMENT DIMENSIONS

1. These dimensions indicate the actual linear distance between measurement points, and are the reference dimensions for use if a tracking gauge is used for measurement.

2. Measure by first adjusting both probes to the same length (A=A')

CAUTIO

Check the probes and gauge itself to make sure there is no free play .

Actually-Measured Dimension

MEASUREMENT POINT

1. Measurements should be taken at the hole center.

Hole Center

BMCBD6003

BMCBD6002

BD-4 BODY DIMENSIONS

FRONT BODY

* These dimensions indicated in this figure are actual-measurement dimensions.

BVQBD6100

Point symbol Length(mm) Point symbol Length(mm)

A-A'

1660

G-G'

1552.1

A-B

584.4

H-H'

1273

A-B'

584.4

H-G

1562.5

B-B'

1484.8

H-G'

1562.5

C-C' D-D' E-E' F-F'

1071.1 1310.5 1104.1 1120

BODY DIMENSIONS BD-5

A,A'

BVQBD6101

Hood hinge mounting hole (ø12)

D,D'

BVQBD6104

B,B'

BVQBD6102

Fender mounting hole (ø8)

BVQBD6105

C,C'

BVQBD6103

Radiator upper member mounting hole (ø8)

BVQBD6106

Front strut mounting hole (ø14)

F,F'

BVQBD6107

Front bumper bracket mounting hole (ø9)

Transaxle bracket mounting hole

(ø12)

G,G'

BVQBD6108

Location notch

Engine bracket mounting hole

(ø18)

H,H'

BVQBD6109

Location notch

BD-6 BODY DIMENSIONS

SIDE BODY (FRONT)

* These dimensions indicated in this figure are actual-measurement dimensions.

BVQBD6200

Point symbol Length(mm) Point symbol Length(mm)

A-B

1244.9

A-E

2079.4

A-C A-D B-C C-D B-E C-E D-E

1119.4 1119.0 536.4 301.7 1005.8 1005.8 1126.2

BODY DIMENSIONS BD-7

BVQBD6201

Tooling hole (ø16)

BVQBD6204

BVQBD6202

Front fender mounting hole (ø10)

BVQBD6205

BVQBD6203

Front door hinge mounting hole

(ø13)

Front fender mounting hole (ø10)

Front door switch mounting hole (R9.2X9.2)

BD-8 BODY DIMENSIONS

SIDE BODY (REAR)

BVQBD6300

* These dimensions indicated in this figure are actual-measurement dimensions.

Point symbol Length(mm) Point symbol Length(mm) Point symbol Length(mm)

A-B

913.6

D-E

535.3

F-G

231.0

A-C

959.7

D-F

1151.5

A-D

1077

D-G

1153.1

A-E

1479.8

D-H

1327.6

B-C

1377.8

D-K

1353.2

B-D

968

E-H

1432

B-E

1000

E-K

1303.1

C-D

658.9

H-K

398.4

BODY DIMENSIONS BD-9

BVQBD6301

Rear door stopper mounting hole (ø10)

BVQBD6304

BVQBD6302

Rear door stopper mounting hole

(ø10)

BVQBD6305

BVQBD6303

Qurter glass guide mounting hole

(S6.2X8)

BVQBD6306

Rear door switch mounting hole

(ø8)

BVQBD6307

Qurter glass stopper mounting hole (ø8.5)

Side garnish mounting hole

(R9X12)

BVQBD6308

Center rail cover mounting hole (ø10)

Qurter glass stopper mounting hole (ø8.5)

BVQBD6309

Rear bumper mounting hole (ø11)

BD-10 BODY DIMENSIONS

INTERIOR A

BVQBD6400

* These dimensions indicated in this figure are actual-measurement dimensions.

Point symbol Length(mm) Point symbol Length(mm)

A-A'

1315.9

K-K'

1639.5

B-B'

1525.9

M-M'

1106.0

C-C'

1550.0

N-N'

1293.0

D-D'

1279.7

P-P'

1317.1

E-E' F-F' G-G' H-H'

1572.0 1569.2 1291.2 1593.3

+ 98 hidden pages