Mitsubishi Grandis 2004 User Manual
0-1
GROUP 0
GENERAL
CONTENTS
VEHICLE IDENTIFICATION . . . . . . . 0-2 MAJOR SPECIFICATIONS . . . . . . . . 0-2
VEHICLE IDENTIFICATION
GENERAL
0-2
VEHICLE IDENTIFICATION
M4000001000264
MODELS
MAJOR SPECIFICATIONS
M4000003000174
Model code Engine model Price
class
Transmission model Fuel supply
system
NA4W LNUYL6/R6 4G69-SOHC-MIVEC
(2,378 mL)
GLX F5M42 <2WD, 5M/T> MPI
LRUYL6/R6 F4A4B <2WD, 4A/T with sport mode>
LNHYL6/R6 F5M42 <2WD, 5M/T>
LRHYL6/R6 F4A4B <2WD, 4A/T with sport mode>
Item NA4W
LNUYL6/R6LNHYL6/R6LRUYL6/R6LRHYL6/
R6
Vehicle
dimension mm
Overall length 4,765
Overall width 1,795
Overall height Without roof rails
1,655/1,665
*1
With roof rails
1,690/1,700
*1
Wheelbase 2,830
Track Front 1,550
Rear 1,555
Front overhang 900
Rear overhang 1,035
Ground clearance 155
Vehicle
wheel
alignment
Front Toe-in (at the centre of tyre tread) mm 0 ± 3
Toe angle (per wheel) 0°00' ± 08'
Camber
*3
0°00' ± 30'
Caster
*3
2°46' ± 1°00', 2°54' ± 1°00'
*1
Kingpin inclination angle
13°12' ± 1°30', 12°54' ± 1°30'
*1
Rear Toe-in (at the centre of tyre tread) mm 3 ± 2
Toe angle (per wheel) 0°08' ± 05'
Camber
*3
-0°45' +45'/-15', -0°05' ± 30'
*1
Wheels and tyres Tyre size
215/60 R16 95H, 215/55 R17 94V
*2
Wheel size
16 × 6 1/2JJ, 17 × 7JJ
*2
Offset mm 46
MAJOR SPECIFICATIONS
GENERAL
0-3
NOTE: .
*1
: Vehicles with high ground suspensions <LH drive vehicles>.
*2
: Vehicles with aluminium wheels.
*3
: Difference between right and left wheels must be less than 30'.
1-1
GROUP 1
BODY
CONSTRUCTION
CONTENTS
BODY COMPONENTS. . . . . . . . . . . . 1-2
BODY MAIN CROSS-SECTIONAL VIEWS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
MAINTENANCE, SERVICEABILITY . 1-6
BODY CONSTRUCTION CHARACTERISTICS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
FRONT BODY. . . . . . . . . . . . . . . . . . . . . . . 1-7
SIDE BODY. . . . . . . . . . . . . . . . . . . . . . . . . 1-12
REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 1-14
ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 1-16
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
SILENCER APPLICATION LOCATIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
LOCATIONS USING URETHANE FOAM AND
FOAM MATERIAL . . . . . . . . . . . . . . . 1-21
STIFFENER AND DAMP SHEET
APPLICATION LOCATIONS . . . . . . . 1-22
BODY COMPONENTS
BODY CONSTRUCTION
1-2
BODY COMPONENTS
M4010001000221
AB301830
AB
1
2
3*
4
5
6
7
8*
9*
10*
11*
12
13
14
15
16
17
18
19
20
21
22
23
24
25*
26
27
28
29
30
31
41
51
61
71*
72
73
74*
75
76
77
78
70
62
63
64
65
66
67
68
69
60
52
53
54
55
56
57
58
59
50
40
42
43
44
45
46
47
48
49
32
33
34
35
36
37
38
39
79
80
81
82
84
85
86
83
: High-tensile steel panels (*: Indicates 590MPa-high-tensile steel panels.)
: Anti-corrosion steel panels
1. Front end crossmember
2. Hood lock stay
3. Front end beam
4. Front end upper bar
5. Front upper bar side
6. Headlamp support brace upper
BODY COMPONENTS
BODY CONSTRUCTION
1-3
7. Dash panel extension
8. Front floor sidemember
9. Front floor sidemember reinforcement
10. Front sidemember inner
11. Front sidemember outer
12. Headlamp bracket
13. Front fender shield
14. Spring house panel
15. Front upper frame inner
16. Front upper frame outer
17. Dash panel crossmember upper
18. Dash panel
19. Upper frame extension
20. Front deck
21. Deck crossmember
22. Guide bracket
23. Front pillar inner lower
24. Front pillar reinforcement outer lower
25. Side sill reinforcement
26. Centre pillar reinforcement outer
27. Centre pillar inner
28. Front pillar reinforcement outer upper
29. Front pillar inner upper
30. Hood inner panel
31. Hood outer panel
32. Front door panel inner
33. Front door side door beam
34. Front door panel outer
35. Rear door panel inner
36. Rear door side door beam
37. Rear door panel outer
38. Roof panel
39. Front roof rail
40. Roof bow A
41. Roof bow B
42. Roof bow C
43. Roof bow D
44. Roof bow E
45. Rear roof rail
46. Tailgate panel inner
47 Tailgate panel outer
48 Quarter extension inner
49. Quarter inner panel
50. Roof reinforcement centre
51. Roof side rail inner
52 Rear wheel house inner panel
53. Shield plate front
54. Shield plate rear
55 Rear pillar reinforcement outer
56. Gate pillar reinforcement
57. Quarter extension outer
58 Fuel filler door panel
59. Side outer panel
60. Rear end outer panel
61 Rear end inner panel
62 Quarter inner extension lower
63. Seat pan reinforcement
64. Rear floor side pan
65 Rear floor side member rear extension
66. Rear floor crossmember D
67. Rear floor sidemember
68. Rear floor crossmember C
69. Rear floor crossmember B
70. Front stringer
71. Rear floor crossmember A
72. Front floor crossmember rear
73. Front floor pan
74. Front floor side sill
75. Front fender
76. Front floor crossmember front centre
77. Buttery tray stay
78. Buttery bracket
79. Buttery tray
80. Foot rest bracket
81. Front floor crossmember front
82. Back bone reinforcement
83. Rear floor pan
84. Front fender bracket
85. Front fender bracket lower
86. Front floor side sill inner front
BODY MAIN CROSS-SECTIONAL VIEWS
BODY CONSTRUCTION
1-4
BODY MAIN CROSS-SECTIONAL VIEWS
M4010002000246
AB300191
AD
A
B
D
E
C
F
AB300345
AC
A
Front end
crossmember lower
Front end
crossmember upper
Front end crossmember
reinforcement
AB300343
AC
B
Roof panel
Over head console bracket
Front roof rail inner
AB300344
AC
C
Side outer panel
Front pillar
reinforcement outer upper
Side roof
rail inner
AB300346
AC
D
Centre pillar
reinforcement outer
Seat belt anchor
reinforcement
Centre pillar inner
Side outer
panel
AB300347
AD
Front floor
side sill
inner front
Side outer panel
Front pillar
reinforcement
bulkhead lower
Front door hinge
reinforcement lower
E
Front floor side sill
reinforcement upper
AB300348
AC
Side outer panel
Front floor
side sill inner
Side sill
reinforcement front
Side sill reinforcement
F
BODY MAIN CROSS-SECTIONAL VIEWS
BODY CONSTRUCTION
1-5
AB300192
AD
G
H
I
J
K
L
AB300349
Front pillar
inner upper
Front pillar reinforcement
outer upper
Side outer panel
AC
G
Front pillar support
(Drivers side)
AB300351
Seat belt reinforcement
rear pillar
Side outer
panel
Rear pillar reinforcement
H
AE
Quarter inner
panel
AB300352
Side
outer panel
Quarter inner panel
Gate pillar
reinforcement
Quarter outer
extension
AC
Quarter inner
extension upper
I
AB300350
Rear roof rail outer
Rear roof
rail inner
Roof panel
AC
J
AB300353
AC
Side outer panel
Quarter inner panel
K
Rear wheel house inner
front panel
AB300354
Rear floor pan
Rear end panel
inner
Rear end
panel outer
Tailgate striker
reinforcement
AC
L
MAINTENANCE, SERVICEABILITY
BODY CONSTRUCTION
1-6
MAINTENANCE, SERVICEABILITY
M4010003000238
SIDE STRUCTURE
A panel positioning notch has been added on the
door opening to improve assembling workability
when replacing the panel.
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.
AB301701
AB
Panel positioning notch
AB301702
AB
AB301703
Quarter outer
Floor side sill outer
Centre pillar outer
Front pillar outer
AB
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
1-7
BODY CONSTRUCTION CHARACTERISTICS
FRONT BODY
M4010010000263
HEADLAMP SUPPORT
• A front end beam with a large cross section has
been adopted to improve safety upon impact.
• The bolt-on front end beam, bolt-on hood lock
stay and bolt-on front end upper bar are used to
improve maintainability.
FENDER SHIELD
• The front frame structure is supported in three
directions by the front floor side members with a
large section, dash braces and dash upper
crossmember (dash panel area) to improve body
rigidity.
• An uneven thickness steel sheet* in which the
sheet thickness is thicker in the forward part of
the vehicle was employed for the front side
member reinforcement to ensure safety upon
impact and improve body rigidity.
NOTE: *: A steel sheet of varying thickness that is
welded into one steel sheet.
AB301705
AB
1
2
3
4
5
9
8
7
6
10
11
1. Front end beam
2. Hood lock stay
3. Front end upper bar
4. Front end crossmember upper
5. Headlamp support brace lower
6. Front end crossmember brace
7. Shipping bracket
8. Front end crossmember reinforcement
9. Front No2 crossmember pipe
10. Shipping reinforcement
11. Front end crossmember lower
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
1-8
The front part of the front side member has octagonal
section that efficiently absorbs energy upon impact.
The coupling between the cowl tops with a large
cross section and the spring house brackets has
been strengthened to heighten body rigidity of the
suspension assembling support area and improve
driving stability.
AB301677
AB
Light side
Right side
A
B
1
10
4
3
5
6
9
2
3
5
8
1
4
6
7
8
7
11
10
11
12
1. Front sidemember
2. Engine mount reinforcement (Right side)
3. Headlamp bracket
4. Front end upper bar side
5. Front fender shield
6. Front upper frame outer
7. Upper frame bulkhead front
8. Front upper frame inner
9. Power steering reservoir tank bracket (Right side)
10. Spring house bracket
11. Spring house panel
12. Relay box bracket (Left side)
AB301688
AB
A
Front sidemember
inner
Front sidemember
outer
AB301689
AB
B
Spring house
bracket
Cowl top
panel inner
Cowl top
panel outer
Spring house
panel
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
1-9
FRONT SIDEMEMBER REINFORCEMENT
AB302050
AB
Right side
1
2
3
4
5
7
8
9
10
11
12
13
14
15
16
19
20
27
22
6
29
25
28
26
21
30
23
24
18
17
AB300245
AC
A
B
3
9
19
15
12
25
4
5
2
18
27
17
1. Front sidemember inner
2. Front sidemember inner reinforcement front
3. Pipe support front
4. Engine mounting bulkhead rear
5. Engine mounting bulkhead front
6. Headlamp support brace upper
7. Brake hose bracket
8. Front sidemember outer
9. Kick up reinforcement
10. Dash brace
11. Accel stopper bracket (R.H. drive vehicles)
12. Front floor side sill inner reinforcement upper
13. Hood opener bracket (R.H. drive vehicles)
14. Front floor side sill inner front
15. Front floor side sill inner reinforcement lower
16. Dash panel extension
17. Front floor sidemember reinforcement upper
18. Front floor sidemember reinforcement middle (R.H.
drive vehicles)
19. Front floor sidemember reinforcement
20. Front floor sidemember
21. Suspension crossmember bracket rear
22. Dash crossmember extension lower
23. Front sidemember brace lower
24. Pipe nut
25. Pipe support rear
26. Accel pedal bracket (R.H. drive vehicles)
27. Stay reinforcement
28. Dash crossmember upper reinforcement extension
(R.H. drive vehicles)
29. Dash crossmember extension upper
30. Suspension crossmember bracket front
AB301690
AB
A
1
8
4
2
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
1-10
AB302054
AB
B
1
9
8
19
3
10
AB302049
Light side
1
2
3
4
6
9
10
11
12
13
14
15
16
17
18
20
22
23
24
25
26
27
AB
28
29
30
31
33
32
8
7
5
19
21
AB302053
A
B
AB
18
4
10
9
30
31
20
13
17
5
7
1. Dash crossmember extension lower
2. Suspension crossmember bracket rear
3. Front floor sidemember
4. Front floor sidemember reinforcement
5. Front floor sidemember reinforcement upper
6. Dash panel extension
7. Front floor sidemember reinforcement middle (L.H.
drive vehicles)
8. Dash crossmember upper reinforcement extension
(L.H. drive vehicles)
9. Front floor side sill inner reinforcement lower
10. Front floor side sill inner reinforcement upper
11. Dash brace
12. Front floor side sill inner front
13. Kick up reinforcement
14. Brake house bracket
15. Headlamp support brace upper
16. Front sidemember outer
17. Towing reinforcement
18. Transmission mounting reinforcement
19. Front sidemember outer reinforcement (L.H. drive
vehicles)
20. Pipe support front
21. Front sidemember inner reinforcement (L.H. drive
vehicles)
22. Front sidemember inner
23. Battery bracket
24. Transmission mounting stay front
25. Transmission mounting gusset
26. Transmission mounting bracket
27. Transmission mounting stay rear
28. Suspension crossmember bracket front
29. Dash crossmember extension upper
30. Stay reinforcement
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
1-11
FRONT DECK
31. Pipe support rear
32 Pipe nut
33. Front sidemember brace lower
AB302055
AB
22
16
18
A
AB302056
AB
22
16
11
B
13
20
4
AB301706
2
3
5
6
AB
7
8
9
12
4
10
11
1
1. Cowl top panel front
2. Cowl top panel inner
3. Wiper bracket A
4. Cowl top bulkhead A
5. Cowl top panel outer
6. Cowl top bulkhead B
7. Cowl top bulkhead C
8. Cowl top gusset side
9. Front upper frame extension inner
10. Upper frame bulkhead rear
11. Front upper frame extension outer
12. Fender bracket
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
1-12
DASH PANEL
SIDE BODY
M4010011000233
SIDE STRUCTURE
• An uneven thickness steel sheet* in which the
sheet thickness is thicker in the order of the
upper section, rear section, and lower section
was employed for the side outer panel to ensure
safety upon side impact.
• The rear wheel houses each consist of a front
and a rear panel, and thick steel plates are used
for the rear wheel house panels where the rear
suspensions are installed, in order to heighten
the body rigidity and improve driving stability.
NOTE: *: A steel sheet of varying thickness that is
welded into one steel sheet.
AB301685
AB
1
7
11
2
9
8
4
3
6
5
10
1. Dash crossmember upper
2. Dash crossmember reinforcement upper
3. Dash panel plate (RH drive vehicles, A/T lever type)
4. Dash panel
5. Dash crossmember lower
6. Accel pedal upper bracket (LH drive vehicles)
7. Clutch pedal support bracket (Vehicle for M/T)
8. Dash panel reinforcement
9. Clutch pedal stopper bracket (RH drive vehicles,
M/T)
10. Accel pedal bracket (LH drive vehicles)
11. Steering shaft bracket
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
1-13
SIDE STRUCTURE REINFORCEMENT
An uneven thickness steel sheet* in which the sheet
thickness is thicker in the forward part of the vehicle
was employed for the side sill reinforcement to
ensure safety upon side impact.
NOTE: *: A steel sheet of varying thickness that is
welded into one steel sheet.
AB301697
AB
1
2
3
4
5
6
7
8
9
10
12
13
14
15
16
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
35
36
37
38
39
40
44
34
17
41
42
43
33
46
45
48
51
50
49
11
47
1. Front fender lower bracket
2. Front door hinges reinforcement lower
3. Front pillar reinforcement bulkhead lower
4. Front pillar reinforcement outer lower
5. Front door checker bulkhead
6. Front door hinges reinforcement upper
7. Front pillar inner lower
8. Deck crossmember bracket
9. Instrument panel side bracket
10. Front pillar inner upper
11. Front pillar support (Driver’s side)
12. Front pillar reinforcement outer upper (Passenger’s
side)
13. Centre pillar inner
14. Seat belt anchor reinforcement
15. Rear door hinges reinforcement upper
16. Side roof rail inner
17. Centre pillar reinforcement outer
18. Third seat anchor reinforcement
19. Rear wheel house inner front panel
20. Shock absorber reinforcement
21. Rear wheel house inner rear panel
22. Rear door striker reinforcement
23. Seat belt reinforcement lower second
24. Seat belt reinforcement rear pillar
25. Rear pillar reinforcement outer
26. Quarter inner panel
27. Radio tuner amplifier bracket (Right side)
28. TV tuner amplifier bracket (Left side)
29. Quarter inner extension upper
30. Seat belt reinforcement lower third
31. Seat belt reinforcement upper
32. Quarter inner extension
33. Gate pillar upper reinforcement
34. Gate pillar reinforcement
35. Fuel filler neck bracket (Left side)
36. Gas spring reinforcement
37. Quarter outer extension
38. Tailgate dumper reinforcement side
39. Side outer panel
40. Fender bracket
41. Side sill reinforcement
42. Side sill reinforcement front
43. Seat belt front anchor reinforcement
44. Side sill reinforcement centre
45. Rear door check bulkhead
46. Side sill bulkhead rear
47. Harness bracket
48. Shock absorber support
49. Rear seat belt reinforcement wheel house
50. Shield plate front
51. Shield plate rear
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
1-14
REAR BODY
M4010012000203
REAR END CROSSMEMBER
AB301707
AB
Side sill reinforcement
AB301708
AB
1
2
3
4
5
6
7
8
9
10
11
12
1. Rear end panel inner
2. Heat protector bracket
3. Muffler hanger bracket rear
4. Tailgate striker reinforcement
5. Rear end panel outer
6. Jack rear bulkhead
7. Spare tyre reinforcement rear end
8. Jack rear bracket A
9. Jack rear bracket B
10. Bumper bracket
11. Rear floor side brace
12. Quarter inner extension lower
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
1-15
ROOF
M4010013000217
AB300305
AB301710
AB300304
Except for sun roof
Vehicles with sun roof
AB
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
2
3
4
5
6
18
19
20
7
11
8
16
15
8
9
8
21
1. Overhead console bracket
2. Front roof rail inner
3. Roof panel
4. Rear roof rail outer
5. Tailgate hinge reinforcement
6. Rear roof rail inner
7. Roof rack reinforcement rear (Vehicles with roof rail)
8. Roof carrier bracket
9. Roof rack reinforcement centre (Vehicles with roof
rail)
10. Roof centre reinforcement
11. Roof rack reinforcement front (Vehicles with roof rail)
12. Roof bow A
13. Roof bow B
14. Roof bow centre
15. Roof bow D
16. Roof bow E
17. Set bracket rear
18. Roof reinforcement rear
19. Set bracket front
20. Roof reinforcement front
21. Room lamp bracket
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
1-16
UNDER BODY
M4010014000265
FRONT FLOOR
REAR FLOOR
• An uneven thickness steel sheet* in which the
sheet thickness is thicker in the forward part of
the vehicle was employed for the rear floor side
member to ensure safety upon impact.
NOTE: *: A steel sheet of varying thickness that is
welded into one steel sheet.
AB301673
AB
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1. Front floor pan
2. Foot rest bracket (R.H. drive vehicles)
3. Backbone reinforcement
4. Front floor crossmember front
5. Front floor side sill inner
6. Front floor crossmember rear bulkhead
7. Front floor crossmember rear reinforcement
8. Fuel tank support bracket front
9. Front floor sidemember extension rear
10. Front seat reinforcement rear side
11. Front floor sidemember extension front
12. Front seat anchor reinforcement centre
13. Front floor crossmember rear
14 Front floor crossmember front centre
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
1-17
AB301667
AB
1
2
3
4
5
6
7
8
9
10
11
12
13
15
17
18
14
16
1. Rear floor crossmember A
2. Seat anchor reinforcement front centre A
3. Seat anchor front reinforcement
4. Rear floor pan
5. Rear floor crossmember D
6. Seat anchor reinforcement D
7. Seat pan reinforcement
8. Rear suspension crossmember bulkhead
9. Mounting bolt
10. Rear floor crossmember C
11. Spring sheet
12. Seat anchor reinforcement B
13. Rear floor crossmember centre reinforcement B
(Seven-passenger model)
14. Rear floor crossmember B
15. Fuel tank support bracket rear
16. Flange reinforcement (Seven-passenger model)
17. Front stringer
18. Rear floor sidemember
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
1-18
REAR FLOOR SIDEMEMBER
REINFORCEMENT
AB301668
AB
1
2
3
4
5
6
8
9
10
11
12
13
14
15
16
20
21
22
23
25
17
19
24
18
7
AB301675
A
B
AB
12
11
13
2
25
5
7
9
14
20
1. Rear floor sidemember extension front
2. Tie down hook plate
3. Fuel tank support bracket
4. Pipe nut
5. Pipe support front
6. Rear floor crossmember extension B
7. Seat anchor rear reinforcement (Seven-passenger
model right side)
8. Seat anchor rear reinforcement (Except for seven
passenger model right side)
9. Rear floor sidemember front bulkhead
10. Rear floor crossmember extension D
11. Rear floor sidemember reinforcement
12. Third seat anchor reinforcement
13. Rear floor sidemember rear bulkhead (Left side)
14. Rear floor sidemember extension rear
15. Rear floor side pan
16. Muffler hanger bracket rear (Right side)
17. Heat protector bracket (Right side)
18. Spare tyre support (Left side)
19. Shipping bracket (Right side)
20. Rear floor sidemember
21. Brake hose bracket
22. Rear floor side sill inner
23. Jack up side reinforcement
24. Sidemember front bulkhead
25. Rear suspension crossmember stopper bracket
AB300434
A
20
12
11
AC
15
AB300435
B
AC
15
14
13
20
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
1-19
DOOR
M4010015000213
• An uneven thickness steel sheet* in which the
sheet thickness is thicker in the forward part of
the vehicle was employed for the inner panel to
improve rigidity.
• The front and rear side door beam was located in
the bumper position of the vehicle to improve
cabin protection upon side impact.
• A belt line inner reinforcement has been adopted
to improve cabin protection upon impact.
• The bottom section of the door sash pillar was
enlarged and the couplings between the hinge,
latch and door sash were strengthened to
improve sash rigidity.
NOTE: *: A steel sheet of varying thickness that is
welded into one steel sheet.
AB301700
1
2
3
4
5
6
AB
7
8
9
10
Front door
AB301699
AB
Rear door
12
13
14
15
16
17
18
11
1. Front door outer panel
2. Front door outside handle reinforcement
3. Front door belt line outer reinforcement
4. Front door latch reinforcement
5. Front door belt line inner reinforcement
6. Front door window sash
7. Front door inner panel
8. Front side door beam
9. Front door outer stiffener
10. Front door hinge upper reinforcement
11. Rear door outer panel
12. Rear door belt line outer reinforcement
13. Rear door latch reinforcement
14. Rear door belt line inner reinforcement
15. Rear door window sash
16. Rear door inner panel
17. Rear side door beam
18. Rear door outer stiffener
SILENCER APPLICATION LOCATIONS
BODY CONSTRUCTION
1-20
SILENCER APPLICATION LOCATIONS
M4010005000278
Sound insulation was improved by using a
spray-type anti-vibration agent on the cabin side of
the dash panel, rear wheel house and rear floor.
Use a melting sheet for repair.
NOTE: ( ) indicates the number of melting sheets that are used for repair.
AB300368
AB301712
AB
Rear wheel house inner
Dash panel
<Left side>
<Right side>
AB301714
AB
Six-passenger model
: 3.2 mm thick melting sheet and RSS (Place two 1.6 mm melting sheet one on top of another.)
AB301713
AB
Seven-passenger model
LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL
BODY CONSTRUCTION
1-21
LOCATIONS USING URETHANE FOAM AND FOAM
MATERIAL
M4010007000177
• Introduction of noise was prevented by adding
acoustic foam materials inside the front pillar,
centre pillar, side roof rail and wheel house arch.
• Introduction of noise was prevented by inserting
urethane foam inside the front pillar, centre pillar
and front fender.
CAUTION
The foam materials may burn when heated.
Always observe the following instructions.
• Never use a gas burner or burn the areas
using foam materials.
• When cutting the parts using foam materials,
ensure to use tools (air saw, etc.) that do not
generate fire.
• If there is residual foam materials remaining
on the cut section (body side) then weld after
removing the foam materials from periphery
of the welding area.
AB300554
AB300416
AB300490
AC
A
B
C
E
F
D
: Acoustic foam
: Urethane foam
AB300446
AC
Acoustic foam
material
Side outer panel
Front pillar
inner upper
A
AB300448
AC
B
Acoustic foam
material
Roof side rail inner
Side outer panel
AB300447
AC
Centre pillar
reinforcement outer
Centre pillar inner
Acoustic foam
material
C
Seat belt anchor
reinforcement
Side outer panel
AB300449
AC
Side outer panel
Quarter inner panel
Acoustic foam
material
D
STIFFENER AND DAMP SHEET APPLICATION LOCATIONS
BODY CONSTRUCTION
1-22
STIFFENER AND DAMP SHEET APPLICATION LOCATIONS
M4010008000192
Sound insulation was improved with anti-vibration
effects and heightening surface rigidity with a
stiffener on the inner side of the side outer panel and
the tailgate outer panel, as well as a damping sheet
adhered to the inner side of the front door and the
rear door outer panel.
NOTE: The main contents of a stiffener are epoxy
resin. It comes in a sheet form and contains a
mixture of glass fibre and filler, and cures (stiffens)
when heated. It is used to improve the rigidity of the
outer plate.
AB300450
AC
Urethane foam
Front pillar
reinforcement
outer lower
Front pillar inner lower
Front door hinge
reinforcement
lower
Front floor side
sill inner front
E
AB300451
AC
Side outer panel
Urethane
foam
Side sill
reinforcement
Seat belt front
anchor reinforcement
F
AB301882
AB
Stiffener
Stiffener
Damp sheet
AB301881
AB
Stiffener
Damp sheet
Front door
Tailgate
2-1
GROUP 2
BODY DIMENSIONS
CONTENTS
BODY DIMENSIONS AND MEASUREMENT
METHODS . . . . . . . . . . . . . . . . . . . . . 2-2
TYPE A (PROJECTED DIMENSIONS)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
UNDER BODY . . . . . . . . . . . . . . . . . . . . . . 2-3
SUSPENSION INSTALLATION DIMENSIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
TYPE B (ACTUAL-MEASUREMENT
DIMENSIONS). . . . . . . . . . . . . . . . . . . 2-7
UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 2-7
SUSPENSION INSTALLATION DIMENSIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
FRONT BODY . . . . . . . . . . . . . . . . . . . . . . . 2-10
SIDE BODY . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 2-13
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
BODY DIMENSIONS AND MEASUREMENT METHODS
BODY DIMENSIONS
2-2
BODY DIMENSIONS AND MEASUREMENT METHODS
M4020001000255
1. Type A (projected dimensions)
Indicates the dimension when a measurement
location is projected onto the plane.
The difference in height of the measurement
points should be taken into consideration when
measuring.
2. Type B (actual-measurement dimensions)
Indicates the actual distance between the
measurement points.
Measure using a tracking gauge or a measuring
tape, etc.
NOTE: .
•
Make the lengths of the tracking gauge probes
the same (A=A’).
•
Do not bend or twist the measuring tape.
3. Insert the tracking gauge probes securely into the
measurement holes.
4. When the standard dimensions in the illustration
are enclosed by rectangle, this indicates that the
symmetrical left and right positions have the same
dimensions.
5. When using a notch for dimension measurement,
set the measuring point at the centre of the notch.
6. When measuring the suspension mounting arm,
or link mounting position, use the suspension
mounting bolt, etc. (Type B only)
7. The body centre points are shown for the purpose
of checking the position of the left and right
symmetry location.
AB100778
Projected dimension
Height
Probe
AB
AB100779
AB
Actual-measured dimension
A
A'
AB100780
AD
Centre of hole
AB100781
AB
AB100782
AB
Bolt
Measurement point
TYPE A (PROJECTED DIMENSIONS)
BODY DIMENSIONS
2-3
TYPE A (PROJECTED DIMENSIONS)
UNDER BODY
M4020005000536
NOTE: The * mark indicates the mounting position for the frame centring gauge.
AB301815
AB
2
1
5
3
4
7
6
8
740
960
908
979
271
870
1200
558
642
628
1261
1230
1240
1160
1030
1180
mm
AB301816
AB
2
1
5
3
4
7
6
8
885
1478
1353
1323
1268
1648
1721
1269
1117
1216
No. Standard measurement point Hole shape Size mm
1* Centre of front end crossmember brace positioning hole Round 12
2* Centre of front sidemember inner positioning hole Round 25
3* Centre of suspension crossmember stay mounting hole Round 14
4* Centre of front floor sidemember positioning hole Round 16
5* Centre of rear floor sidemember extension front positioning hole Round 25
6* Centre of rear floor sidemember water draining hole Round 25
7* Centre of rear floor sidemember positioning hole Round 35
8* Centre of hichmember mounting hole (This hole also serves as a
shipping bracket mounting hole on left side.)
Round 16
TYPE A (PROJECTED DIMENSIONS)
BODY DIMENSIONS
2-4
AB301817
1195
676
128
330
100
150
165
219
282 269
605 557
1655
1903
1818
AB
2
1
5
3
4
7
6
8
mm
AB300200
AB
1
AB300201
AB
2
AB300195
AB
3
AB300196
AB
4
AB300197
AB
5
AB300194
AB
6
AB301814AB301814
AB
7
AB300199
AB
8
TYPE A (PROJECTED DIMENSIONS)
BODY DIMENSIONS
2-5
SUSPENSION INSTALLATION
DIMENSIONS
M4020013000467
AB301820
AB
9
12
11
392
297
181
206
154
940
908
970
1250
474
89
574
480
1192
1230
13
3
14
15
16
mm
10
1145
1165
AB301821
AB
12
11
13
3
14
15
16
1000
1153
1085
1112
1214
959
985
956
No. Standard measurement point Hole shape Size mm
3 Centre of suspension crossmember stay mounting hole Round 14
9 Centre of front shock absorber mounting hole Round 104.6
10 Centre of rear shock absorber mounting hole Round 22
11 Tip of front suspension crossmember mounting bolt
−−
12 Centre of suspension crossmember positioning hole Round 15.5
13 Centre of suspension crossmember stay mounting hole Round 16
14 Centre of rear suspension stopper front mounting hole Round 11
15 Centre of rear suspension crossmember mounting hole Round 15.5
16 Tip of rear suspension crossmember mounting bolt
−−
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