Mitsubishi Grandis 2004 User Manual

0-1

GROUP 0

GENERAL

CONTENTS

VEHICLE IDENTIFICATION . . . . . . .

0-2 MAJOR SPECIFICATIONS . . . . . . . .

0-2

0-2	GENERAL
	VEHICLE IDENTIFICATION

VEHICLE IDENTIFICATION

MODELS					M4000001000264
Model code		Engine model	Price	Transmission model	Fuel supply
			class		system
NA4W	LNUYL6/R6	4G69-SOHC-MIVEC	GLX	F5M42 <2WD, 5M/T>	MPI
		(2,378 mL)
	LRUYL6/R6			F4A4B <2WD, 4A/T with sport mode>
	LNHYL6/R6			F5M42 <2WD, 5M/T>
	LRHYL6/R6			F4A4B <2WD, 4A/T with sport mode>

MAJOR SPECIFICATIONS

								M4000003000174
Item					NA4W
					LNUYL6/	LNHYL6/	LRUYL6/	LRHYL6/
					R6	R6	R6	R6
Vehicle		Overall length			4,765
dimension mm
		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	Front	Toe-in (at the centre of tyre tread)		mm	0 ± 3
wheel
		Toe angle (per wheel)			0°00' ± 08'
alignment
		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

GENERAL	0-3
MAJOR SPECIFICATIONS

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

1-2	BODY CONSTRUCTION
	BODY COMPONENTS

BODY COMPONENTS

										M4010001000221
				38						47
	37							46
								45	48
34								49
						42	43	44
					41
	36 35
							50
		39		40		51				56
33
										55
32							52
		29						54
				28						57
	31						53
				27
	30	23
	21	22		26
	20			24
									59	58
				25*
	18									60
										61
	17			86
16		19		85		83				62
	15			82	84
		81
	14									63
13
	10*
											64
		9*
12
11*	6							70		66	65
5
	4						72
		8*							68
	7						73	71*		67
		80
									69
3*						74*
		79
				76
	2
			78
	1
		77				75
: Anti-corrosion steel panels
: High-tensile steel panels (*: Indicates 590MPa-high-tensile steel panels.)										AB301830AB

1.	Front end crossmember	4.	Front end upper bar
2.	Hood lock stay	5.	Front upper bar side
3.	Front end beam	6.	Headlamp support brace upper

		BODY CONSTRUCTION		1-3
		BODY COMPONENTS
7.	Dash panel extension	66.	Rear floor crossmember D
8.	Front floor sidemember	67.	Rear floor sidemember
9.	Front floor sidemember reinforcement	68.	Rear floor crossmember C
10.	Front sidemember inner	69.	Rear floor crossmember B
11.	Front sidemember outer	70.	Front stringer
12.	Headlamp bracket	71.	Rear floor crossmember A
13.	Front fender shield	72.	Front floor crossmember rear
14.	Spring house panel	73.	Front floor pan
15.	Front upper frame inner	74.	Front floor side sill
16.	Front upper frame outer	75.	Front fender
17.	Dash panel crossmember upper	76.	Front floor crossmember front centre
18.	Dash panel	77.	Buttery tray stay
19.	Upper frame extension	78.	Buttery bracket
20.	Front deck	79.	Buttery tray
21.	Deck crossmember	80.	Foot rest bracket
22.	Guide bracket	81.	Front floor crossmember front
23.	Front pillar inner lower	82.	Back bone reinforcement
24.	Front pillar reinforcement outer lower	83.	Rear floor pan
25.	Side sill reinforcement	84.	Front fender bracket
26.	Centre pillar reinforcement outer	85.	Front fender bracket lower
27.	Centre pillar inner	86.	Front floor side sill inner front

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

47Tailgate panel outer

48Quarter extension inner

49.Quarter inner panel

50.Roof reinforcement centre

51.Roof side rail inner

52Rear wheel house inner panel

53.Shield plate front

54.Shield plate rear

55Rear pillar reinforcement outer

56.Gate pillar reinforcement

57.Quarter extension outer

58Fuel filler door panel

59.Side outer panel

60.Rear end outer panel

61Rear end inner panel

62Quarter inner extension lower

63.Seat pan reinforcement

64.Rear floor side pan

65Rear floor side member rear extension

1-4	BODY CONSTRUCTION
	BODY MAIN CROSS-SECTIONAL VIEWS

BODY MAIN CROSS-SECTIONAL VIEWS

M4010002000246

B C

D

E

F

A

AB300191AD

A	Front end
	crossmember upper

	Front end	Front end crossmember
	crossmember lower
		reinforcement
		AB300345AC

B

Over head console bracket

Roof panel

	Front roof rail inner
	AB300343AC
C	Side outer panel

Side roof

rail inner

Front pillar

reinforcement outer upper

AB300344AC

D	Centre pillar
	reinforcement outer
	Centre pillar inner
	Side outer
	panel

Seat belt anchor

reinforcement

AB300346AC

EFront pillar reinforcement

bulkhead lower	Front floor side sill
	reinforcement upper
Front floor
side sill
inner front
Side outer panel	Front door hinge
	reinforcement lower
	AB300347AD
F	Side sill reinforcement
Front floor
side sill inner

Side outer panel

Side sill

reinforcement front

AB300348AC

BODY CONSTRUCTION

1-5

BODY MAIN CROSS-SECTIONAL VIEWS

J

G

H

I

K

L

AB300192AD

GFront pillar support (Drivers side)

Front pillar inner upper

Front pillar reinforcement			Side outer panel
outer upper			AB300349AC
H		Seat belt reinforcement
		rear pillar
			Quarter inner
			panel
	Side outer
	panel
		Rear pillar reinforcement
			AB300351AE
I	Quarter inner panel		Quarter inner
			extension upper

Side
outer panel
Gate pillar	Quarter outer
	extension
reinforcement	AB300352AC

J

Roof panel

Rear roof rail inner

Rear roof rail outer

AB300350AC

K

Quarter inner panel

Side outer panel

Rear wheel house inner front panel

AB300353AC

L

Rear end panel	Rear end
inner	panel outer
Rear floor pan
	Tailgate striker
	reinforcement
	AB300354AC

1-6	BODY CONSTRUCTION
	MAINTENANCE, SERVICEABILITY

MAINTENANCE, SERVICEABILITY

M4010003000238

SIDE STRUCTURE

A panel positioning notch has been added on the door opening to improve assembling workability when replacing the panel.

Panel positioning notch AB301701AB

AB301702AB

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.

Centre pillar outer

Front pillar outer

Quarter outer

Floor side sill outer

AB301703AB

BODY CONSTRUCTION	1-7
BODY CONSTRUCTION CHARACTERISTICS

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.

3

2

1

•The bolt-on front end beam, bolt-on hood lock stay and bolt-on front end upper bar are used to improve maintainability.

4

5

6 8

9

11

7

10

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

AB301705AB

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.

1-8	BODY CONSTRUCTION
	BODY CONSTRUCTION CHARACTERISTICS
Right side 7	B
6
	8
	10
5			7
9		8
	Light side		6
4
	11

10

3	11	4
	2	12

A

1

3

5

1

AB301677AB

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)

The front part of the front side member has octagonal section that efficiently absorbs energy upon impact.

B	Cowl top
	panel outer
Spring house	Cowl top
	panel inner
bracket
Spring house
panel

	AB301689AB
A	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.
Front sidemember	Front sidemember
inner	outer
	AB301688AB

BODY CONSTRUCTION	1-9
BODY CONSTRUCTION CHARACTERISTICS

FRONT SIDEMEMBER REINFORCEMENT

Right side		7	8				15
							16
			10		14		19
			9			13
							17
6					12		18
					11
5		4	3		26
						25
							20
	2			27
							21
						24
				28
							22
	1
		30	29			23
							AB302050AB
		2	4	9	17		12
							15
	5	A	3
			B	25	27	18	19
							AB300245AC

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

A

1

8

4

2

AB301690AB

1-10	BODY CONSTRUCTION
	BODY CONSTRUCTION CHARACTERISTICS

B	1
	10
	8	9
	19
	3
		AB302054AB
Light side							14	15
	6
				12
	5	9			13
4
								16
	8	10
	7	31		11		20
								19
			30
	32							18
3								17
								21
	2			28
								22
						25
	1		29	27				23
	33			26		24		AB302049AB
		10	5	13	20	18		17
		9
						A
	4	7	30	B
				31				AB302053AB

1.	Dash crossmember extension lower	16.	Front sidemember outer
2.	Suspension crossmember bracket rear	17.	Towing reinforcement
3.	Front floor sidemember	18.	Transmission mounting reinforcement
4.	Front floor sidemember reinforcement	19.	Front sidemember outer reinforcement (L.H. drive
5.	Front floor sidemember reinforcement upper		vehicles)
6.	Dash panel extension	20.	Pipe support front
7.	Front floor sidemember reinforcement middle (L.H.	21.	Front sidemember inner reinforcement (L.H. drive
	drive vehicles)		vehicles)
8.	Dash crossmember upper reinforcement extension	22.	Front sidemember inner
	(L.H. drive vehicles)	23.	Battery bracket
9.	Front floor side sill inner reinforcement lower	24.	Transmission mounting stay front
10.	Front floor side sill inner reinforcement upper	25.	Transmission mounting gusset
11.	Dash brace	26.	Transmission mounting bracket
12.	Front floor side sill inner front	27.	Transmission mounting stay rear
13.	Kick up reinforcement	28.	Suspension crossmember bracket front
14.	Brake house bracket	29.	Dash crossmember extension upper
15.	Headlamp support brace upper	30.	Stay reinforcement

		BODY CONSTRUCTION	1-11
		BODY CONSTRUCTION CHARACTERISTICS
31.	Pipe support rear	B
32	Pipe nut
33. Front sidemember brace lower		4
	A
			11
		22
			16
		18
			20
		13
	22	16	AB302056AB
		FRONT DECK
		AB302055AB

			4
			6
			7
	3		5
			8
			9
		2	10
			11
1			12

AB301706AB

1.	Cowl top panel front	7.	Cowl top bulkhead C
2.	Cowl top panel inner	8.	Cowl top gusset side
3.	Wiper bracket A	9.	Front upper frame extension inner
4.	Cowl top bulkhead A	10.	Upper frame bulkhead rear
5.	Cowl top panel outer	11.	Front upper frame extension outer
6.	Cowl top bulkhead B	12.	Fender bracket

1-12			BODY CONSTRUCTION
		BODY CONSTRUCTION CHARACTERISTICS
DASH PANEL
		4		6	7
			5
	3
1	2
					8

11	10	9

AB301685AB

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

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.

BODY CONSTRUCTION	1-13
BODY CONSTRUCTION CHARACTERISTICS

		27	28	29		31	33
16	25	26			30		34
							32
		24

10				17	21	23	35	37
							36	38
		14		19
			15		20
						22
				18
	13						51
11	12						50
9	6
8						49
				47
	43		45		48
		44
7				46		40		39
	42
5
4
3
2
1		41						AB301697AB

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

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.

1-14	BODY CONSTRUCTION
	BODY CONSTRUCTION CHARACTERISTICS

Side sill reinforcement

AB301707AB

REAR BODY

M4010012000203

REAR END CROSSMEMBER

5

2	3	4

			6
			7
			10
	1		8
			9
			11
			12
			AB301708AB
1.	Rear end panel inner	8. Jack rear bracket A
2.	Heat protector bracket	9. Jack rear bracket B
3.	Muffler hanger bracket rear	10.	Bumper bracket
4.	Tailgate striker reinforcement	11. Rear floor side brace
5.	Rear end panel outer	12.	Quarter inner extension lower

6.Jack rear bulkhead

7.Spare tyre reinforcement rear end

BODY CONSTRUCTION	1-15
BODY CONSTRUCTION CHARACTERISTICS

ROOF

Except for sun roof

3

2

1

Vehicles with sun roof

M4010013000217

	16
14	15
	AB300304

13

10	9

12	8
	11

3

AB300305

2	8
21	11
	20

4

5 6

7

8

4

			5
			6
			7
		15	16
	9	8
18	17
19

AB301710AB

1.	Overhead console bracket	11.	Roof rack reinforcement front (Vehicles with roof rail)
2.	Front roof rail inner	12.	Roof bow A
3.	Roof panel	13.	Roof bow B
4.	Rear roof rail outer	14.	Roof bow centre
5.	Tailgate hinge reinforcement	15.	Roof bow D
6.	Rear roof rail inner	16.	Roof bow E
7.	Roof rack reinforcement rear (Vehicles with roof rail)	17.	Set bracket rear
8.	Roof carrier bracket	18.	Roof reinforcement rear
9.	Roof rack reinforcement centre (Vehicles with roof	19.	Set bracket front
	rail)	20.	Roof reinforcement front
10.	Roof centre reinforcement	21.	Room lamp bracket

1-16	BODY CONSTRUCTION
	BODY CONSTRUCTION CHARACTERISTICS

UNDER BODY

M4010014000265

FRONT FLOOR

3

4

2
1		5
		6
		7
		8
	13	9
14	12	11
		10

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

AB301673AB

13. Front floor crossmember rear

14 Front floor crossmember front centre

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.

BODY CONSTRUCTION	1-17
BODY CONSTRUCTION CHARACTERISTICS

					5	6	7
4						8
			13
						9
		16
2						10
	3			12		11
				14
				15
1			17				18
							AB301667AB

1.	Rear floor crossmember A	12.	Seat anchor reinforcement B
2.	Seat anchor reinforcement front centre A	13.	Rear floor crossmember centre reinforcement B
3.	Seat anchor front reinforcement		(Seven-passenger model)
4.	Rear floor pan	14.	Rear floor crossmember B
5.	Rear floor crossmember D	15.	Fuel tank support bracket rear
6.	Seat anchor reinforcement D	16.	Flange reinforcement (Seven-passenger model)
7.	Seat pan reinforcement	17.	Front stringer
8.	Rear suspension crossmember bulkhead	18.	Rear floor sidemember

9.Mounting bolt

10.Rear floor crossmember C

11.Spring sheet

1-18	BODY CONSTRUCTION
	BODY CONSTRUCTION CHARACTERISTICS

REAR FLOOR SIDEMEMBER

REINFORCEMENT

			10	12	13
		7
			9	11	14
	6		8		15
		5		20	16
		4		21	17
	3	2		22	18
				23	19
		1
			25	24			AB301668AB
		7	9		20
2	25	5
					14		13
			11	A	12	B
						AB301675AB

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

A

15

12

20

11

AB300434AC

B

15

13

20 14

AB300435AC

BODY CONSTRUCTION	1-19
BODY CONSTRUCTION CHARACTERISTICS

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.

Front door		2
	1	3	4	6
				5

7

10	8
	9

AB301700AB

Rear door

11

12

13

14

15

16

18	17
	AB301699AB

1.	Front door outer panel	10.	Front door hinge upper reinforcement
2.	Front door outside handle reinforcement	11.	Rear door outer panel
3.	Front door belt line outer reinforcement	12.	Rear door belt line outer reinforcement
4.	Front door latch reinforcement	13.	Rear door latch reinforcement
5.	Front door belt line inner reinforcement	14.	Rear door belt line inner reinforcement
6.	Front door window sash	15.	Rear door window sash
7.	Front door inner panel	16.	Rear door inner panel
8.	Front side door beam	17.	Rear side door beam
9.	Front door outer stiffener	18.	Rear door outer stiffener

1-20 BODY CONSTRUCTION

SILENCER APPLICATION LOCATIONS

SILENCER APPLICATION LOCATIONS

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.

M4010005000278

Use a melting sheet for repair.

<Left side>	<Right side>
	AB300368
	AB301712AB
Dash panel	Rear wheel house inner

Six-passenger model

AB301714AB

: 3.2 mm thick melting sheet and RSS (Place two 1.6 mm melting sheet one on top of another.)

Seven-passenger model

AB301713AB

NOTE: ( ) indicates the number of melting sheets that are used for repair.

BODY CONSTRUCTION	1-21
LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL

LOCATIONS USING URETHANE FOAM AND FOAM

MATERIAL

•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.

M4010007000177

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.

		B
	A
		C
		D
	E	F
AB300416	: Acoustic foam	AB300490
	: Urethane foam
		AB300554AC

A	Front pillar	Acoustic foam
	inner upper	material

Side outer panel

AB300446AC

B

Side outer panel

Acoustic foam material

Roof side rail inner

AB300448AC

C	Centre pillar inner

Seat belt anchor Acoustic foam reinforcement

material

	Side outer panel	Centre pillar
		reinforcement outer
		AB300447AC

D

Quarter inner panel

Acoustic foam material

Side outer panel

AB300449AC

1-22		BODY CONSTRUCTION
	STIFFENER AND DAMP SHEET APPLICATION LOCATIONS
E		F
	Front pillar	Side outer panel
		Seat belt front
Front pillar inner lower	reinforcement
	outer lower	anchor reinforcement
Urethane foam		Urethane
		foam
Front door hinge	Front floor side
	sill inner front
reinforcement		Side sill
lower
		reinforcement
	AB300450AC
		AB300451AC

STIFFENER AND DAMP SHEET APPLICATION LOCATIONS

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.

M4010008000192

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.

Stiffener

Damp sheet

Stiffener

AB301882AB

Front door		Tailgate

Damp sheet

Stiffener

AB301881AB

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

2-2	BODY DIMENSIONS
	BODY DIMENSIONS AND MEASUREMENT METHODS

BODY DIMENSIONS AND MEASUREMENT METHODS

Projected dimension

Height

Probe

AB100778AB

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.

M4020001000255

Centre of hole

AB100780AD

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.

Actual- measured A

A'

dimension

AB100781AB

AB100779AB

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.

5.When using a notch for dimension measurement, set the measuring point at the centre of the notch.

Bolt

Measurement point

AB100782AB

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.

BODY DIMENSIONS	2-3
TYPE A (PROJECTED DIMENSIONS)

TYPE A (PROJECTED DIMENSIONS)

UNDER BODY

		M4020005000536
				1200		mm
						1261
	1230
740	908	1240			1030
960		870		1160		1180
1	979			642		628
2	3	4	558
				6	7
271		5				8
						AB301815AB
				1268		1721
	1478
885			1323
		1117
	1353	1216		1648		1269
1	3	4
2				6	7	8
		5

			AB301816AB
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	Round	16
	shipping bracket mounting hole on left side.)

NOTE: The * mark indicates the mounting position for the frame centring gauge.

2-4	BODY DIMENSIONS
	TYPE A (PROJECTED DIMENSIONS)

							mm
	2					7	8
		4	5		6
1	3
128	330			165	219	282	269
	100	150
	676	605		557
	1655				1195
	1903					1818
							AB301817AB
1	2				3

AB300200AB	AB300201AB	AB300195AB
4	5	6
AB300196AB	AB300197AB	AB300194AB
7	8

AB301814AB

AB300199AB

BODY DIMENSIONS	2-5
TYPE A (PROJECTED DIMENSIONS)

SUSPENSION INSTALLATION
DIMENSIONS				M4020013000467
							mm
				474
		392
1145		970		1250	1192
							480
			908			1230	1165
	940			181
		12
11				3		574	16
		297
9		154	13	206	14	15	10
					89
							AB301820AB
				1112
	1000		956			959
					1214
				1085		985
	1153
							16
11		12		3
			13		14	15
							AB301821AB

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	−	−