Page 1
2011
GROUP INDEX
MITSUBISHI
OUTLANDER SPORT/
RVR
SERVICE MANUAL
Volume 1
FOREWORD
This service manual is subdivided into various group
categories. Each section contains diagnostic,
disassembly, repair, and installation procedures,
along with complete specifications and tightening
references. Use of this manual will aid in properly
performing any service necessary to maintain or
restore the high levels of performance and reliability
designed into this Mitsubishi vehicle.
This manual is designed for use with the 2011 Service
Manual Volume 2, 3 and the 2011 OUTLANDER
SPORT/RVR Body Repair Manual to provide
complete service information for the OUTLANDER
SPORT/RVR.
When reference is made in this manual to a brand
name, number, or specific tool, an equivalent product
may be used in place of the recommended item. All
information, illustrations and specifications contained
in this manual are based on the latest product
information available at the time of publication
approval. The right is reserved to make changes at
any time without notice.
General . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling . . . . . . . . . . . . . . . . .
Intake and Exhaust . . . . . . . . . . . . . .
Engine Electrical. . . . . . . . . . . . . . . .
Engine and Emission Control . . . . .
Alphabetical Index . . . . . . . . . . . . . .
NOTE:
For the information on all service manual
groups not listed above, please refer to
Volume 2 and 3.
00
11
12
13
14
15
16
17
No part of this publication may be reproduced, stored in any retrieval
system of transmitted, in any form or by any means, including but not
limited to electronic, mechanical photocopying, recording or otherwise,
without the prior written permission of Mitsubishi Motors Corporation.
©2010 Mitsubishi Motors Corporation
All Rights, Reserved
Printed in USA
MSCD-017B-2011(1/3)
Page 2
WARNING
Proper service methods and repair procedures are necessary for the safe,
reliable operation of all motor vehicles as well as the personal safety of the
person doing the repair. There are many types of procedures, techniques,
tools, and parts for servicing vehicles, as well as differences in the skills of
the people doing the work. This manual cannot give advice or precautions for
every possible situation. Because of this, anyone who does not follow the
instructions in this manual must first make sure that the choice of methods,
tools, or parts will not cause damage to the vehicle or injury to the person
doing the work. The following list contains general precautions that should
always be followed while working on a vehicle.
• Always wear safety glasses for eye protection.
• Use safety stands whenever a procedure requires work under the
vehicle.
• Be sure the ignition switch is always "off" unless otherwise specified by
a procedure.
• Set the parking brake when working on a vehicle.
• Operate the engine only in a well-ventilated area.
• Keep clear of moving parts when the engine is running.
• 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 or near a vehicle.
Page 3
CALIFORNIA PROPOSITION 65 WARNING
WARNING
•
This product contains or emits chemicals known to the State of California to cause cancer and
birth defects or other reproductive harm.
CALIFORNIA PERCHLORATE MATERIALS REQUIREMENTS
WARNING
•
Certain components of this vehicle, such as air bag modules and seat belt pre-tensioners, may
contain perchlorate materials. Special handling may apply. For additional information, see
www.dtsc.ca.gov/hazardouswaste/perchlorate.
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) EQUIPPED VEHICLES
WARNING
•
Improper service or maintenance of any component of the SRS, or any SRS-related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air bag)
or to the driver and passenger (from rendering the SRS inoperative).
•
If it is possible that the SRS components are subjected to heat over 93°C (200°F) in baking or in
drying after painting, remove the SRS components [air bag module (driver's side and front
passenger's side), SRS-ECU, clock spring, side impact sensor, front seat assembly (side air bag
module)] beforehand.
•
Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
•
MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP
52B, Supplemental Restraint System (SRS), before beginning any service or maintenance of any
component of the SRS or any SRS-related component.
NOTE
Section titles with the asterisks (*) in the table of contents in each group indicate operations requiring
warnings.
Page 4
MITSUBISHI PUBLICATION COMMENT FORM
Use this form to advise us of any errors you might find in this publication. We also welcome your
suggestions that might help us improve Mitsubishi publications.
Publication that contains error: __________________________________________________________
Page number where the error appears:____________________________________________________
Figure number where the error appears:___________________________________________________
Vehicle application and system identification: _______________________________________________
Describe, in detail, the error found or your suggestion. Please attach additional pages as necessary.
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
Dealer ___________________________________ Dealer Code________________________________
From: Name_________________________________________________________________________
City/Town____________________________ State________________ Zip Code______________
Signature ____________________________ Date ________________ Phone________________
Mail To: Mitsubishi Motors North America, Inc.
6400 Katella Avenue
P.O. Box 6400
Cypress, California 90630-0064
Fax to: Mitsubishi Motors North America, Inc.
Technical Information Dept.
(714) 373-1021
Attn: Technical Information Dept.
Page 5
NOTE:
For the information on all service manual
groups not listed above, please refer to
Volume 1 and 3.
2011
GROUP INDEX
MITSUBISHI
OUTLANDER SPORT/
RVR
SERVICE MANUAL
Volume 2
FOREWORD
This service manual is subdivided into various group
categories. Each section contains diagnostic,
disassembly, repair, and installation procedures,
along with complete specifications and tightening
references. Use of this manual will aid in properly
performing any service necessary to maintain or
restore the high levels of performance and reliability
designed into this Mitsubishi vehicle.
This manual is designed for use with the 2011 Service
Manual Volume 1, 3 and the 2011 OUTLANDER
SPORT/RVR Body Repair Manual to provide
complete service information for the OUTLANDER
SPORT/RVR.
When reference is made in this manual to a brand
name, number, or specific tool, an equivalent product
may be used in place of the recommended item. All
information, illustrations and specifications contained
in this manual are based on the latest product
information available at the time of publication
approval. The right is reserved to make changes at
any time without notice.
Clutch. . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transaxle . . . . . . . . . . . . . . .
Automatic Transaxle . . . . . . . . . . . .
Propeller Shaft . . . . . . . . . . . . . . . . .
Front Axle . . . . . . . . . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . . . . . . . . . . . .
Wheel and Tire . . . . . . . . . . . . . . . . .
Power Plant Mount . . . . . . . . . . . . . .
Front Suspension . . . . . . . . . . . . . . .
Rear Suspension . . . . . . . . . . . . . . .
Service Brakes . . . . . . . . . . . . . . . . .
Parking Brakes . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . .
Body. . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior . . . . . . . . . . . . . . . . . . . . . . .
Interior and Supplemental
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Restraint System (SRS) . . . . . . . . . .
21
22
23
25
26
27
31
32
33
34
35
36
37
42
51
52
No part of this publication may be reproduced, stored in any retrieval
system of transmitted, in any form or by any means, including but not
limited to electronic, mechanical photocopying, recording or otherwise,
without the prior written permission of Mitsubishi Motors Corporation.
©2010 Mitsubishi Motors Corporation
All Rights, Reserved
Printed in USA
MSCD-017B-2011 (2/3)
Alphabetical Index . . . . . . . . . . . . . .
Page 6
Proper service methods and repair procedures are necessary for the safe,
WARNING
reliable operation of all motor vehicles as well as the personal safety of the
person doing the repair. There are many types of procedures, techniques,
tools, and parts for servicing vehicles, as well as differences in the skills of
the people doing the work. This manual cannot give advice or precautions for
every possible situation. Because of this, anyone who does not follow the
instructions in this manual must first make sure that the choice of methods,
tools, or parts will not cause damage to the vehicle or injury to the person
doing the work. The following list contains general precautions that should
always be followed while working on a vehicle.
• Always wear safety glasses for eye protection.
• Use safety stands whenever a procedure requires work under the
vehicle.
• Be sure the ignition switch is always "off" unless otherwise specified by
a procedure.
• Set the parking brake when working on a vehicle.
• Operate the engine only in a well-ventilated area.
• Keep clear of moving parts when the engine is running.
• 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 or near a vehicle.
Page 7
CALIFORNIA PROPOSITION 65 WARNING
WARNING
WARNING
WARNING
•
This product contains or emits chemicals known to the State of California to cause cancer and
birth defects or other reproductive harm.
CALIFORNIA PERCHLORATE MATERIALS REQUIREMENTS
•
Certain components of this vehicle, such as air bag modules and seat belt pre-tensioners, may
contain perchlorate materials. Special handling may apply. For additional information, see
www.dtsc.ca.gov/hazardouswaste/perchlorate.
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) EQUIPPED VEHICLES
•
Improper service or maintenance of any component of the SRS, or any SRS-related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air bag)
or to the driver and passenger (from rendering the SRS inoperative).
•
If it is possible that the SRS components are subjected to heat over 93°C (200°F) in baking or in
drying after painting, remove the SRS components [air bag module (driver's side and front
passenger's side), SRS-ECU, clock spring, side impact sensor, front seat assembly (side air bag
module)] beforehand.
•
Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
•
MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP
52B, Supplemental Restraint System (SRS), before beginning any service or maintenance of any
component of the SRS or any SRS-related component.
NOTE
Section titles with the asterisks (*) in the table of contents in each group indicate operations requiring
warnings.
Page 8
MITSUBISHI PUBLICATION COMMENT FORM
Use this form to advise us of any errors you might find in this publication. We also welcome your
suggestions that might help us improve Mitsubishi publications.
Publication that contains error: __________________________________________________________
Page number where the error appears:____________________________________________________
Figure number where the error appears:___________________________________________________
Vehicle application and system identification: _______________________________________________
Describe, in detail, the error found or your suggestion. Please attach additional pages as necessary.
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
Dealer ___________________________________ Dealer Code________________________________
From: Name_________________________________________________________________________
City/Town____________________________ State________________ Zip Code______________
Signature ____________________________ Date ________________ Phone________________
Mail To: Mitsubishi Motors North America, Inc.
6400 Katella Avenue
P.O. Box 6400
Cypress, California 90630-0064
Fax to: Mitsubishi Motors North America, Inc.
Technical Information Dept.
(714) 373-1021
Attn: Technical Information Dept.
Page 9
2011
GROUP INDEX
MITSUBISHI
OUTLANDER SPORT/
RVR
SERVICE MANUAL
Volume 3
FOREWORD
This service manual is subdivided into various group
categories. Each section contains diagnostic,
disassembly, repair, and installation procedures,
along with complete specifications and tightening
references. Use of this manual will aid in properly
performing any service necessary to maintain or
restore the high levels of performance and reliability
designed into this Mitsubishi vehicle.
This manual is designed for use with the 2011 Service
Manual Volume 1, 2 and the 2011 OUTLANDER
SPORT/RVR Body Repair Manual to provide
complete service information for the OUTLANDER
SPORT/RVR.
When reference is made in this manual to a brand
name, number, or specific tool, an equivalent product
may be used in place of the recommended item. All
information, illustrations and specifications contained
in this manual are based on the latest product
information available at the time of publication
approval. The right is reserved to make changes at
any time without notice.
Chassis Electrical . . . . . . . . . . . . . . .
Heater, Air Conditioning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
and Ventilation . . . . . . . . . . . . . . . . .
Component Locations . . . . . . . . . . .
Configuration Diagrams
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
and Splice Locations . . . . . . . . . . . .
Circuit Diagrams . . . . . . . . . . . . . . . .
Alphabetical Index . . . . . . . . . . . . . .
NOTE:
For the information on all service manual
groups not listed above, please refer to
Volume 1 and 2.
54
55
70
80
90
No part of this publication may be reproduced, stored in any retrieval
system of transmitted, in any form or by any means, including but not
limited to electronic, mechanical photocopying, recording or otherwise,
without the prior written permission of Mitsubishi Motors Corporation.
©2010 Mitsubishi Motors Corporation
All Rights, Reserved
Printed in USA
MSCD-017B-2011 (3/3)
Page 10
WARNING
Proper service methods and repair procedures are necessary for the safe,
reliable operation of all motor vehicles as well as the personal safety of the
person doing the repair. There are many types of procedures, techniques,
tools, and parts for servicing vehicles, as well as differences in the skills of
the people doing the work. This manual cannot give advice or precautions for
every possible situation. Because of this, anyone who does not follow the
instructions in this manual must first make sure that the choice of methods,
tools, or parts will not cause damage to the vehicle or injury to the person
doing the work. The following list contains general precautions that should
always be followed while working on a vehicle.
• Always wear safety glasses for eye protection.
• Use safety stands whenever a procedure requires work under the
vehicle.
• Be sure the ignition switch is always "off" unless otherwise specified by
a procedure.
• Set the parking brake when working on a vehicle.
• Operate the engine only in a well-ventilated area.
• Keep clear of moving parts when the engine is running.
• 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 or near a vehicle.
Page 11
CALIFORNIA PROPOSITION 65 WARNING
WARNING
•
This product contains or emits chemicals known to the State of California to cause cancer and
birth defects or other reproductive harm.
CALIFORNIA PERCHLORATE MATERIALS REQUIREMENTS
WARNING
•
Certain components of this vehicle, such as air bag modules and seat belt pre-tensioners, may
contain perchlorate materials. Special handling may apply. For additional information, see
www.dtsc.ca.gov/hazardouswaste/perchlorate.
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) EQUIPPED VEHICLES
WARNING
•
Improper service or maintenance of any component of the SRS, or any SRS-related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air bag)
or to the driver and passenger (from rendering the SRS inoperative).
•
If it is possible that the SRS components are subjected to heat over 93°C (200°F) in baking or in
drying after painting, remove the SRS components [air bag module (driver's side and front
passenger's side), SRS-ECU, clock spring, side impact sensor, front seat assembly (side air bag
module)] beforehand.
•
Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
•
MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP
52B, Supplemental Restraint System (SRS), before beginning any service or maintenance of any
component of the SRS or any SRS-related component.
NOTE
Section titles with the asterisks (*) in the table of contents in each group indicate operations requiring
warnings.
Page 12
MITSUBISHI PUBLICATION COMMENT FORM
Use this form to advise us of any errors you might find in this publication. We also welcome your
suggestions that might help us improve Mitsubishi publications.
Publication that contains error: __________________________________________________________
Page number where the error appears:____________________________________________________
Figure number where the error appears:___________________________________________________
Vehicle application and system identification: _______________________________________________
Describe, in detail, the error found or your suggestion. Please attach additional pages as necessary.
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
Dealer ___________________________________ Dealer Code________________________________
From: Name_________________________________________________________________________
City/Town____________________________ State________________ Zip Code______________
Signature ____________________________ Date ________________ Phone________________
Mail To: Mitsubishi Motors North America, Inc.
6400 Katella Avenue
P.O. Box 6400
Cypress, California 90630-0064
Fax to: Mitsubishi Motors North America, Inc.
Technical Information Dept.
(714) 373-1021
Attn: Technical Information Dept.
Page 13
MANUAL DESCRIPTION
AB900381
3
1
4
7
5
6
2
AB
9
8
9
8
3
A
10
5
7
9.0 ± 2.0 N·m
80 ± 17 in-lb
9.0 ± 2.0 N·m
80 ± 17 in-lb
20 ± 5 N·m
15 ± 3 ft-lb
AB900384
AB
A
Crush box
CONTENTS
The first page of this manual contains a table of contents which lists the name of vehicle models and groups
within each model.
TEXT
The vehicles to which the information in the text pertains are generally designated according to their body
classification. In some cases, other limiting designations such as model name, type of drive system, etc., are
given. If there are no such limiting designations, the information can be assumed to cover all models.
PAGE NUMBERS
All pages are numbered consecutively within each model. The page number can be found on the upper left or
right of each page.
SECTION TITLES
The group titles and section titles can be found at the upper center of each page.
Page number
Group number
Group title
Section title
1-8
BODY CONSTRUCTION CHARACTERISTICS
FRONT BODY
HEADLIGHT SUPPORT
• The crush box structure, which has an octagonal
cross-section at the front end of the front sidemember, has been adopted. This structure can
effectively absorb energy upon frontal impact and
reduces the vehicle repair cost caused by a light
collision.
1. Front bumper reinforcement
2. Headlight support panel upper
3. Front end crossmember gusset
4. Front end crossmember upper
5. Radiator bracket lower A
6. Front end crossmember bulkhead
7. Radiator bracket lower B
8. Shipping hook front
9. Shipping reinforcement front
10. Front end crossmember lower
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
• The bolt-on headlight support panel upper is
used to improve maintainability.
The crush box structure has been changed to
straight type with an octagon cross-section so that
the structure can effectively absorb energy from the
impact at the time of collision.
TSB Revision
M4010010001608
Page 14
2011
GROUP INDEX
MITSUBISHI
OUTLANDER SPORT/
RVR
BODY
REPAIR MANUAL
FOREWORD
This manual has been prepared for the use of all
service mechanics engaged in the body repair service.
Body dimensions, welded panel replacement
procedures, body sealing application instructions, and
all the other information required to provide quick and
accurate body repair service are contained herein.
One especially important point is the welding method.
All of the vehicle’s original strength and durability can
be maintained by following the welding procedures
contained in this manual.
Now that, in order to maximize the efficiency of the
repair work, first, both the extent of the damage and
the replacement parts that are needed must be
calculated accurately, and then the actual work must
be performed accurately and efficiently.
The publications shown on the following page are also
available, and should be used in conjunction with this
manual.
SERVICE MANUAL MSCD-017B-2011
PARTS CATALOG BUMA8501A
BODY CONSTRUCTION . . . . . . . . .
BODY DIMENSIONS . . . . . . . . . . . . .
WELDED PANEL REPLACEMENT. .
CORROSION PROTECTION . . . . . .
BODY COLOR . . . . . . . . . . . . . . . . . .
BASE OF BODY REPAIR . . . . . . . . .
1
2
3
4
6
9
Mitsubishi Motors Corporation reserves the right to make changes in
design or to make additions to or improvements in its products without
imposing any obligations upon itself to install them on its products
previously manufactured.
©2010 Mitsubishi Motors Corporation
All Rights, Reserved
Printed in USA
MSSP-217B-2011
Page 15
GROUP 1
BODY
CONSTRUCTION
CONTENTS
1-1
BODY COMPONENTS. . . . . . . . . . . . 1-2
BODY MAIN CROSS-SECTIONAL
VIEWS . . . . . . . . . . . . . . . . . . . . . . . . 1-4
MAINTENANCE,
SERVICEABILITY . . . . . . . . . . . . . . . 1-6
BODY CONSTRUCTION
CHARACTERISTICS . . . . . . . . . . . . . 1-8
FRONT BODY. . . . . . . . . . . . . . . . . . . . . . . 1-8
SIDE BODY. . . . . . . . . . . . . . . . . . . . . . . . . 1-14
REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 1-16
ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 1-18
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
SILENCER APPLICATION
LOCATIONS . . . . . . . . . . . . . . . . . . . . 1-22
FOAMING MATERIAL USAGE
LOCATIONS . . . . . . . . . . . . . . . . . . . . 1-23
STIFFENER AND DAMP SHEET
APPLICATION LOCATIONS . . . . . . . 1-24
Page 16
1-2
ABA00162
AB
1
2
3
4*
56
90
5
7
9*
11
16
*
17
21
28
22
63
**
87
88
68
18
31
32
34
27
24
67
66
72
71**
84*
85
79
78*
8
6
19
65
81**
82
30
29
36*
33
39
69
42
45
46
70
47
49
50
51
91
92
48
89
38
40
41
20
10
62
12
13
14
15
64*
49
52
54
80
83
35
44
55
86
37
43
53
58
61
57
59
60*
73
74**
75*
76*
77**
23
25
26
: Anti-corrosion steel panels
: High-tensile steel panels (*: Indicates 590MPa-high-tensile steel panels.)
(**: Indicates 980MPa-ultra-high-tensile steel panels.)
NOTE:
BODY CONSTRUCTION
BODY COMPONENTS
BODY COMPONENTS
M4010001002056
TSB Revision
Page 17
BODY CONSTRUCTION
BODY COMPONENTS
1-3
1. Front bumper reinforcement
2. Headlight support panel upper
3. Front body frame to side sill brace
4. Front sidemember rear
5. Front inner sidemember
6. Headlight support panel
7. Front sidemember plate
8. Front outer sidemember
9. Front sidemember extension
10. Front fender gusset
11. Headlight support panel upper
12. Front fender shield
13. Engine mounting gusset
14. Fender shield frame upper inner
15. Spring house panel
16. Dash panel crossmember upper
17. Dash panel crossmember lower
18. Upper frame to front pillar brace
19. Front deck frame upper outer
20. Dash panel
21. Cowl top panel
22. Front deck crossmember
23. Front lower inner pillar
24. Hood panel inner
25. Hood panel outer
26. Front door side door beam
27. Front door panel inner
28. Front door panel outer
29. Rear door side door beam
30. Rear door side door beam lower
31. Rear door panel inner
32. Rear door panel outer
33. Roof rail front upper <Vehicles with panorama glass
roof>
34. Roof side rail <Vehicles with panorama glass roof>
35. Roof rail front
36. Roof bow center
37. Roof rail rear
38. Roof panel
39. Liftgate panel outer
40. Liftgate panel inner
41. Gate pillar reinforcement
42. Quarter panel extension outer
43. Quarter panel extension lower rear
44. Side outer panel
45. Fuel filler door panel (Left side)
46. Rear bumper reinforcement
47. Rear bumper reinforcement
48. Rear end panel outer
49. Rear end panel inner
50. Rear end inner crossmember
51. Rear floor crossmember
52. Rear floor crossmember
53. Rear floor
54. Second seat anchor reinforcement
55. Rear floor under stringer
56. Rear floor side panel
57. Rear floor sidemember extension
58. Rear floor sidemember lower
59. Rear floor extension
60. Rear floor rear seat under crossmember
61. Front floor
62. Front floor reinforcement
63. Front floor side sill inner
64. Front floor sidemember
65. Front floor crossmember rear center
66. Front floor crossmember front
67. Battery tray stay rear (Left side)
68. Battery tray stay front (Left side)
69. Radiator bracket lower
70. Headlight support panel lower
71. Front floor crossmember front
72 Front floor crossmember rear
73. Front floor backbone reinforcement
74. Side sill reinforcement
75. Front pillar reinforcement lower inner
76. Center pillar reinforcement
77. Front pillar reinforcement upper
78. Roof side rail reinforcement center
79. Roof side rail reinforcement rear
80. Center inner pillar
81. Front upper inner pillar
82. Roof rail extension front inner
83. Roof rail extension rear inner <Vehicles without
panorama glass roof>
84. Roof side rail inner
85. Rear wheel house panel inner
86. Rear pillar brace
87. Second seat anchor reinforcement
88. Quarter panel extension lower inner
89. Rear pillar inner
90. Quarter panel inner
91. Quarter panel extension inner
92. Rear pillar reinforcement lower
TSB Revision
Page 18
1-4
AB900379
AB
A
B
D
C
E
F
AB900400
AB
A
Roof panel
Roof rail
front
ABA00121
AB
B
Roof side rail
reinforcement
center
Side outer panel
Roof side
rail inner
Roof side reinforcement
support
AB900749
AB
Center pillar
reinforcement
Center pillar
inner upper
Rear door hinge
reinforcement
Side outer
panel
C
AB900399
D
AB
Front end
crossmember upper
Front end
crossmember lower
Front end
crossmember
bulkhead
AB900724
AB
E
Front pillar
reinforcement lower inner
Front pillar
inner lower
Side outer
panel
ABA00122
F
AB
Side sill reinforcement
outer rear
Side outer panel
Front floor
side sill inner
Side sill
reinforcement
support center
BODY CONSTRUCTION
BODY MAIN CROSS-SECTIONAL VIEWS
BODY MAIN CROSS-SECTIONAL VIEWS
M4010002001283
TSB Revision
Page 19
BODY CONSTRUCTION
AB900380
AB
G
I
J
K
H
L
AB900586
AB
G
Side outer
panel
Front upper
inner pillar
Front pillar reinforcement
upper
AB900401
AB
H
Roof panel
Roof rail rear inner
Roof rail rear outer
AB900648
AB
I
Quarter panel inner
Side outer panel
AB900649
J
AB
Gate pillar
reinforcement
upper
Quarter outer
panel extension upper
Second seat belt
reinforcement upper
(Left side)
Quarter panel inner
Side outer
panel
AB900725
AB
K
Rear pillar
reinforcement
lower
Rear wheel
house panel inner
Quarter panel
extension front
Side sill
end plate
Side outer
panel
AB900398
AB
L
Rear end
panel outer
Rear end inner
crossmember
Tailgate striker
reinforcement
BODY MAIN CROSS-SECTIONAL VIEWS
1-5
TSB Revision
Page 20
1-6
ABA00008
AB
BODY CONSTRUCTION
MAINTENANCE, SERVICEABILITY
MAINTENANCE, SERVICEABILITY
FENDER SHIELD
A positioning hole, lug, and notch have been added
on the front end upper bar side, front upper frame
inner, upper frame extension inner, front side mem
ber brace upper and dash panel to improve assembling workability during panel replacement.
M4010003001112
-
TSB Revision
Page 21
BODY CONSTRUCTION
AB201388
AB
Panel positioning notch
AB900484
AB
MAINTENANCE, SERVICEABILITY
SIDE STRUCTURE
A panel positioning notch has been added on the
door opening to improve assembling workability
when replacing the panel.
1-7
TSB Revision
Page 22
1-8
AB900381
3
1
4
7
5
6
2
AB
9
8
9
8
3
A
10
5
7
9.0 ± 2.0 N·m
80 ± 17 in-lb
9.0 ± 2.0 N·m
80 ± 17 in-lb
20 ± 5 N·m
15 ± 3 ft-lb
AB900384
AB
A
Crush box
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION CHARACTERISTICS
FRONT BODY
HEADLIGHT SUPPORT
• The crush box structure, which has an octagonal
cross-section at the front end of the front side
member, has been adopted. This structure can
effectively absorb energy upon frontal impact and
reduces the vehicle repair cost caused by a light
collision.
M4010010001608
• The bolt-on headlight support panel upper is
used to improve maintainability.
-
1. Front bumper reinforcement
2. Headlight support panel upper
3. Front end crossmember gusset
4. Front end crossmember upper
5. Radiator bracket lower A
6. Front end crossmember bulkhead
7. Radiator bracket lower B
8. Shipping hook front
9. Shipping reinforcement front
10. Front end crossmember lower
TSB Revision
The crush box structure has been changed to
straight type with an octagon cross-section so that
the structure can effectively absorb energy from the
impact at the time of collision.
Page 23
BODY CONSTRUCTION
AB602313
AB900390
1
15
21
7
AB
20
19
4
3
2
18
17
16
14
9
12
10
11
6
5
8
13
(Right side)
AB900741
AB
22
24
23
1
25
2
6
5
7
8
14
9
12
13
10
15
19
21
(Left side)
26
BODY CONSTRUCTION CHARACTERISTICS
FENDER SHIELD
• The front frame structure is supported in three
directions by the dash crossmember center, dash
crossmember lower and front sidemember rear in
order to improve the frontal collision characteris
tics, and increase the vehicle body rigidity.
• The padding structure of the front fender bracket
upper front and the front fender bracket rear has
been adopted to have a crushable structure in
-
order to efficiently absorb energy upon impact,
improving the pedestrian protection capability.
1-9
1. Front fender gusset
2. Front fender shield
3. Condense tank reinforcement
4. Engine mounting gusset
5. Front end upper bar side
6. Front fender bracket upper front
7. Upper frame bulkhead front
8. Front fender bracket rear
9. Upper frame bulkhead rear
10. Front upper frame inner
TSB Revision
11. Horn bracket
12. Spring house bracket reinforcement
13. Spring house corner gusset
14. Spring house bracket front
15. Spring house panel rear
16. Grand strap bracket
17. Suction hose bracket
18. Spring house harness bracket
19. Spring house panel
20. Engine mounting bracket upper
Page 24
1-10
ABA00123
3
13
2
9
8
12
11
10
19
16
6
*
18
14
1*
AB
17
5
*
20
4
15
7
21
22
(Right side)
NOTE: *: Indicates 590MPa-high-tensile steel panels.
23
ABA00125
AB
22
12
5
6
15
16
17
A
B
21
21
11
4
10
14
21. Front sidemember
22. Engine control module bracket
23. Relay box bracket
24. Relay box bracket rear
25. Transmission mounting gusset
26. Clutch tube bracket <M/T>
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
FRONT SIDEMEMBER REINFORCEMENT
The 590-MPa class high tensile strength steel panels
have been adopted for the front sidemember exten
sion, front sidemember rear bulkhead and front sidemember rear to improve the frontal collision
characteristics.
-
1. Front sidemember extension
2. Front sidemember outer
3. Front brake hose bracket
4. Front sidemember reinforcement rear lower
5. Front sidemember rear bulkhead
6. Front sidemember rear
7. Height sensor bracket
8. Dash crossmember extension lower
9. Front body frame to side sill brace
10. Tie down reinforcement front
11. Front suspension crossmember bracket front
12. Front sidemember inner
TSB Revision
13. Front sidemember plate
14. Front sidemember support front
15. Front sidemember bulkhead front
16. Engine mounting bulkhead
17. Front suspension crossmember bulkhead
18. Headlight bracket lower
19. Headlight support panel
20. Engine mounting reinforcement
21. Engine mounting bracket
22. Front sidemember brace upper
23. Front sidemember reinforcement rear
Page 25
BODY CONSTRUCTION
AB602309
2
16
AK
A
20
21
12
AB602310
2
17
AH
12
11
B
22
ABA00124
16
13
15
11
10
12
20
21
AB
14
18
6
7
8
19
17
9
*
4
*
5
*
22
23
NOTE:
*: Indicates 590MPa-high-tensile steel panels.
(Left side)
2
1
3
24 ± 4 N·m
18 ± 2 ft-lb
ABA00126
AB
18
15
23
17
5
16
22
A
B
3
4
6
11
BODY CONSTRUCTION CHARACTERISTICS
1-11
1. Dash crossmember extension lower
2. Front body frame to side sill brace
3. Tie down reinforcement front
4. Front sidemember rear
5. Front sidemember rear bulkhead
6. Front sidemember reinforcement rear lower
7. Front sidemember outer
8. Front brake hose bracket
9. Front sidemember extension
10. Harness bracket
11. Front sidemember support front
12. Front sidemember plate
TSB Revision
13. Battery tray stay front
14. Battery tray stay rear
15. Front suspension crossmember bracket front
16. Front sidemember inner
17. Front sidemember brace upper
18. Transmission mounting bracket
19. Connecter bracket
20. Headlight support panel
21. Headlight bracket lower
22. Front suspension crossmember bulkhead
23. Transmission mounting bulkhead
Page 26
1-12
AB602311
AF
16
23
A
7
18
AB602312
7
17
AF
15
16
B
22
AB602312
AB900743
5
6
10
AC
7
8
4
1
3
2
12
11
13
9
14
15
16
17
18
19
20
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
FRONT DECK
Rigidity was heightened and driving stability was
improved by bonding the front deck frame upper
outer and front pillar by the upper frame to front pillar
brace.
1. Brake pedal reinforcement upper
2. Insulator bracket
3. Harness bracket
4. Cowl top panel lower
5. Harness bracket
6. Wiper bracket center
7. Cowl top panel inner
8. Cowl top stay center
9. Cowl top panel upper
10. Deck crossmember bracket reinforcement
TSB Revision
11. Brake pedal support bracket
12. Deck crossmember bracket
13. Fender bracket
14. Cowl top bulkhead side
15. Clutch pedal support bracket <M/T>
16. Cowl top bracket side
17. Upper frame to front pillar brace
18. Front deck frame upper outer
19. Upper frame extension inner
20. Harness bracket
Page 27
BODY CONSTRUCTION
AB900742
AC
2
3*
13
9
6
1
5
7
12
4
14
15*
16
10*
11
8
17
NOTE: *: Indicates 590MPa-high-tensile steel panels.
18*
19
BODY CONSTRUCTION CHARACTERISTICS
DASH PANEL
• The front frame structure is supported in three
directions by the dash crossmember center, dash
crossmember lower and front sidemember rear in
order to improve the frontal collision characteris
tics, and increase the vehicle body rigidity.
• The 590-MPa class high tensile strength steel
panels have been adopted for the dash cross
member center, dash crossmember extension,
-
dash panel reinforcement and dash crossmem
ber side to improve the frontal collision characteristics.
1-13
-
-
1. Brake tube bracket
2. Harness bracket
3. Dash crossmember center
4. Dash heat protector bracket
5. Dash panel
6 Backbone reinforcement front
7. Dash panel lower
8. Accelerator pedal bracket
9. Steering shaft bracket
10. Dash panel reinforcement
11. Clutch pedal reinforcement <M/T>
12. EPS ECU A bracket
13. EPS ECU B bracket
14. EPS ECU C bracket
15. Dash crossmember side
16. Dash crossmember lower bulkhead
17. Canister bracket
18. Dash crossmember extension
19. Dash crossmember lower
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Page 28
1-14
ABA00131
AB
1
2
3**
5*
6*
7*
8
9
10
4
13
15
16
17
18
11
12
28
24
23
21
29
26
27
25
33
36
38
35
37
31
32
34
30
46
44
45
48
50
49*
47**
41
42
53
54
57**
56*
61
62*
52
55
64
65
63*
19
20
58
1
39
66
67
68
60**
59
40
51
22
43**
14
69
38
26
*: Indicates 590MPa-high-tensile steel panels.
**: Indicates 980MPa-ultra-high-tensile steel panels.
NOTE:
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
SIDE BODY
SIDE STRUCTURE
• The 590 MPa-high-tensile steel panel has been
adopted for the center pillar and the roof side rail,
and the 980 MPa-ultra-high-tensile steel panel
has been adopted for the front pillar and the side
sill to improve the collision characteristics.
• The front pillar, center pillar and rear pillar have
been connected to the roof, and the closed sec
tion structure has been adopted to the liftgate
opening to improve body rigidity, steering stability,
and riding comfort.
M4010011001560
-
TSB Revision
Page 29
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
1-15
1. Front pillar inner lower
2. Cowl side trim bracket
3. Front upper inner pillar
4. Roof rail extension front inner
5. Roof rail extension rear inner <Vehicles without
panorama glass roof>
6 Roof side rail inner
7. Center pillar inner upper
8. Center pillar inner lower
9. Cargo hook bracket
10. Rear wheel house reinforcement
11. Seat striker reinforcement
12. Gate pillar brace
13. Harness bracket (Right side)
14. Second seat anchor reinforcement
15. Gate inner pillar extension upper
16. Gate inner pillar upper
17. Second seat belt reinforcement upper (Left side)
18. Gate inner pillar lower
19. Second seat belt reinforcement lower (Left side)
20. Gate pillar reinforcement upper
21. Gate pillar reinforcement lower
22. Gate inner pillar extension lower
23. Quarter panel extension lower inner
24. Quarter panel inner
25. Headrest bracket
26. Rear wheel house panel inner
27. Filler pipe mounting bracket (Left side)
28. Side sill end plate
29. Rear pillar reinforcement lower
30. Quarter panel extension front
31. Fuel filler neck bracket (Left side)
32. Quarter outer panel extension rear
33. Liftgate damper reinforcement side
34. Gas spring reinforcement
35. Quarter outer panel extension upper
36. Rear combination lamp housing panel
37. ORVR bracket (Left side)
38. Nut plate
39. Side outer panel
40. Front fender bracket upper
41. Front fender bracket lower
42. Front fender bracket
43. Side sill reinforcement outer rear
44. Side sill bulkhead A
45. Side sill reinforcement support center
46. Side sill bulkhead C
47. Side sill reinforcement outer front
48. Side sill reinforcement support front
49. Side sill bulkhead front
50. Side sill inner support front
51. Front door hinge reinforcement lower
52. Front pillar reinforcement bulkhead center
53. Front door checker reinforcement
54. Front door hinge reinforcement upper
55. Front pillar reinforcement lower support
56. Front pillar reinforcement lower
57. Front pillar reinforcement upper
58. Center pillar seat belt reinforcement upper
59. Center pillar seat belt reinforcement lower
60. Rear door hinge reinforcement
61. Rear door hinge reinforcement lower
62. Center pillar reinforcement
63. Roof side rail reinforcement center
64. Roof side reinforcement support
65. Roof side rail reinforcement rear
66. Harness bracket (Left side)
67. Deck crossmember bracket (Right side)
68. Hood opener bracket (Left side)
69. Deck support pipe (Left side)
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Page 30
1-16
AB900434
Front pillar reinforcement
lower inner
AB900434
AB
Gate pillar brace
Front pillar reinforcement
upper
Gate pillar
reinforcement upper
Second seat anchor
reinforcement upper
Side sill
reinforcement
outer front
Side sill
reinforcement
outer rear
Center pillar
reinforcement
Rear pillar
reinforcement
lower
Gate pillar
reinforcement lower
Roof side rail
reinforcement
center
Roof side rail
reinforcement
rear
AB900394
AB
1
2
3
4
5
6
2
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
SIDE STRUCTURE REINFORCEMENT
The ring structure of the side structure reinforcement
has been adopted to improve the side collision char
acteristics and the rigidity of the whole vehicle.
-
REAR BODY
REAR END CROSSMEMBER
M4010012000946
1. Rear end inner crossmember
2. Rear end panel inner
3. Liftgate striker reinforcement
TSB Revision
4. Nut plate
5. Rear end panel outer
6. Rear bumper reinforcement
Page 31
BODY CONSTRUCTION
ABA00132
4
5
2
AB
7
10
6
8
1
12
14*
13*
15
16
2
3
3
1
9
6
15
11
11
<Vehicles without panorama glass roof>
NOTE: *: Indicates 590MPa-high-tensile steel panels.
17
17
AB900402
AC
19
5
3
2
1
6
7
8
18
20
21
3
2
18
19
1
15
16
15
6
14*
12
13*
<Vehicles with panorama glass roof>
NOTE: *: Indicates 590MPa-high-tensile steel panels.
BODY CONSTRUCTION CHARACTERISTICS
1-17
ROOF
The 590-MPa class high tensile strength steel panels
has been adopted for the roof bow center lower and
the roof rail front to improve the side collision charac
teristics.
M4010013001737
-
1. Roof rail bracket <Vehicles with roof rail>
2. Sunvisor bracket
3. Holder bracket
4. Map lamp bracket
5. Roof panel
6. Liftgate hinge reinforcement
7. Roof rail rear outer
TSB Revision
8. Roof rail rear inner
9. Roof bow C
10. Roof bow B
11. Head lining bracket
12. Roof bow center upper
13. Roof bow center lower
14. Roof rail front
Page 32
1-18
AB500724
AB900391
AF
6
7
5
1
3
8
16
**
12
9
11
*
10
4
13
14
2
**
15
*: Indicates 590MPa-high-tensile steel panels.
**: Indicates 980MPa-ultra-high-tensile steel panels.
NOTE :
15. Roof rail bracket front <Vehicles with roof rail>
16. Roof rail bracket <Vehicles with roof rail>
17. Roof rail bracket <Vehicles without roof rail>
18. Roof side rail plate lower
19. Roof side rail plate upper
20. Roof rail front upper
21. Roof rail support
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
UNDER BODY
FRONT FLOOR
The 590-MPa class high tensile strength steel panels
have been adopted for the front floor sidemember
front, and the 980-MPa class ultra high tensile
strength steel panels for the front floor crossmember
front and front floor side sill inner, to improve the
body rigidity.
M4010014001570
1. Front floor
2. Front floor crossmember front
3. Parking brake lever reinforcement
4. Backbone reinforcement
5. Parking brake cable reinforcement
6. Seat center bracket rear
7. Front floor crossmember rear
8. Seat side bracket rear
TSB Revision
9. Front floor sidemember plate
10. Front floor reinforcement
11. Front floor sidemember front
12. Front floor crossmember rear center
13. Muffler hanger rear hook
14. Front floor crossmember front
15. Seat belt reinforcement
16. Front floor side sill inner
Page 33
BODY CONSTRUCTION
AB900392
AB
1*
3
5
2
7
11
12
13
17
14
15*
16
6
16
10
4
8
14
9
8
*: Indicates 590MPa-high-tensile steel panels.
NOTE :
BODY CONSTRUCTION CHARACTERISTICS
REAR FLOOR
The 590-MPa class high tensile strength steel panels
have been adopted for the rear floor extension and
rear seat crossmember to improve the side collision
characteristics.
1-19
1. Rear floor extension
2. Rear seat reinforcement front side
3. Rear floor
4. Spare tire reinforcement
5. Rear floor crossmember
6. Rear seat bracket
7. Rear floor crossmember front
8. Fuel tank rear bracket
9. Second seat reinforcement center
10. Nut plate
11. Second seat hinge reinforcement
12. Front stringer
13. Rear seat crossmember bulkhead inner
14. Rear seat crossmember bulkhead side
15. Rear seat crossmember
16. Sidemember front floor extension
17. Rear floor sidemember
TSB Revision
Page 34
1-20
ABA00127
AB
NOTE :
*: Indicates 590MPa-high-tensile steel panels.
1*
2
3
5
6
7
8
9
10
11
12
13*
14
15
16
17
4
29
18
19
20*
21
22
23
24
25
26
27
28
ABA00128
AB
29
1
18
28 7
22
A
B
20
19
21
17
23
9
24
27
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
REAR FLOOR SIDEMEMBER
REINFORCEMENT
The 590-MPa class high tensile strength steel panels
have been adopted for the rear floor sidemember
reinforcement, rear floor side sill inner and rear floor
sidemember bulkhead to improve the rear collision
characteristics.
1. Rear floor sidemember reinforcement
2. Rear floor side panel
3. Seat under frame reinforcement
4. Bracket
5. Muffler rear hanger
6. Shipping pipe
7. Rear floor sidemember extension
8. Rear bumper support
9. Canister bracket center
10. Rear spring house panel
11. Rear spring house bracket
TSB Revision
12. Rear spring house reinforcement
13. Rear floor side sill inner
14. Rear suspension bracket front
15. Rear brake hose bracket
16. Rear parking brake cable rear bracket
17. Rear floor sidemember lower
18. Rear floor sidemember extension front
19. Rear tie down plate
20. Rear floor sidemember bulkhead
21. Rear floor sidemember reinforcement A
22. Trailing arm bracket
Page 35
BODY CONSTRUCTION
AB900397
A
AC
1
17
13
22
2
AB900396
B
26
27
AC
2
17
11
AB900416
6
1
13
10
3
AB
11
2
5
8
9
7
4
12
Welded area
(Front door)
BODY CONSTRUCTION CHARACTERISTICS
23. Rear floor sidemember reinforcement front
24. Rear floor sidemember reinforcement rear
25. Rear floor crossmember extension front
26. Rear floor crossmember extension rear
27. Rear floor sidemember bulkhead rear
28. Rear suspension bracket rear
29. Pipe nut
1-21
DOOR
An uneven thickness steel sheet* has been used for
the front door panel inners to make the forward part
of the vehicle thicker for reduction in vehicle weight
and higher rigidity.
M4010015001089
NOTE: *: A steel sheet of varying thickness that is
welded into one steel sheet.
TSB Revision
Page 36
1-22
ABA00129
AB
18
21
19
17
16
22
23
25
15
24
20
14
(Rear door)
AB900571
AB
: 2.5 mm film thick spray-type anti-vibration agent. (Place two 1.6 mm melting sheet one on top of another.)
: 5.0 mm film thick spray-type anti-vibration agent. (Place four 1.6 mm melting sheet one on top of another.)
( ) indicates the number of 1.6 mm thick melting sheets that are used for repair.
NOTE:
BODY CONSTRUCTION
SILENCER APPLICATION LOCATIONS
1. Front door panel outer
2. Front door window upper sash
3. Front door window rear sash
4. Front door latch reinforcement
5. Front door panel inner
6. Front door side door beam
7. Nut plate
8. Nut plate
9. Front door outer stiffener
10. Front door beltline outer reinforcement
11. Front door mirror reinforcement
12. Front door window front sash
13. Front door beltline inner reinforcement
SILENCER APPLICATION LOCATIONS
A silencer (spray-type anti-vibration agent) has been
adhered on the top part of the floor to improve
anti-vibration performance and to shutout exhaust
gas heat.
14. Rear door panel outer
15. Rear door window upper sash
16. Rear door window rear sash
17. Rear door latch reinforcement
18. Rear door panel inner
19. Rear door side door beam
20. Rear door side door beam lower
21. Rear door hinge reinforcement
22. Nut plate
23. Nut plate
24. Rear door window front sash
25. Rear door beltline outer reinforcement
M4010000100117
TSB Revision
Page 37
BODY CONSTRUCTION
CAUTION
AB900748
AB
Sound dampening foam material
Sound dampening foam material
FOAMING MATERIAL USAGE LOCATIONS
1-23
FOAMING MATERIAL USAGE LOCATIONS
The sound dampening foam material may burn
when heated. Always observe the following
instructions:
• Never use a gas burner to burn the areas
where sound dampening foam material is
used.
• When cutting the parts which are provided
with sound dampening foam material, ensure
to use tools (air saw, etc.) that do not gener
ate fire.
• If there are residual sound dampening foam
material remaining on the cut section (body
side), remove the sound dampening foam
material from periphery of the welding area
before welding work.
The sound dampening foam material has been
adopted to the upper and lower sections of the front
pillar, center pillar lower section, wheel house arch,
and rear end inside to shield from external noise.
-
M4010006000282
TSB Revision
Page 38
1-24
ABA00130
ABA00013
AB
Damp sheet (Cowl top insulator upper)
BODY CONSTRUCTION
STIFFENER AND DAMP SHEET APPLICATION LOCATIONS
STIFFENER AND DAMP SHEET APPLICATION LOCATIONS
M4010001400489
To increase the surface rigidity, the stiffener has
been attached to the passenger compartment side of
the front door outer panel, rear door outer panel and
side outer panel, and the damp sheet has been
attached to the passenger compartment side of the
cowl top panel inner.
NOTE: .
•
The main contents of a stiffener are epoxy resin.
It comes in a sheet form and contains a mixture
of glass fiber and filler, and cures (stiffens) when
heated.
•
No spare part of the stiffener for repair is available in the field. If the stiffener is damaged,
replace it together with the panel.
TSB Revision
Page 39
GROUP 2
BODY DIMENSIONS
CONTENTS
2-1
BODY DIMENSIONS AND
MEASUREMENT METHODS. . . . . . . 2-2
TYPE A
(PROJECTED DIMENSIONS) . . . . . . 2-3
UNDER BODY . . . . . . . . . . . . . . . . . . . . . . 2-3
SUSPENSION INSTALLATION
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . 2-6
TYPE B (ACTUAL-MEASUREMENT
DIMENSIONS) . . . . . . . . . . . . . . . . . . 2-8
UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 2-8
SUSPENSION INSTALLATION
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . 2-10
FRONT BODY . . . . . . . . . . . . . . . . . . . . . . . 2-12
SIDE BODY . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 2-18
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
ROOF <VEHICLES WITH PANORAMA
GLASS ROOF> . . . . . . . . . . . . . . . . . . . . . . 2-24
Page 40
2-2
AB302138
AE
Probe
Height
Projected dimension
AB302139
AE
A'
A
Actual-measured
dimension
AB302140
AF
Center of hole
AB302141
AD
BODY DIMENSIONS
BODY DIMENSIONS AND MEASUREMENT METHODS
BODY DIMENSIONS AND MEASUREMENT METHODS
M4020001000448
• Type A (projected dimensions) is the dimension when a
measurement location is projected onto the plane.
NOTE: The height indicates a distance from the assumed
standard line established 100 mm (3.9in) below the lowest
measurement point.
• Type B (actual-measurement dimensions) is 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.
• Insert the tracking gauge probes securely into the measurement holes.
• When the standard dimensions in the illustration are
enclosed by rectangle, this indicates that the symmetrical
left and right positions have the same dimensions.
• When using a notch for dimension measurement, set the
measuring point at the center of the outer panel notch.
• The body center points are shown for the purpose of checking the position of the left and right symmetry location.
TSB Revision
Page 41
BODY DIMENSIONS
AB900410
1
2
3
4
6
5
7
9
10
11
12
13
8
AB
Center line
of the vehicle
mm (in)
967
(38.1)
960
(37.8)
616
(24.3)
616
(24.3)
910
(35.8)
510
(20.1)
540
(21.3)
1,050
(41.3)
875
(34.4)
564
(22.2)
624
(24.6)
462
(18.2)
375
(14.8)
197
(7.8)
894
(35.2)
894
(35.2)
350
(13.8)
701
(27.6)
1,262
(49.7)
877
(34.5)
990
(39.0)
1,022
(40.2)
752
(29.6)
833
(32.8)
726
(28.6)
344
(13.5)
393
(15.5)
440
(17.3)
374
(14.7)
76
(3.0)
76
(3.0)
AB900411
AB
123
4
7
5
6
9
10
11
12
13
8
1028
Center line of the vehicle
544
(21.4)
960
(37.8)
993
(39.1)
969
(38.1)
964
(38.0)
1,394
(54.9)
1,028
(40.5)
1,124
(44.3)
1,138
(44.8)
1,218
(48.0)
1,025
(40.4)
1,240
(48.8)
1,342
(52.8)
1,217
(47.9)
1,126
(44.3)
1,120
(44.1)
1,079
(42.5)
763
(30.0)
641
(25.2)
686
(27.0)
1,272
(50.1)
TYPE A (PROJECTED DIMENSIONS)
TYPE A (PROJECTED DIMENSIONS)
2-3
UNDER BODY
M4020005002509
TSB Revision
Page 42
2-4
AB900412
AB
5
3
4
6
7
8
9
10
12
11
13
1
2
Standard line
NOTE: The assumed standard line is established 100 mm (3.9 in) below the measurement point No.5.
mm (in)
105
(4.1)
100
(3.9)
157
(6.2)
105
(4.1)
230
(9.1)
154
(6.1)
347
(13.7)
354
(13.9)
357
(14.1)
1,125
(44.3)
1,049
(41.3)
286
(11.3)
259
(10.2)
510
(20.1)
716
(28.2)
486
(19.1)
280
(11.0)
294
(11.6)
350
(13.8)
1,475
(58.1)
1,136
(44.7)
750
(29.5)
326
(12.8)
AB900418
1, 3
1
3
AB
AB900419
2
AB
AB900420
4
AB
TYPE A (PROJECTED DIMENSIONS)
BODY DIMENSIONS
No. Standard measurement point Hole shape Size mm (in)
1 Center of front end crossmember lower water draining hole (left side) Round 8.0 (0.31)
2 Center of front end crossmember lower water draining hole (right side) Round 8.0 (0.31)
3* Center of front sidemember inner positioning hole Round 25.0 (0.98)
4* Center of front axle crossmember mounting hole Round 15.5 (0.61)
5* Center of front sidemember rear water draining hole Round 16.0 (0.63)
6 Center of propeller shaft assembly mounting hole (left side) Round 11.0 (0.43)
7 Center of propeller shaft assembly mounting hole (right side) Round 11.0 (0.43)
8* Center of front floor sidemember front positioning hole Round 16.0 (0.63)
9* Center of front floor sidemember front positioning hole Round 16.0 (0.63)
10* Center of rear floor sidemember lower positioning hole Oblong 33.9×18.0
×0.71)
(1.33
11* Center of rear suspension bracket front water draining hole Round 16.0 (0.63)
12* Center of rear floor sidemember lower positioning hole Round 25.0 (0.98)
13* Center of trailer hitch mounting hole Round 11.0 (0.43)
NOTE: The * mark indicates the mounting position for the frame centering gauge.
TSB Revision
Page 43
BODY DIMENSIONS
AB900429
5
AB
AB600999
6, 7
AB
6
7
AB900422
8, 9
AB
8
9
AB900423
AB
10
AB900424
AB
11
AB900425
12, 13
12
13
AB
TYPE A (PROJECTED DIMENSIONS)
2-5
TSB Revision
Page 44
2-6
AB900413
AB
4
5
9
15
16
17
14
18
20
19
1093
Center line of the vehicle
903
(35.6)
894
(35.2)
886
(34.9)
mm (in)
510
(20.1)
875
(34.4)
910
(35.8)
1,129
(44.4)
1,000
(39.4)
441
(17.4)
293
(11.5)
217
(8.5)
1,288
(50.7)
1,092
(43.0)
1,093
(43.0)
603
(23.7)
579
(22.8)
822
(32.4)
695
(27.4)
714
(28.1)
289
(11.4)
254
(10.0)
98
(3.9)
AB900414
AB
4
5
9
15
16
17
14
18
20
19
Center line of the vehicle
1,048
(41.3)
945
(37.2)
907
(35.7)
1,028
(40.5)
1,145
(45.1)
1,231
(48.5)
1,212
(47.7)
1,294
(50.9)
1,253
(49.3)
1,171
(46.1)
1,076
(42.4)
BODY DIMENSIONS
TYPE A (PROJECTED DIMENSIONS)
SUSPENSION INSTALLATION DIMENSIONS
M4020013002407
No. Standard measurement point Hole shape Size mm (in)
4 Center of front axle crossmember mounting hole Round 15.5 (0.61)
5 Center of front sidemember rear water draining hole Round 16.0 (0.63)
9 Center of front floor sidemember front positioning hole Round 16.0 (0.63)
14 Center of front shock absorber mounting hole Round 80.0 (3.15)
15 Center of front axle crossmember mounting hole Round 15.5 (0.61)
16 Center of trailing arm assembly mounting hole Round 14.0 (0.55)
17 Center of trailing arm assembly mounting hole Round 14.0 (0.55)
18 Center of rear suspension crossmember mounting hole Round 15.0 (0.59)
19 Center of rear shock absorber mounting hole Round 64.0 (2.52)
20 Center of rear suspension crossmember mounting hole Round 15.0 (0.59)
TSB Revision
Page 45
BODY DIMENSIONS
AB900415
A
6˚54´
B
6˚30´
3˚06´
0˚
AB
A
B
4
5 9
15
16
17
14
18
20
19
Vehicle center
Standard line
NOTE: The assumed standard line is established 100 mm (3.9 in) below the measurement point No.5.
Vehicle center
1,122
(44.2)
539
(21.2)
100
(3.9)
mm (in)
782
(30.8)
294
(11.6)
510
(20.1)
284
(11.2)
354
(13.9)
162
(6.4)
217
(8.5)
105
(4.1)
1,258
(49.5)
1,066
(42.0)
820
(32.3)
462
(18.2)
570
(22.4)
222
(8.7)
AB900420
4
AB
AB900421
5, 15
15
AB
5
AB900430
9
AB
AB900426
AB
14
AB900431
16, 17, 18
AB
17
18
16
AB900427
19, 20
19
20
AB
TYPE A (PROJECTED DIMENSIONS)
2-7
TSB Revision
Page 46
2-8
AB900367
AB
1
2
3
4
7
5
6
9
10
11
12
13
8
967
(38.1)
960
(37.8)
542
(21.3)
546
(21.5)
1,079
(42.5)
910
(35.8)
875
(34.4)
894
(35.2)
894
(35.2)
877
(34.5)
990
(39.0)
487
(19.2)
1,262
(49.7)
567
(22.3)
378
(14.9)
350
(13.8)
644
(25.4)
mm (in)
1,022
(40.2)
344
(13.5)
399
(15.7)
460
(18.1)
101
(4.0)
102
(4.0)
616
(24.3)
616
(24.3)
222
(8.7)
702
(27.6)
774
(30.5)
856
(33.7)
729
(28.7)
378
(14.9)
AB900368
AB
123
4
7
5
6
9
10
11
12
13
8
566
(22.3)
960
(37.8)
993
(39.1)
1,415
(55.7)
1,127
(44.4)
1,046
(41.2)
1,225
(48.2)
1,027
(40.4)
1,242
(48.9)
1,230
(48.4)
1,356
(53.4)
1,120
(44.1)
765
(30.1)
643
(25.3)
1,273
(50.1)
704
(27.7)
1,138
(44.8)
1,081
(42.6)
971
(38.2)
966
(38.0)
1,124
(44.3)
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
UNDER BODY
M4020005002491
TSB Revision
Page 47
BODY DIMENSIONS
AB900418
1, 3
1
3
AB
AB900419
2
AB
AB900420
4
AB
AB900429
5
AB
AB600999
6, 7
AB
6
7
AB900422
8, 9
AB
8
9
AB900423
AB
10
AB900424
AB
11
AB900425
12, 13
12
13
AB
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
2-9
No. Standard measurement point Hole shape Size mm (in)
1 Center of front end crossmember lower water draining hole (left side) Round 8.0 (0.31)
2 Center of front end crossmember lower water draining hole (right side) Round 8.0 (0.31)
3 Center of front sidemember inner positioning hole Round 25.0 (0.98)
4 Center of front axle crossmember mounting hole Round 15.5 (0.61)
5 Center of front sidemember rear water draining hole Round 16.0 (0.63)
6 Center of propeller shaft assembly mounting hole (left side) Round 11.0 (0.43)
7 Center of propeller shaft assembly mounting hole (right side) Round 11.0 (0.43)
8 Center of front floor sidemember front positioning hole Round 16.0 (0.63)
9 Center of front floor sidemember front positioning hole Round 16.0 (0.63)
10 Center of rear floor sidemember lower positioning hole Oblong 33.9×18.0
×0.71)
(1.33
11 Center of rear suspension bracket front water draining hole Round 16.0 (0.63)
12 Center of rear floor sidemember lower positioning hole Round 25.0 (0.98)
13 Center of trailer hitch mounting hole Round 11.0 (0.43)
TSB Revision
Page 48
2-10
AB900369
AB
4 5
9
15
16
17
18
20
886
(34.9)
mm (in)
546
(21.5)
875
(34.4)
910
(35.8)
226
(8.9)
322
(12.7)
903
(35.6)
894
(35.2)
841
(33.1)
1,000
(39.4)
1,288
(50.7)
1,092
(43.0)
707
(27.8)
727
(28.6)
614
(24.2)
590
(23.2)
262
(10.3)
295
(11.6)
98
(3.9)
446
(17.6)
AB900370
AB
4 5 915
16
17
18
20
954
(37.6)
909
(35.8)
1,046
(41.2)
1,050
(41.3)
1,151
(45.3)
1,173
(46.2)
1,236
(48.7)
1,219
(48.0)
1,265
(49.8)
1,300
(51.2)
1,077
(42.4)
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
SUSPENSION INSTALLATION DIMENSIONS
M4020013002418
No. Standard measurement point Hole shape Size mm (in)
4 Center of front axle crossmember mounting hole Round 15.5 (0.61)
5 Center of front sidemember rear water draining hole Round 16.0 (0.63)
9 Center of front floor sidemember front positioning hole Round 16.0 (0.63)
15 Center of front axle crossmember mounting hole Round 15.5 (0.61)
16 Center of trailing arm assembly mounting hole Round 14.0 (0.55)
17 Center of trailing arm assembly mounting hole Round 14.0 (0.55)
18 Center of rear suspension crossmember mounting hole Round 15.0 (0.59)
20 Center of rear suspension crossmember mounting hole Round 15.0 (0.59)
TSB Revision
Page 49
BODY DIMENSIONS
AB900420
4
AB
AB900421
5, 15
15
AB
5
AB900430
9
AB
AB900431
16, 17, 18
AB
17
18
16
AB900432AB
20
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
2-11
TSB Revision
Page 50
2-12
AB900466
21
23
22
24
25
34
26
27
33
AB
28
30
31
29
32
Body center point
1,672
(65.8)
1,624
(63.9)
1,111
(43.7)
1,026
(40.4)
944
(37.2)
512
(20.2)
917
(36.1)
412
(16.2)
416
(16.4)
891
(35.1)
418
(16.5)
419
(16.5)
1,494
(58.8)
1,436
(56.5)
1,450
(57.1)
1,516
(59.7)
1,524
(60.0)
1,069
(42.1)
1,060
(41.7)
1,166
(45.9)
1,168
(46.0)
mm (in)
283
(11.1)
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
FRONT BODY
M4020006001606
TSB Revision
Page 51
BODY DIMENSIONS
AB900363
35
38
39
40
AB
41
43
42
44
36
37
21
26
27
28
30
31
35
36
21
23
22
24
25
28
30
31
29
37
Body center point
Body center point
Body center point
877
(34.5)
748
(29.4)
630
(24.8)
713
(28.1)
841
(33.1)
230
(9.1)
276
(10.9)
834
(32.8)
714
(28.1)
719
(28.3)
789
(31.1)
880
(34.6)
625
(24.6)
741
(29.2)
1,065
(41.9)
1,468
(57.8)
1,459
(57.4)
1,076
(42.4)
1,026
(40.4)
1,391
(54.8)
1,460
(57.5)
1,492
(58.7)
1,496
(58.9)
1,466
(57.7)
1,559
(61.4)
391
(15.4)
392
(15.4)
336
(13.2)
265
(10.4)
269
(10.6)
880
(34.6)
867
(34.1)
826
(32.5)
883
(34.8)
858
(33.8)
913
(35.9)
820
(32.3)
961
(37.8)
mm (in)
773
(30.4)
363
(14.3)
365
(14.4)
548
(21.6)
369
(14.5)
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
2-13
TSB Revision
Page 52
2-14
AB900438
22
21
AB
21, 22, 39
39
AB900439
AB
23, 40
40
23
AB900440
24
AB
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
BODY DIMENSIONS
No. Standard measurement point Hole shape Size mm (in)
21 Center of front bumper reinforcement mounting hole Round 9.0 (0.35)
22 Center of front bumper reinforcement mounting hole (left side) Round 9.0 (0.35)
23 Center of front bumper reinforcement mounting hole (right side) Round 9.0 (0.35)
24 Center of front sidemember inner positioning notch (left side)
25 Center of front sidemember inner positioning notch (right side)
− −
− −
26 Center of headlight support panel upper mounting hole (left side) Round 6.6 (0.26)
27 Center of headlight support panel upper mounting hole (right side) Round 6.6 (0.26)
28 Center of front end upper bar side positioning hole Round 5.0 (0.20)
29 Center of front strut mounting hole Round 11.5 (0.45)
30 Center of front fender mounting hole Round 6.6 (0.26)
31 Center of hood hinge mounting hole Round 9.0 (0.35)
32 Center of pin mounting hole (Body center point) Rectangle 8.0×10.0
(0.31
×0.39)
33 Corner of roof panel <vehicles without panorama glass roof>
34 Center of roof rail mounting hole <vehicles with panorama glass
− −
Round 6.6 (0.26)
roof>
35 Center of charge air cooler bracket mounting hole (left side) Round 9.0 (0.35)
36 Center of charge air cooler bracket mounting hole (right side) Round 9.0 (0.35)
37 Cowl top panel lower positioning notch (Body center point)
38 Front end crossmember upper positioning notch (Body center point)
− −
− −
39 Center of front fender gusset positioning hole (left side) Round 15.0 (0.59)
40 Center of front fender gusset positioning hole (right side) Round 15.0 (0.59)
41 Center of headlight support panel upper mounting hole (left side) Round 6.6 (0.26)
42 Center of headlight support panel upper mounting hole (right side) Round 6.6 (0.26)
43 Center of front fender mounting hole Round 6.6 (0.26)
44 Center of front fender mounting hole Round 7.0 (0.28)
TSB Revision
Page 53
BODY DIMENSIONS
AB900441
25
AB
AB900442
26, 41
26
41
AB
AB900443
27, 42
27
42
AB
AB900444
28, 43
28
43
AB
AB900445
29, 30
30
29
AB
AB900446
31, 44
44
31
AB
AB900447
32
AB
AB900481
33
AB
AB900448
34
AB
AB700488
35, 38
38
35
AC
AB700489
36
AC
AB900449
37
AB
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
2-15
TSB Revision
Page 54
2-16
AB900371
45
47
46
48
50
49
51
53
52
54
AB
mm (in)
751
(29.6)
862
(33.9)
869
(34.2)
649
(25.6)
749
(29.5)
960
(37.8)
792
(31.2)
715
(28.1)
705
(27.8)
1,093
(43.0)
1,064
(41.9)
1,089
(42.9)
1,210
(47.6)
AB900372
56
55
57
59
58
47 51
AB
409
(16.1)
1,092
(43.0)
1,216
(47.9)
354
(13.9)
1,118
(44.0)
1,118
(44.0)
842
(33.1)
954
(37.6)
939
(37.0)
609
(24.0)
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
SIDE BODY
M4020007001342
No. Standard measurement point Hole shape Size mm (in)
45 Front pillar positioning notch
46 Front pillar positioning notch
47 Roof side rail positioning notch
48 Side sill positioning notch
49 Center pillar positioning notch
50 Center pillar positioning notch
51 Roof side rail positioning notch
52 Side sill positioning notch
53 Quarter panel positioning notch
54 Quarter panel positioning notch
55 Center of front door upper hinge mounting hole Round 11.0 (0.43)
56 Center of front door lower hinge mounting hole Round 11.0 (0.43)
− −
− −
− −
− −
− −
− −
− −
− −
− −
− −
TSB Revision
Page 55
BODY DIMENSIONS
AB900452
45
AB
AB900453
46, 56
46
56
AB
AB900454
47
AB
AB900455
48
AB
AB900456
49
AB
AB900457
50, 58
50
58
AB
AB900458
51, 53
51
53
AB
AB900459
52
AB
AB900460
54
AB
AB900461
55
AB
AB900462
57
AB
AB900463
59
AB
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
2-17
No. Standard measurement point Hole shape Size mm (in)
57 Center of rear door upper hinge mounting hole Round 11.0 (0.43)
58 Center of rear door lower hinge mounting hole Round 11.0 (0.43)
59 Center of rear door switch mounting hole Round 5.0 (0.20)
TSB Revision
Page 56
2-18
AB900365
AB
66
62
64
63
65
61
60
mm (in)
979
(38.5)
992
(39.1)
990
(39.0)
700
(27.6)
1,120
(44.1)
1,173
(46.2)
1,236
(48.7)
1,302
(51.3)
1,405
(55.3)
680
(26.8)
353
(13.9)
648
(25.5)
683
(26.9)
1,139
(44.8)
1,100
(43.3)
1,522
(59.9)
AB900366
AB
65
67
66
1,201
(47.3)
631
(24.8)
1,050
(41.3)
117
(4.6)
1,260
(49.6)
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
REAR BODY
M4020008001312
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Page 57
BODY DIMENSIONS
AB900467
60, 61
AB
60
61
AB900468
AB
62 67
62, 63, 67
63
AB900471
AB
64
AB900470
AB
65, 66
66
65
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
2-19
No. Standard measurement point Hole shape Size mm (in)
60 Center of liftgate hinge mounting hole Round 12.0 (0.47)
61 Center of liftgate gas spring mounting hole Round 9.0 (0.35)
62 Center of rear combination light mounting hole Round 8.0 (0.31)
63 Center of rear bumper mounting hole Round 7.0 (0.28)
64 Center of liftgate striker mounting hole Round 14.0 (0.55)
65 Center of rear bumper reinforcement mounting hole Round 15.0 (0.59)
66 Center of rear bumper reinforcement mounting hole Round 15.0 (0.59)
67 Center of rear combination light mounting hole Square 8.5 (0.33)
TSB Revision
Page 58
2-20
AB900373
AB
48
46
45
47
53
50
49
51
54
52
1,331
(52.4)
1,215
(47.8)
1,244
(49.0)
1,356
(53.4)
1,369
(53.9)
mm (in)
1,430
(56.3)
1,430
(56.3)
1,439
(56.7)
1,430
(56.3)
1,430
(56.3)
AB900374
AB
68
48
46
45
47
53
50
49
51
69
54
52
Body center point
Body center point
1,039
(40.9)
1,222
(48.1)
1,217
(47.9)
1,169
(46.0)
1,169
(46.0)
1,181
(46.5)
807
(31.8)
785
(30.9)
719
(28.3)
783
(30.8)
AB900375
AB
69
70
71
Body center point
1,093
(43.0)
1,017
(40.0)
1,040
(40.9)
700
(27.6)
518
(20.4)
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
INTERIOR
M4020009001683
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Page 59
BODY DIMENSIONS
AB900452
45
AB
AB900478
46
AB
AB900454
47
AB
AB900455
48
AB
AB900456
49
AB
AB900479
50
AB
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
2-21
No. Standard measurement point Hole shape Size mm (in)
45 Front pillar positioning notch
46 Front pillar positioning notch
− −
− −
47 Roof side rail positioning notch
48 Side sill positioning notch
49 Center pillar positioning notch
50 Center pillar positioning notch
51 Roof side rail positioning notch
52 Side sill positioning notch
53 Quarter panel positioning notch
54 Quarter panel positioning notch
− −
− −
− −
− −
− −
− −
− −
− −
68 Center of backbone reinforcement positioning hole (Body center point) Round 25.0 (0.98)
69 Body center point of rear floor extension (Body center point)
− −
70 Center of rear shock absorber mounting hole Round 14.0 (0.55)
71 Center of rear end trim mounting hole Round 8.5 (0.33)
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Page 60
2-22
AB900458
51, 53
51
53
AB
AB900459
52
AB
AB900460
54
AB
AB900464
68
AB
AB900465
69
AB
AB900469
AB
70
AB900472
AB
71
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
TSB Revision
Page 61
BODY DIMENSIONS
AB900376AD
73
72
74
75
1,431
(56.3)
1,431
(56.3)
1,428
(56.2)
106
(4.2)
1,435
(56.5)
mm (in)
102
(4.0)
AB900473
72, 73
72
73
AC
AB900474
74, 75
75
74
AC
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
2-23
No. Standard measurement point Hole shape Size mm (in)
72 Center of front deck crossmember mounting hole Round 13.0 (0.51)
73 Center of front deck crossmember mounting hole Round 13.0 (0.51)
74 Center of front deck crossmember mounting hole Round 9.0 (0.35)
75 Center of front deck crossmember mounting hole Round 9.0 (0.35)
TSB Revision
Page 62
2-24
AB900388
AD
76
77 78
mm (in)
980
(38.6)
815
(32.1)
338
(13.3)
680
(26.8)
916
(36.1)
942
(37.1)
584
(23.0)
1,151
(45.3)
1,223
(48.1)
AB900475
AD
76
AB900476
AD
77
AB900477
AD
78
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
ROOF <VEHICLES WITH PANORAMA GLASS ROOF>
M4020015000076
No. Standard measurement point Hole shape Size mm (in)
76 Center of roof rail front upper positioning hole Oblong 14.0×10.0
(0.55
×0.39)
77 Center of roof side rail plate upper positioning hole Round 8.0 (0.31)
78 Center of roof side rail plate upper positioning hole Round 8.0 (0.31)
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Page 63
GROUP 3
WELDED PANEL
REPLACEMENT
CONTENTS
3-1
ULTRA HIGH STRENGTH
STEEL PLATE . . . . . . . . . . . . . . . . . . 3-2
FRONT END CROSSMEMBER . . . . . 3-3
FENDER SHIELD. . . . . . . . . . . . . . . . 3-4
FRONT SIDEMEMBER
(PARTIAL REPLACEMENT) . . . . . . . 3-8
FRONT PILLAR . . . . . . . . . . . . . . . . . 3-9
FRONT PILLAR
(PARTIAL REPLACEMENT) . . . . . . . 3-14
CENTER PILLAR . . . . . . . . . . . . . . . . 3-18
SIDE SILL. . . . . . . . . . . . . . . . . . . . . . 3-22
QUARTER OUTER . . . . . . . . . . . . . . 3-26
ROOF . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
REAR END CROSSMEMBER . . . . . . 3-32
REAR FLOOR. . . . . . . . . . . . . . . . . . . 3-33
QUARTER INNER. . . . . . . . . . . . . . . . 3-35
QUARTER INNER
(PARTIAL REPLACEMENT) . . . . . . . 3-39
FRONT DOOR OUTER PANEL
(WELDED TYPE) . . . . . . . . . . . . . . . . 3-41
FRONT DOOR OUTER PANEL
(ADHESION TYPE). . . . . . . . . . . . . . . 3-42
REAR DOOR OUTER PANEL
(WELDED TYPE) . . . . . . . . . . . . . . . . 3-43
REAR DOOR OUTER PANEL
(ADHESION TYPE). . . . . . . . . . . . . . . 3-44
Page 64
3-2
WELDED PANEL REPLACEMENT
ULTRA HIGH STRENGTH STEEL PLATE
ULTRA HIGH STRENGTH STEEL PLATE
ADVANTAGES OF ULTRA HIGH
STRENGTH STEEL PLATE
The ultra high strength steel plate has the following
advantages as compared with conventional high
strength steel plate.
• It has tensile strength approximately 1.7 times
higher than the conventional high strength steel
sheet.
• It has a higher yielding point and yielding ratio
(yielding point/tensile strength).
These advantages allow thinner and lighter plates
and better fuel efficiency than the high strength steel
plate.
M4030002800073
PRECAUTION UPON MAINTENANCE OF
ULTRA HIGH STRENGTH STEEL PLATE
• Use a spot cutter for ultra high strength steel
plate to ensure that the spot-welded area is cut
off. The following tools are recommended.
• Drill bit, spot weld cutter (8) (Number:
MB992621)
• For the part in which the ultra high strength steel
plate is used, do not repair it by cutting and bond
ing to avoid the reduction in strength by heat.
Instead, replace the whole assembly including
the part.
• Be careful with rough extending work, because
the ultra high strength steel plate has higher ten
sile strength and a higher yielding point than high
strength steel plate and general steel plate. Care
less work will cause symptom such as over-pulling and springback. Do not extend it completely
at a time. Do it gradually while removing the dis
tortion by sheet metal processing with a hammer.
• Plug welding of φ 8 mm (0.31 inch) diameter plug
for repair ensures the strength equivalent to spot
welding for 2 steel sheets. For 3 sheets, weld 2
sheets from both sides instead of welding from
one side to give sufficient welding strength.
-
-
-
-
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Page 65
WELDED PANEL REPLACEMENT
AB900590
AB
Symbol
Operation description
Spot welding
MIG plug welding : indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
( )
AB900435
AB900436
AB900437
AB900589
AB
A
A
B
B
REPAIR WELDS
FRONT END CROSSMEMBER
3-3
FRONT END CROSSMEMBER
M4030003100367
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Page 66
3-4
AB900597
AB
Symbol
Operation description
Spot welding
MIG plug welding : indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
( )
AB900604
A
AB
A
REPAIR WELDS
WELDED PANEL REPLACEMENT
FENDER SHIELD
FENDER SHIELD
M4030004001690
NOTE: Refer to the Front End Crossmember section on P.3-3 for the welding point with headlight support
panel lower.
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Page 67
WELDED PANEL REPLACEMENT
AB900605
I
G
C
F
H
B
B
C
E
D
AB
FENDER SHIELD
3-5
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Page 68
3-6
AB900733
D
E
F
G
H
I
AB
(With the front deck frame upper outer
and upper frame to front pillar brace removed)
Left
side
only
Right
side
only
H
(Right side) (Left side)
WELDED PANEL REPLACEMENT
FENDER SHIELD
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Page 69
WELDED PANEL REPLACEMENT
ABA00120
90 mm
(3.54 in)
180 mm
(7.1 in)
AB
Front upper
frame inner
Front deck frame
upper outer
AB900486
AB
Front sidemember
outer
Front body frame
to side sill brace
Front sidemember
inner
AB601423
AC
Front
sidemember
outer
Front
sidemember
inner
FENDER SHIELD
NOTE: Partial replacement of the front upper frame is possible
depending on the range of damage. For partial replacement, cut
the front deck frame upper outer at 90 mm (3.54 inches) forward
of the vehicle from its positioning hole, and front upper frame
inner at 180 mm (7.1 inches).
NOTE ON REPAIR WORK
.
REMOVAL
Turn up the front sidemember outer as shown to cut off the
welded point between the front sidemember inner and the front
body frame to side sill brace.
.
INSTALLATION
3-7
When installing the new front sidemember parts, align the hole
of the front body frame to side sill brace with the front sidemem
ber to make a hole because the front sidemember outer prevents the front sidemember inner and front body frame to side
sill brace from being welded. Then, weld the front sidemember
outer, front sidemember inner, and front body frame to side sill
brace.
-
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Page 70
3-8
AB900598
AB
Symbol
Operation description
Spot welding
MIG plug welding : indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
( )
AB900607
AB
A
275 mm
(10.8 in)
B
315 mm
(12.4 in)
135 mm
(5.3 in)
210 mm
(8.3 in)
B
A
REPAIR WELDS
(Right side)
(Left side)
Center of engine room side cover
mounting hole
WELDED PANEL REPLACEMENT
FRONT SIDEMEMBER (PARTIAL REPLACEMENT)
FRONT SIDEMEMBER (PARTIAL REPLACEMENT)
M4030000100896
NOTE: .
•
Refer to the Front End Crossmember section on P.3-3 for the welding point with the headlight support
panel lower.
•
Refer to the Fender Shield section on P.3-4 for the welding points with the headlight support panel, front
fender gusset and front fender shield.
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WELDED PANEL REPLACEMENT
CAUTION
AB900594
AB
Symbol
Operation description
Spot welding
MIG plug welding : indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
( )
ABA00176
A
B
C
100 mm (3.9 in)
C
AB
B
E
D
A
G
F
Sound dampening
foam material
REPAIR WELDS
The same position as the
new front outer pillar parts
(With the upper frame to front pillar brace
and front deck frame upper outer removed)
FRONT PILLAR
3-9
When repairing the area using sound dampening foam material do not use firing tools since the
sound dampening foam material may burn.
FRONT PILLAR
M4030005002072
NOTE: Refer to the Fender Shield section on P.3-4 for the welding points with the upper frame to front pillar
brace and front deck frame upper outer.
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Page 72
3-10
ABA00177
AB
E
F
D
G
Sound dampening
foam material
(With the side outer panel removed)
(With the side outer panel removed)
WELDED PANEL REPLACEMENT
FRONT PILLAR
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Page 73
WELDED PANEL REPLACEMENT
ABA00174
320 mm
(12.6 in)
AB
ABA00175
The same position as the
new front outer pillar parts
AB
200 mm
(7.8 in)
AB900563
AB
Side sill bulkhead A
Side sill reinforcement
outer rear
AB900508
AB
Front pillar
silencer lower
FRONT PILLAR
NOTE ON REPAIR WORK
.
REMOVAL
1. As for the upper part of the front pillar, cut only the outer
panel 320 mm (12.6 inches) below the notch and remove it
to disconnect the welding point of the front pillar
reinforcement upper and the front pillar reinforcement lower.
2. As for the side sill, cut only the outer panel 200 mm (7.8
inches) forward of the cut area of the side sill and remove it
to disconnect the welding point of the side sill reinforcement
outer front and the side sill reinforcement outer rear.
3-11
.
INSTALLATION
1. Install the new front lower inner pillar.
2. When installing the new side sill reinforcement, remove the
side sill reinforcement outer rear and the side sill bulkhead A
from the side sill reinforcement.
3. When installing the new front pillar reinforcement lower
inner, in order to prevent the dripping of sound dampening
foam material to be filled into the front pillar in the next
process, install the front pillar silencer lower to the front pillar
reinforcement lower inner, and then apply the butyl-tape to
close the hole and gap of the front pillar silencer lower.
4. When installing the new front outer pillar parts, perform the
following procedures.
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Page 74
3-12
AB900595
AB
A
A
130 mm
(5.1 in)
30 mm
(1.18 in)
50 mm
(1.97 in)
Front pillar
reinforcement upper
Side outer panel
: Body loose panel cushion
NOTE:
AB900587
AB
: Body sealant
NOTE:
WELDED PANEL REPLACEMENT
FRONT PILLAR
(1) Machine the body loose panel cushion (MR565301 or
MR435765) as shown and apply it to the body side to
prevent the sound dampening foam material from
dropping when the material is filled into the front pillar
upper in the next process.
(2) Apply the body sealant to the areas as shown in
advance.
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Page 75
WELDED PANEL REPLACEMENT
AB900596
AB
A
A
: Sound dampening foam material
NOTE:
Front pillar
inner lower
Front pillar
reinforcement lower
AB100787
FRONT PILLAR
5. After installing the front outer pillar, seal the hole and flange
with bolt and sheet-metal tape, and then fill the hole with
foam materials as shown in the figure.
Sound dampening foam material: 3M™ AAD Part
No.08463
3-13
6. Wait 2 hours after filling the sound dampening foam material
to remove the bolt and aluminum tape, then melt the sound
dampening foam material with a soldering gun so a clip, etc.
can thoroughly be inserted in the hole filled with sound
dampening foam material.
TSB Revision
Page 76
3-14
CAUTION
ABA00173
AB
Symbol
Operation description
Spot welding
MIG plug welding : indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
( )
ABA00172
B
B
A
A
140 mm
(5.5 in)
D
C
E
AB
The same position as the
new front outer pillar parts
(With the upper frame to front pillar brace
and front deck frame upper outer removed)
REPAIR WELDS
Cutting
position
WELDED PANEL REPLACEMENT
FRONT PILLAR (PARTIAL REPLACEMENT)
FRONT PILLAR (PARTIAL REPLACEMENT)
M4030001200119
When repairing the area using sound dampening foam material do not use firing tools since the
sound dampening foam material may burn.
NOTE: Refer to the Fender Shield section on P.3-4 for the welding points with the front upper frame outer
rear.
TSB Revision
Page 77
WELDED PANEL REPLACEMENT
ABA00178
AB
D
C
E
Sound dampening
foam material
(With the side outer panel removed)
Cutting position
ABA00175
The same position as the
new front outer pillar parts
AB
200 mm
(7.8 in)
FRONT PILLAR (PARTIAL REPLACEMENT)
3-15
TSB Revision
NOTE ON REPAIR WORK
.
REMOVAL
1. As for the side sill, cut only the side outer panel 200 mm (7.8
inches) forward of the cut area of the side sill and remove it
to disconnect the welding point of the side sill reinforcement
outer front and the side sill reinforcement outer rear.
2. After removing the front pillar, remove the front pillar inner
lower on the body side.
.
Page 78
3-16
ABA00171
Side outer
panel
50 mm
(1.97 in)
AB
AB900563
AB
Side sill bulkhead A
Side sill reinforcement
outer rear
AB900508
AB
Front pillar
silencer lower
ABA00179AB
: Body sealant
NOTE:
WELDED PANEL REPLACEMENT
FRONT PILLAR (PARTIAL REPLACEMENT)
INSTALLATION
1. To reinforce the strength in the front pillar cut area, cut the
side outer panel 50 mm (1.97 inches) above the cut area.
2. Install the new front lower inner pillar.
3. When installing the new side sill reinforcement, remove the
side sill reinforcement outer rear and the side sill bulkhead A
from the side sill reinforcement.
4. When installing the new front pillar reinforcement lower
inner, in order to prevent the dripping of sound dampening
foam material to be filled into the front pillar in the next
process, install the front pillar silencer lower to the front pillar
reinforcement lower inner, and then apply the butyl-tape to
close the hole and gap of the front pillar silencer lower.
5. When installing the new front outer pillar parts, apply the
body sealant to the areas as shown in advance.
TSB Revision
Page 79
WELDED PANEL REPLACEMENT
AB900596
AB
A
A
: Sound dampening foam material
NOTE:
Front pillar
inner lower
Front pillar
reinforcement lower
AB100787
FRONT PILLAR (PARTIAL REPLACEMENT)
6. After installing the front outer pillar, seal the hole and flange
with bolt and sheet-metal tape, and then fill the hole with
foam materials as shown in the figure.
Sound dampening foam material: 3M™ AAD Part
No.08463
3-17
7. Wait 2 hours after filling the sound dampening foam material
to remove the bolt and aluminum tape, then melt the sound
dampening foam material with a soldering gun so a clip, etc.
can thoroughly be inserted in the hole filled with sound
dampening foam material.
TSB Revision
Page 80
3-18
CAUTION
AB900599
AB
Symbol
Operation description
Spot welding
MIG plug welding : indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
( )
AB900608
E
B
A
AB
D
C
210 mm
(8.3 in)
250 mm
(9.8 in)
350 mm
(13.8 in)
90 mm
(3.54 in)
100 mm
(3.9 in)
A
D
60 mm (2.36 in)
E
B
C
Sound dampening
foam material
The same position as the
new center outer pillar part
Cutting position
Sound dampening
foam material
REPAIR WELDS
WELDED PANEL REPLACEMENT
CENTER PILLAR
When repairing the area using sound dampening foam material do not use firing tools since the
sound dampening foam material may burn.
CENTER PILLAR
M4030006001306
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Page 81
WELDED PANEL REPLACEMENT
AB900721
AC
Center pillar
reinforcement
Side sill reinforcement
outer rear
Side outer
panel
Side outer
panel
Center pillar
reinforcement
Roof side rail
reinforcement center
(Upper)
(Lower)
AB900522
AB
Center pillar
inner upper
60 mm
(2.36 in)
60 mm
(2.36 in)
AB900562
AB
Center pillar
inner lower
Center pillar
inner upper
CENTER PILLAR
NOTE ON REPAIR WORK
.
REMOVAL
1. To detach the welding of the center pillar reinforcement, roof
side rail reinforcement center and side sill reinforcement
outer rear, cut the side outer panel as shown in the figure of
the instructions.
3-19
2. Since the center pillar inner upper remaining on the body
side is hard to remove, cut the roof side rail inner up to the
position shown in the figure, and remove the center pillar
inner upper by pulling it towards you.
.
INSTALLATION
1. Remove the center pillar inner lower from the new center
inner pillar parts, and install the center inner pillar to the
body.
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Page 82
3-20
AB900627
AB
A
A
450 mm
(17.7 in)
40 mm
(1.57 in)
Side outer
panel
Center pillar
reinforcement
: Body loose panel cushion
NOTE:
90 mm
(3.54 in)
90 mm
(3.54 in)
50 mm
(1.97 in)
50 mm
(1.97 in)
50 mm
(1.97 in)
20 mm
(0.79 in)
50 mm
(1.97 in)
AB900628
AB
A
A
Center pillar reinforcement
Side sill reinforcement
outer rear
: Sound dampening foam material
NOTE:
WELDED PANEL REPLACEMENT
CENTER PILLAR
2. When installing the new center outer pillar, because the
sound dampening foam material cannot be filled into the
center pillar, machine the body loose panel cushion
(MR565301 or MR435765) as a substitute according to the
method shown in the figure, and then attach it to the body.
3. After installing the center outer pillar, seal the hole and
flange with bolt and aluminum tape, then fill the hole with
sound dampening foam material as shown in the figure of
the instructions.
Sound dampening foam material: 3M™ AAD Part
No.08463
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Page 83
WELDED PANEL REPLACEMENT
AB200418
CENTER PILLAR
4. Wait 2 hours after filling the sound dampening foam material
to remove the bolt and aluminum tape, then melt the sound
dampening foam material with a soldering gun so a clip, etc.
can thoroughly be inserted in the hole filled with sound
dampening foam material.
3-21
TSB Revision
Page 84
3-22
CAUTION
AB900600
AB
Symbol
Operation description
Spot welding
MIG plug welding : indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
( )
AB900610
A
30 mm
(1.18 in)
95 mm (3.74 in)
AC
B
C
A
B
C
E
D
Sound dampening
foam material
Sound dampening
foam material
Sound dampening
foam material
(With the side outer panel removed)
REPAIR WELDS
Notch
WELDED PANEL REPLACEMENT
SIDE SILL
When repairing the area using sound dampening foam material do not use firing tools since the
sound dampening foam material may burn.
SIDE SILL
M4030007001611
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Page 85
WELDED PANEL REPLACEMENT
AB900611
D
AB
E
AB900625
AB
Cutting
position
Side sill end plate
Quarter panel
extension front
SIDE SILL
3-23
NOTE ON REPAIR WORK
.
REMOVAL
To remove the side sill reinforcement outer rear, remove the
side sill end plate and cut the quarter panel extension front at
the position shown in the figure because they interfere with the
side sill reinforcement outer rear at the rear wheelhouse.
.
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Page 86
3-24
AB900562
AB
Center pillar
inner lower
Center pillar
inner upper
AB501219
AD
Side sill bulkhead A
Side sill reinforcement outer rear
AB900627
AB
A
A
450 mm
(17.7 in)
40 mm
(1.57 in)
Side outer
panel
Center pillar
reinforcement
: Body loose panel cushion
NOTE:
90 mm
(3.54 in)
90 mm
(3.54 in)
50 mm
(1.97 in)
50 mm
(1.97 in)
50 mm
(1.97 in)
20 mm
(0.79 in)
50 mm
(1.97 in)
WELDED PANEL REPLACEMENT
SIDE SILL
INSTALLATION
1. When installing the new center inner pillar, remove the
center pillar inner upper from the center inner pillar.
2. When installing the new side sill reinforcement, use only the
side sill reinforcement outer rear and the side sill bulkhead
A.
3. After installing the side sill reinforcement, install the side sill
end plate and the quarter panel extension front.
4. When assembling the new front floor side sill outer, carry out
the following procedure.
(1) Machine the body loose panel cushion (MR565301 or
MR435765) for replacement as shown and apply it to the
body side because the sound dampening foam material
cannot be filled into the center pillar.
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Page 87
WELDED PANEL REPLACEMENT
AB900575
AB
: Body sealant
NOTE :
AB900628
AB
A
A
Center pillar reinforcement
Side sill reinforcement
outer rear
: Sound dampening foam material
NOTE:
AB200418
SIDE SILL
(2) Apply body sealant in the area shown in the figure of the
front floor side sill outer.
5. After installing the front floor side sill outer seal the hole and
flange with bolts and aluminum tape, then fill the hole with
sound dampening foam material as shown in the figure of
the instructions.
Sound dampening foam material: 3M™ AAD Part
No.08463
3-25
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6. Wait 2 hours after filling the sound dampening foam material
to remove the bolt and aluminum tape, then melt the sound
dampening foam material with a soldering gun so a clip, etc.
can thoroughly be inserted in the hole filled with sound
dampening foam material.
Page 88
3-26
CAUTION
ABA00003
AB
Symbol
Operation description
Spot welding
MIG plug welding : indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
( )
AB900755
A
B
A
AB
D
E
B
35 mm
(1.38 in)
C
C
Sound dampening
foam material
REPAIR WELDS
4 points on
left side only
Notch
20 mm
(0.79 in)
WELDED PANEL REPLACEMENT
QUARTER OUTER
When repairing the area using sound dampening foam material do not use firing tools since the
sound dampening foam material may burn.
QUARTER OUTER
M4030008001346
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Page 89
WELDED PANEL REPLACEMENT
AB900751
D
AB
E
50 mm (1.97 in)
Left side only
Right side
AB900534
: Cuttable range
AB
NOTE:
QUARTER OUTER
3-27
.
NOTE: Partial replacement is possible depending on the range
of damage.
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Page 90
3-28
AB900615
AB
A
A
45 mm
(1.77 in)
30 mm
(1.18 in)
200 mm
(7.9 in)
: Body loose panel cushion
NOTE:
Gate pillar
reinforcement
lower
Quarter outer panel
extension rear
AB900914
AB
A
A
245 mm (9.6 in)
40 mm
(1.57 in)
: Body loose panel cushion
Side outer
panel
Quarter panel
extension
front
Rear pillar
reinforcement lower
NOTE:
20 mm
(0.79 in)
WELDED PANEL REPLACEMENT
QUARTER OUTER
NOTE ON REPAIR WORK
.
INSTALLATION
1. When installing the new quarter panel extension lower rear,
because the body sealant cannot be filled into the rear pillar,
machine the body loose panel cushion (MR435765 or
MR565301) as a substitute according to the method shown
in the figure, and then attach it to the body.
2. When assembling the new quarter panel outer, carry out the
following procedure.
(1) After cutting the new quarter panel outer, remove the
stiffener completely.
(2) Machine the body loose panel cushion (MR565301 or
MR435765) for replacement as shown and apply it to the
body side because the sound dampening foam material
cannot be filled into the wheel arch.
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Page 91
WELDED PANEL REPLACEMENT
AB900530
AB
Left side only
: Body sealant
NOTE:
ABA00007
5 mm
(0.20 in)
AB
Stiffener
QUARTER OUTER
(3) Apply the body sealant in advance to the areas as
shown.
(4) In order to prevent burnout of the stiffener on the body
side, remove the stiffener 5 mm (0.20 inches) above the
cutting position. As for the stiffener application area,
perform butt welding while cooling it.
3-29
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Page 92
3-30
AB900601
AB
Symbol
Operation description
Spot welding
MIG plug welding : indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
( )
AB900669
AB
B
B
A
A
REPAIR WELDS
: Adhesive
NOTE :
<Vehicles with panorama glass roof>
<Vehicles without panorama glass roof>
WELDED PANEL REPLACEMENT
ROOF
ROOF
M4030011001681
Adhesive: Urethane body sealer
Brand: 3M™ AAD Part No.08360 or equiva-
lent
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Page 93
WELDED PANEL REPLACEMENT
AB900670
A
B
AB
5.5 ± 1.5 N·m
(49 ± 13 in-lb)
5.5 ± 1.5 N·m
(49 ± 13 in-lb)
5.5 ± 1.5 N·m
(49 ± 13 in-lb)
AB900631
AB
Roof rack seal
ROOF
NOTE ON REPAIR WORK
.
INSTALLATION
When installing the new roof carrier bracket, roof rail bracket
and roof rail bracket front, install the roof rack seal to avoid
water ingress.
3-31
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Page 94
3-32
AB900514
AB
Symbol
Operation description
Spot welding
MIG plug welding : indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
( )
AB900513
AB
A
A
REPAIR WELDS
WELDED PANEL REPLACEMENT
REAR END CROSSMEMBER
REAR END CROSSMEMBER
M4030015000710
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Page 95
WELDED PANEL REPLACEMENT
AB900576
AB
Symbol
Operation description
Spot welding
MIG plug welding : indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
( )
AB900577
D
B
A
AB
A
E
C
REPAIR WELDS
REAR FLOOR
3-33
REAR FLOOR
M4030010001268
NOTE: Refer to the Rear End Crossmember section on P.3-32 for the welding points with the rear end crossmember.
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Page 96
3-34
AB900578
B
D
E
C
AB
Right side only
AB900561
AB
110 mm
(4.3 in)
275 mm
(10.8 in)
WELDED PANEL REPLACEMENT
REAR FLOOR
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NOTE ON REPAIR WORK
.
REMOVAL
1. When removing the rear floor, cut at 110 mm (4.3 inches)
rearward from the rear seat side hinge installation hole.
When removing the rear floor side panel after the rear floor
removal, cut at 275 mm (10.8 inches) rearward from the rear
seat hinge bracket center installation hole.
Page 97
WELDED PANEL REPLACEMENT
CAUTION
AB900603
AB
Symbol
Operation description
Spot welding
MIG plug welding : indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
( )
ABA00017
;
AB
A
A
AB
E
B
F
C
Sound dampening
foam material
Sound dampening
foam material
(With the side outer panel removed)
REPAIR WELDS
QUARTER INNER
3-35
When repairing the area using sound dampening foam material do not use firing tools since the
sound dampening foam material may burn.
QUARTER INNER
M4030012001394
NOTE: Refer to the Quarter Outer section on P.3-26 for the welding points with the quarter outer.
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3-36
AB900617
D
F
F
AB
E
B
C
D
(Left side)
(Right side)
(Right side)
Left side
only
Left side only
7.0 ± 3.0 N·m
(62 ± 26 in-lb)
WELDED PANEL REPLACEMENT
QUARTER INNER
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Page 99
WELDED PANEL REPLACEMENT
AB900722
AB
Rear pillar brace
Flange
AB900619
AB
A
A
50 mm
(1.97 in)
: Body loose panel cushion
NOTE:
Rear pillar
reinforcement lower
Quarter panel
extension front
40 mm
(1.57 in)
85 mm
(3.35 in)
AB900552
AC
Rear end panel silencer
QUARTER INNER
NOTE ON REPAIR WORK
.
INSTALLATION
1. When installing the new rear pillar brace, align the gate pillar
brace with the flange part on the front side of the vehicle.
Then, install the rear pillar brace to the area surrounded by 3
bottoming marks stamped on the quarter panel inner.
2. When installing the new rear pillar reinforcement lower part,
machine the body loose panel cushion (MR565301 or
MR435765) for replacement as shown and apply it to the
body side because the sound dampening foam material
cannot be filled into the rear pillar reinforcement lower.
3-37
3. When installing the new gate pillar reinforcement, in order to
prevent the dripping of sound dampening foam material to
be filled into the rear end in the next process, install the rear
end panel silencer to the gate pillar reinforcement, and then
apply the butyl-tape to close the hole and gap of the rear
end panel silencer.
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3-38
AB900620
B
AB
B
: Sound dampening foam material
NOTE:
Gate pillar
reinforcement lower
Gate inner pillar
extension lower
AB100787
WELDED PANEL REPLACEMENT
QUARTER INNER
4. After installing the quarter panel extension lower rear, seal
the hole and flange with sheet-metal tape, and then fill the
hole with the sound dampening foam material as shown in
the figure of the instructions.
Sound dampening foam material: 3M™ AAD Part
No.08463
5. Wait 2 hours after filling the sound dampening foam material
to remove the bolt and aluminum tape, then melt the sound
dampening foam material with a soldering gun so a clip, etc.
can thoroughly be inserted in the hole filled with sound
dampening foam material.
TSB Revision
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