tions and country of destination. Therefore, please keep in mind that the information contained herein is based on vehicles for general destinations. For the repair procedures and specifications other than collision- damaged body components of the SCION xA refer to the repair manuals.<br><br> If you require the above manuals, please contact your SCION Dealer. All information contained in this manual is the most up-to-date at the time of publication. However, specifications and procedures are subject to change without prior notice.<br><br> F10004 F10001A F10002A F10003A Glass Cover Seat Cover WRONG WRONG INTRODUCTION IN-1 GENERAL REPAIR INSTRUCTIONS 1. WORK PRECAUTIONS (a) VEHICLE PROTECTION (1) When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fire-proof covers. (b) SAFETY (1) Never stand in direct line with the chain when using a puller on the body or frame, and be sure to attach a safety cable.<br><br> (2) Before performing repair work, check for fuel leaks. If a leak is found, be sure to close the opening totally. (3) If it is necessary to use a flame in the area of the fuel tank, first remove the tank and plug the fuel line.<br><br> (c) SAFETY WORK CLOTHES (1) In addition to the usual mechanic 9s wear, cap and safety shoes, the appropriate gloves, head protector, glasses, ear plugs, face protector, dust-prevention mask, etc. should be worn as the situation demands. Code Name A Dust-Prevention Mask B Face Protector C Eye Protector D Safety Shoes E Welder 9s Glasses F Ear Plugs G Head Protector H Welder 9s Gloves INTRODUCTION IN-2 2.<br><br> HANDLING PRECAUTIONS OF PLASTIC BODY PARTS (1) The repair procedure for plastic body parts must conform with the type of plastic material. (2) Plastic body parts are identified by the codes in the following table. (3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, paint- ing etc.), consideration must be given to the property of the plastic.<br><br> Code Material name Heat * resistant temperature limit _ C ( _ F) Resistance to alcohol or gasoline Notes AAS Acrylonitrile Acrylic Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. ABS Acrylonitrile Butadiene Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).<br><br> Avoid gasoline and organic or aromatic solvents. AES Acrylonitrile Ethylene Styrene 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents.<br><br> ASA Acrylonitrile Styrene Acrylate 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. CAB Cellulose Acetate 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).<br><br> Avoid gasoline and organic or aromatic solvents. EPDM Ethylene Propylene 100 (212) Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts.<br><br> Most solvents are harmless but avoid dipping in gasoline, solvents, etc. FRP Fiber Reinforced Plastics 180 (356) Alcohol and gasoline are harmless. Avoid alkali.<br><br> EVA Ethylene Acetate 70 (158) Alcohol is harmless if applid only for short time in small amounts (e.g., quick wiping to remove grease). Avoid gasoline and organic or aromatic solvents. PA Polyamide (Nylon) 80 (176) Alcohol and gasoline are harmless.<br><br> Avoid battery acid. PBT Polybutylene Terephthalate 160 (320) Alcohol and gasoline are harmless. Most solvents are harmless.<br><br> PC Polycarbonate 120 (248) Alcohol is harmless. Avoid gasoline brake fluid, wax, wax removers and organic solvents. Avoid alkali.<br><br> *Temperatures higher than those listed here may result in material deformation during repair. INTRODUCTION IN-3 Code Material name Heat * resistant temperature limit _ C ( _ F) Resistance to alcohol or gasoline Notes PE Polyethylene 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless.<br><br> PET Polyethylene Terephthalate 75 (167) Alcohol and gasoline are harmless. Avoid dipping in water. PMMA Polymethyl Methacrylate 80 (176) Alcohol is harmless if applied only for short time in small amounts.<br><br> Avoid dipping or immersing in alcohol, gasoline, solvents, etc. POM Polyoxymethylene (Polyacetal) 100 (212) Alcohol and gasoline are harmless. Most solvents are harmless.<br><br> PP Polypropylene 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless. PPO Modified Polyphenylene Oxide 100 (212) Alcohol is harmless.<br><br> Gasoline is harmless if applied only for quick wiping to remove grease. PS Polystyrene 60 (140) Alcohol and gasoline are harmless if applied only for short time in small amounts. Avoid dipping or immersing in alcohol, gasoline, solvents, etc.<br><br> PUR Polyurethane 80 (176) Alcohol is harmless if applied only for very short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. PVC Polyvinylchloride (Vinyl) 80 (176) Alcohol and gasoline are harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).<br><br> Avoid dipping or immersing in alcohol, gasoline, solvents, etc. SAN Styrene Acrylonitrile 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents etc.<br><br> TPO Thermoplastic Olefine 80 (176) Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts. Most solvents are harmless but avoid dipping in gasoline, solvents, etc.<br><br> TPU Thermoplastic Polyurethane 80 (176) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Avoid dipping or immersing in alcohol, gasoline, solvents, etc. TSOP TOYOTA Super Olefine Polymer 80 (176) Alcohol and gasoline are harmless.<br><br> Most solvents are harmless. UP Unsaturated Polyester 110 (233) Alcohol and gasoline are harmless. Avoid alkali.<br><br> *Temperatures higher than those listed here may result in material deformation during repair. INTRODUCTION IN-4 3. LOCATION OF PLASTIC BODY PARTS Parts Name Code Radiator Grille TSOP Front Bumper Cover TSOP Front Bumper Hole Cover TSOP Headlight PP/PC Fog light TSOP Side Turn Signal Light PMMA/ABS Fender Panel Mudguard TSOP Front Fender Mudguard PP/EPDM Cowl Top Ventilator Louver TSOP Outer Rear View Mirror ABS/PA Front Pillar Upper Cover AES Side Mudguard TSOP Front Door Outside Handle PC/PA Rear Door Outside Handle PC/PA Quarter Panel Rear Mudguard TSOP Rear Wheel House Plate PP/EPDM Back Door Outside Garnish ABS Back Door Outside Handle PA High Mount Stop Light PMMA/ABS Rear Bumper Cover TSOP Rear Combination Light PMMA/AAS License Plate Light PMMA/ABS Rear Fog Light PC/ABS Rear Spoiler ABS S Resin material differs with model.<br><br> / Made up of 2 or more kinds of materials. INTRODUCTION IN-15 HANDLING PRECAUTIONS ON RELATED COMPONENTS 1. BRAKE SYSTEM The brake system is one of the most important safety components.<br><br> Always follow the directions and notes given in brake (32) section of the repair manual for the relevant model when handling brake system parts. NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC sys- tem. 2.<br><br> DRIVE TRAIN AND CHASSIS The drive train and chassis are components that can have great effects on the running performance and vibration resistance of the vehicle. After installing components in the sections listed in the table below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate repair of the body must also be done to ensure correct alignment.<br><br> HINT: Correct procedures and special tools are required for alignment. Always follow the directions giv- en in the repair manual for the relevant model during alignment and section DI of this section. Component to be aligned Section of repair manual for relevant model Front Wheels Front Suspension (26) section Rear Wheels Rear Suspension (27) section 3.<br><br> COMPONENTS ADJACENT TO THE BODY PANELS Various types of component parts are mounted directly on or adjacently to the body panels. Strictly ob- serve the following precautions to prevent damaging these components and the body panels during han- dling. S Before repairing the body panels, remove their components or apply protective covers over the com- ponents.<br><br> S Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool tip or blade to prevent damaging the components and the body paint. S Before removing components from the outer surface of the body, attach protective tape to the body to ensure no damage to painted areas. HINT: Apply touch-up paint to any damaged paint surfaces.<br><br> S Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side. 4.<br><br> ECU (ELECTRONIC CONTROL UNIT) Many ECUs are mounted in this vehicle. Take the following precautions during body repair to prevent damage to the ECUs. S Before starting electric welding operations, disconnect the negative (-) terminal cable from the bat- tery.<br><br> When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by each memory system. Then when work is finished, reset the clock and audio systems as before.<br><br> When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all equipped with memory function, it is not possible to make a record of the memory contents. So when the operation is finished, it will be necessary to explain this fact to the customer, and request the customer to adjust the features and reset the memory. S Do not expose the ECUs to ambient temperatures above 80 _ C (176 _ F).<br><br> NOTICE: If it is possible the ambient temperature may reach 80 _ C (176 _ F) or more, remove the ECUs from the vehicle before starting work. S Be careful not to drop the ECUs and not to apply physical shocks to them. INTRODUCTION F13890A REPLACEMENT PART AND METHOD QUARTER PANEL (CUT) BODY PANEL REPLACEMENT REPLACEMENT BP-34 QUARTER PANEL (CUT) POINT 1 Remove the [A] at the same time.<br><br> PART NAME [A] Fuel Filler Opening Lid A : Replacement part Replacement method (ASSY) ... Assembly replacement (CUT) ... Major cutting (less than 1/2 of part used) (CUT-H) ...<br><br> Half cutting (about 1/2 of part used) (CUT-P) ... Partial cutting (most of part used) REMOVAL CONDTIONS B : PART LOCATION C : REMOVAL DIAGRAM Describes in detail removal of the damaged part involving repair by cutting. D : REMOVAL GUIDE Provides additional information to more efficiently help you perform the removal.<br><br> E : REMOVAL IN-5 HOW TO USE THIS MANUAL 1. BODY PANEL REPLACEMENT THIS MANUAL INTRODUCTION F13891A BODY PANEL REPLACEMENT BP-35 INSTALLATION S Temporaily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fiting of the related parts around the new parts before welding.<br><br> This affects the appearance of the finish. S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts.<br><br> S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. I INSTALLATION CONDITIONS POINT 1 Before temporarily installing the new parts, apply body sealer to the wheel arch. HINT: 1) Apply body sealer about 5mm (0.20in.) front the flange, avoiding any oozing.<br><br> 2) Apply sealer evenly, about 3 - 4mm (0.12 - 0.16in.) in diameter. 3) For other sealing points, refer to section PC. PART NAME [A] Fuel Filler Opening Lid [B] Waterproof Rivet INSTALLATION DIAGRAM Describes in detail installation to the new part involving repair by welding and/or cutting, but excluding painting.<br><br> INSTALLATIOLN GUIDE Provides additional information to more efficiently help you perform the installation. SYMBOLS (See page IN-7) ILLUSTRATION OF WELD POINTS Weld method and panel position symbols (See page IN-9) PART NAME J I F G H 5mm F : G : H : I : J : K : IN-6 F13893A SYMBOLS MEANING ILLUSTRATION CUT AND JOIN LOCATION (SAW CUT) CUT AND JOIN LOCATION (Cut Location for Supply Parts) CUT LOCATION CUT WITH DISC SANDER, ETC. BRAZE (Removal) BRAZE (Installation) SPOT WELD OR MIG PLUG WELD (See Page IN-9) BODY SEALER WELD POINTS CONTINUOUS MIG WELD (BUTT WELD) CONTINUOUS MIG WELD (TACK WELD) 4 4 INTRODUCTION IN-7 2.<br><br> SYMBOLS The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas and the types of weld required. INTRODUCTION F13894A SYMBOLS MEANING ILLUSTRATION Assembly Mark BODY SEALER (Flat Finishing) BODY SEALER (No flat Finishing) 4 4 4 IN-8 F13892A REMOVAL INSTALLATION SYMBOLS Remove Weld Points (Outside) HINT: Panel position symbols are as seen from the working posture. Spot Weld MIG Plug Weld Spot MIG Weld Weld points Remove weld point and panel position Weld method and panel position Weld points MEANING ILLUSTRATION SYMBOLS MEANING ILLUSTRATION (Middle) (Inside) INTRODUCTION IN-9 3.<br><br> ILLUSTRATION OF WELD POINT SYMBOLS EXAMPLE: INTRODUCTION IN-16 PRECAUTIONS FOR REPAIRING BODY STRUCTURE PANELS 1. HEAT REPAIR FOR BODY STRUCTURE PANELS Toyota prohibits the use of the heat repair method on body structure panels when repairing a vehicle damaged in a col- lision. Panels that have high strength and rigidity, as well as a long life span for the automobile body are being sought after.<br><br> At Toyota, in order to fulfill these requirement, we use high tensile strength steel sheets and rust preventive steel sheets on the body. High tensile steel sheets are made with alloy additives and a special heat treatment in order to improve the strength. To prevent the occurrence of rust for a long period of time, the surface of the steel is coated with a zinc alloy.<br><br> If a body structure parts are heat repaired with an acetylene torch or other heating source, the crystalline organization of the steel sheet will change and the strength of the steel sheet will be reduced. The ability of the body to resist rust is significantly lowered as well since the rust resistant zinc coating is destroyed by heat and the steel sheet surface is oxidized. 2.<br><br> STRUCTURE PANEL KINKS A sharp deformation angle on the panel that cannot be re- turned to its original shape by pulling or hammering is called a kink. Since structure parts were designed to exhibit a 100% per- formance when they were in their original shape, if they are deformed in an accident, or if the deformed parts are re- paired and reused, they become unable to exhibit the same performance as intended in the design. It is necessary to replace the part where the kink has oc- curred.<br><br> INTRODUCTION IN-17 3. IMPACT BEAM REPAIR The impact beam and bracket are necessary and important parts in maintaining a survival space for passengers in a side collision. For impact beam, we use special high tensile strength steel.<br><br> The high tensile strength steel maintains its special crystal- line organization by heat treatment or alloy additives. Since these parts were designed to exhibit a 100% perfor- mance when they were in their original shape, if they are deformed in an accident, or if the deformed parts are re- paired and reused, they become unable to exhibit the same performance as intended in the design. It is necessary to replace the door assembly when impact beam or bracket is damaged.<br><br> F10007 F10008A F10009A F10010 Cutting Okay Reinforcement Corners WRONG INTRODUCTION IN-10 PROPER AND EFFICIENT WORK PROCEDURES 1. REMOVAL (a) PRE-REMOVAL MEASURING (1) Before removal or cutting operations, take measure- ments in accordance with the dimension diagram. Al- ways use a puller to straighten a damaged body or frame.<br><br> (b) CUTTING AREA (1) Always cut in a straight line and avoid reinforced area. (c) PRECAUTIONS FOR DRILLING OR CUTTING (1) Check behind any area to be drilled or cut to insure that there are no hoses, wires, etc., that may be dam- aged. HINT: See cHandling Precautions on Related Compo- nents d on page IN-15.<br><br> (d) REMOVAL OF ADJACENT COMPONENTS (1) When removing adjacent components, apply protec- tive tape to the surrounding body and your tools to pre- vent damage. HINT: See cHandling Precautions on Related Compo- nents d on page IN-15. F10011A F10012 F10013A F10014 F10015A Less than 3mm Puncher Air Saw Overlap 20 X 30mm INTRODUCTION IN-11 2.<br><br> PREPARATION FOR INSTALLATION (a) SPOT WELD POINTS (1) When welding panels with a combined thickness of over 3mm (0.12in.), use a MIG (Metal Inert Gas) weld- er for plug welding. HINT: Spot welding will not provide sufficient durability for panels over 3mm (0.12in.) thick. (b) APPLICATION OF WELD-THROUGH PRIMER (SPOT SEALER) (1) Remove the paint from the portion of the new parts and body to be welded, and apply weld-through prim- er.<br><br> (c) MAKING HOLES FOR PLUG WELDING (1) For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding. REFERENCE: mm (in.) Thickness of welded portion Size of plug hole 1.0 (0.04) under 5 (0.20) ø over 1.0 (0.04) - 1.5 (0.06) 6.4 (0.26) ø over 1.5 (0.06) over 8 (0.31) ø over (d) SAFETY PRECAUTIONS FOR ELECTRICAL COM- PONENTS (1) When welding, there is a danger that electrical compo- nents will be damaged by the electrical current flowing through the body. (2) Before starting work, disconnect the negative terminal of the battery and ground the welder near the welding location of the body.<br><br> (e) ROUGH CUTTING OF JOINTS (1) For joint areas, rough cut the new parts, leaving 20 - 30mm (0.79 - 1.18in.) overlap. F10016A F10017A F10018A F10019A F10020A Body Measurement Diagrams WRONG CORRECT WRONG Tip Cutter Old Spot Locations New Spot Locations INTRODUCTION IN-12 3. INSTALLATION (a) PRE-WELDING MEASUREMENTS (1) Always take measurements before installing under- body or engine components to insure correct assem- bly.<br><br> After installation, confirm proper fit. (b) WELDING PRECAUTIONS (1) The number of welding spots should be as follows. Spot weld:1.3 X No.<br><br> of manufacturer 9s spots. Plug weld: More than No. of manufacturer 9s plugs.<br><br> (2) Plug welding should be done with a MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at areas other than specified. (c) POST-WELDING REFINISHING (1) Always check the welded spots to insure they are se- cure.<br><br> (2) When smoothing out the weld spots with a disc grind- er, be careful not to grind off too much as this would weaken the weld. (d) SPOT WELD LOCATIONS (1) Try to avoid welding over previous spots. (e) SPOT WELDING PRECAUTIONS (1) The shape of the welding tip point has an effect on the strength of the weld.<br><br> (2) Always insure that the seams and welding tip are free of paint. F10021A F10022 F10023 Sealer Gun INTRODUCTION IN-13 4. ANTI-RUST TREATMENT (a) BODY SEALER APPLICATION (1) For water-proofing and anti-corrosion measures, al- ways apply the body sealer to the body panel seams and hems of the doors, hoods, etc.<br><br> (b) UNDERCOAT APPLICATION (1) To prevent corrosion and protect the body from dam- age by flying stones, always apply sufficient under- coat to the bottom surface of the under body and in- side of the wheel housings. 5. ANTI-RUST TREATMENT AFTER PAINTING PROCESS (a) ANTI-RUST AGENT (WAX) APPLICATION (1) To preserve impossible to paint areas from corrosion, always apply sufficient anti-rust agent (wax) to the in- side of the hemming areas of the doors and hoods, and around the hinges, or the welded surfaces inside the boxed cross-section structure of the side member, body pillar, etc.<br><br> F10024A S Apply the anti-chipping paint after the top coat. S Apply the anti-chipping paint before the second coat. Anti-Chipping Paint Top Coat Second Coat Under Coat (ED Primer) Steel Metal Top Coat Second Coat Anti-Chipping Paint Under Coat (ED Primer) Steel Metal INTRODUCTION IN-14 6.<br><br> ANTI-RUST TREATMENT BY PAINTING REFERENCE: Painting prevents corrosion and protect the sheet metal from damage. In this section, anti-chipping paint only for anti-corrosion purpose is described. (a) ANTI-CHIPPING PAINT (1) To prevent corrosion and protect the body from dam- age by flying stones, etc., apply anti-chipping paint to the rocker panel, wheel arch areas, balance panel, etc.<br><br> HINT: Depending on the model or the application area, there are cases where the application of anti-chipping paint is necessary before the second coat or after the top coat. VIEWS OF THIS TEXT Scope of the repair work explanation S This text explains the welding panel replacement instructions from the vehicle 9s white body condi- tion. We have abbreviated the explanations of the removal and reinstallation of the equipment parts up to the white body condition and of the installation, inspection, adjustment and final inspection of equipment parts after replacing the weld panel.<br><br> Section categories S Each section has been divided as shown below. Section Title Contents Examples INTRODUCTION Explanation of general body repair. Views of weld panel replacement instructions.<br><br> Cautionary items. Views of weld panel replacement instructions. BODY PANEL REPLACEMENT Instructions for replacing the weld panels from the white body condition, from which bolted parts have been removed, with individual supply parts.<br><br> Front side member replacement. Quarter panel replacement. BODY DIMENSIONS Body aligning measurements.<br><br> Dimension diagrams. PAINT S COATING Scope and type of anti-rust treatment, etc. together with weld panel replacement.<br><br> Under coat. Body sealer. Abbreviation of contents in this text.<br><br> S The following essential procedures have been abbreviated. When actually working, conduct this work properly. (1) Jack and lift operations.<br><br> (2) Clean and wash removed parts, if necessary. (3) Visual inspection. BODY PANEL REPLACEMENT F15540 POINT 1 Remove the [A] at the same time.<br><br> PART NAME [A] Back door Opening Lower Reinforcement F15540A REMOVAL BP-40 BACK DOOR OPENING TROUGH (ASSY) REPLACEMENT With the body lower back panel removed. BODY PANEL REPLACEMENT F15541 POINT 1 Inspect the fitting of the back door and rear combination light, etc., before welding, since this affects the ap- pearance of the finish. PART NAME [A] Back Door Opening Lower Reinforcement [B] Rear Bumper Upper Side Retainer BP-41 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram.<br><br> (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. S After welding, apply the polyurethane foam to the corresponding parts.<br><br> S After welding, apply body sealer and under-coating to the corresponding parts. S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT F15538 F15538A REMOVAL BP-38 BODY LOWER BACK PANEL (ASSY) REPLACEMENT BODY PANEL REPLACEMENT F15539 POINT 1 Inspect the fitting of the back door and rear combination light, etc., before welding, since this affects the ap- pearance of the finish.<br><br> BP-39 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.<br><br> S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts. S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.<br><br> BODY PANEL REPLACEMENT F15527 40mm (1.57in.) 50mm (1.97in.) 70mm (2.76in.) F15527A REMOVAL BP-27 CENTER BODY PILLAR (CUT) REPLACEMENT BODY PANEL REPLACEMENT F15528 10mm (0.39in.) 62mm (2.44in.) 240mm (9.45in.) POINT 1 Before temporarily installing the new parts, weld the [A], [B] and [C] with standard points. PART NAME [A] Rocker Outer Reinforcement [C] Center Body Inner Pillar [B] Center Body Pillar Lower Reinforcement BP-28 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding.<br><br> This affects the appearance of the finish. S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts.<br><br> S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT F15529 10mm (0.39in.) 20mm (0.79in.) POINT 1 Inspect the fitting of the front door and rear door, etc., before welding, since this affects the appearance of the finish. 2 After welding the reinforcement to the vehicle side, install the outer panel.<br><br> BP-29 BODY PANEL REPLACEMENT F15521 F15521A REMOVAL BP-21 COWL TOP SIDE PANEL (ASSY) REPLACEMENT BODY PANEL REPLACEMENT F15522 25mm (0.98 in.) 30mm (1.18 in.) BP-22 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.<br><br> S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts. S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.<br><br> BODY PANEL REPLACEMENT F15511 F15511A REMOVAL BP-11 COWL TOP SIDE UPPER PANEL (ASSY) REPLACEMENT With the cowl top side panel removed. BODY PANEL REPLACEMENT F15512 20mm (0.79in.) 30mm (1.18in.) POINT 1 Inspect the fitting of the front fender and hood, etc. before welding, since this affects the appearance of the finish.<br><br> BP-12 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.<br><br> S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts. S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.<br><br> F15515 F15515A REMOVAL BODY PANEL REPLACEMENT BP-15 FRONT FENDER APRON (ASSY) REPLACEMENT With the radiator upper support and cowl top side panel removed. F15516 POINT 1 Inspect the fitting of the front fender and hood, etc. before welding, since this affects the appearance of the finish.<br><br> 2 Make sure each measurement is correct, as this parts affects the front wheel alignment. PART NAME [A] Front Fender Mounting Bracket [B] Fender Apron Gusset BODY PANEL REPLACEMENT BP-16 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding.<br><br> This affects the appearance of the finish. S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts.<br><br> S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT F15519 F15519A REMOVAL BP-19 FRONT SIDE MEMBER (ASSY) REPLACEMENT With the radiator side support and front fender apron removed. BODY PANEL REPLACEMENT F15520 POINT 1 Make sure each measurement is correct, as this parts affects the front wheel alignment.<br><br> PART NAME [A] Front Bumper Mounting Reinforcement (RH: Front Side Member Front Plate) BP-20 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.<br><br> S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts. S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.<br><br> BODY PANEL REPLACEMENT F15513 F15513A REMOVAL BP-13 FRONT APRON TO COWL SIDE UPPER MEMBER (ASSY) REPLACEMENT With the front fender front apron and cowl top side panel removed. BODY PANEL REPLACEMENT F15514 POINT 1 Inspect the fitting of the front fender and hood, etc. before welding, since this affects the appearance of the finish.<br><br> PART NAME [A] Fender Apron Gusset BP-14 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.<br><br> S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts. S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.<br><br> BODY PANEL REPLACEMENT F15523 30mm (1.18in.) 275mm (10.83in.) F15523A REMOVAL BP-23 FRONT BODY PILLAR (CUT) REPLACEMENT With the cowl top side upper panel removed. F15524 BODY PANEL REPLACEMENT BP-24 BODY PANEL REPLACEMENT F15525 10mm (0.39in.) 15mm (0.59in.) 80mm (3.15in.) 100mm (3.94in.) POINT 1 Before temporarily installing the new parts, weld the [A], [B], [C] and [d] with standard points. 2 Cut the outer pillar on the rocker section and but-weld the rocker outer reinforcement before installing the outer pillar.<br><br> PART NAME [A] Rocker Outer Reinforcement [C] Front Body Upper Outer Pillar [B] Front Body Pillar Lower Reinforcement [D] Front Body Inner Pillar BP-25 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.<br><br> S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts. S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.<br><br> BODY PANEL REPLACEMENT F15526 15mm (0.59in.) 20mm (0.79in.) POINT 1 Inspect the fitting of the front door, front fender and windshield glass, etc., before welding, since this affects the appearance of the finish. BP-26 BODY PANEL REPLACEMENT F15509 F15509A REMOVAL BP-9 FRONT FENDER FRONT APRON (ASSY) REPLACEMENT With the radiator upper support removed. BODY PANEL REPLACEMENT F15510 POINT 1 Inspect the fitting of the front fender and hood, etc.<br><br> before welding, since this affects the appearance of the finish. PART NAME [A] Engine Front Support Retainer (RH Only) [B] Front Fender Mounting Bracket BP-10 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding.<br><br> This affects the appearance of the finish. S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts.<br><br> S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT F15517 PART NAME [A] Front Bumper Mounting Reinforcement 200mm (7.87in.) 215mm (8.46in.) [B] Front Side Member Front Plate F15517A REMOVAL BP-17 FRONT SIDE MEMBER (CUT-P) REPLACEMENT With the radiator side support removed. BODY PANEL REPLACEMENT F15518 PART NAME [A] Front Bumper Mounting Reinforcement [C] Front Bumper Arm [B] Front Side Member Front Plate BP-18 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram.<br><br> (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. S After welding, apply the polyurethane foam to the corresponding parts.<br><br> S After welding, apply body sealer and under-coating to the corresponding parts. S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT F15542 POINT 1 Remove the [A] and [B] at the same time.<br><br> PART NAME [A] Quarter Wheel Housing Center Gusset F15542A REMOVAL [B] Quarter Wheel Housing No.2 Brace BP-42 QUARTER WHEEL HOUSING EXTENSION (ASSY) REPLACEMENT With the body lower back panel, quarter panel removed. BODY PANEL REPLACEMENT F15543 PART NAME [A] Quarter Wheel Housing Center Gusset [B] Quarter Wheel Housing No.2 Brace BP-43 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding.<br><br> This affects the appearance of the finish. S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts.<br><br> S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT F15544 80mm (3.15in.) F15544A REMOVAL BP-44 QUARTER PANEL UPPER EXTENSION (CUT) REPLACEMENT With the quarter panel, back door opening trough removed. BODY PANEL REPLACEMENT F15545 BP-45 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram.<br><br> (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. S After welding, apply the polyurethane foam to the corresponding parts.<br><br> S After welding, apply body sealer and under-coating to the corresponding parts. S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT F15534 200mm (7.87in.) 220mm (8.66in.) F15534A REMOVAL BP-34 QUARTER PANEL (CUT) REPLACEMENT BODY PANEL REPLACEMENT F15535 POINT 1 Before temporarily installing the new parts, apply sealer to wheel arch.<br><br> HINT: 1) Apply body sealer about 5mm (0.20in.) from the flange, avoiding any oozing. 2) Apply sealer evenly, about 3 - 4mm (0.12 - 0.16in.) in diameter. 2 Inspect the fitting of the rear door, back door and rear combination light, etc., before welding, since this affects the appearance of the finish.<br><br> PART NAME [A] Fuel Filler Opening Lid [B] Waterproof Rivets BP-35 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.<br><br> S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts. S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.<br><br> BODY PANEL REPLACEMENT F15536 POINT 1 After removing [A], remove the quarter wheel housing outer panel. PART NAME [A] Roof Side Outer Panel 80mm (3.15 in.) F15536A REMOVAL BP-36 QUARTER WHEEL HOUSING OUTER PANEL (ASSY) REPLACEMENT With the quarter panel removed. BODY PANEL REPLACEMENT F15537 POINT 1 Determine the position of the new parts by assembly marks of the inner and outer panels.<br><br> PART NAME [A] Roof side Outer Panel BP-37 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.<br><br> S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts. S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.<br><br> BODY PANEL REPLACEMENT F15503 F15503A REMOVAL BP-3 RADIATOR SIDE SUPPORT (ASSY) REPLACEMENT With the radiator upper support removed. BODY PANEL REPLACEMENT F15504 PART NAME [A] Front Bumper Side Mounting Bracket [B] Radiator Support Reinforcement BP-4 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding.<br><br> This affects the appearance of the finish. S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts.<br><br> S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT F15505 F15505A REMOVAL BP-5 RADIATOR LOWER SUPPORT (ASSY) REPLACEMENT BODY PANEL REPLACEMENT F15506 BP-6 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding.<br><br> This affects the appearance of the finish. S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts.<br><br> S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT F15507 F15507A REMOVAL BP-7 RADIATOR SUPPORT (ASSY) REPLACEMENT BODY PANEL REPLACEMENT F15508 BP-8 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding.<br><br> This affects the appearance of the finish. S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts.<br><br> S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F15501 F15501A REMOVAL BODY PANEL REPLACEMENT BP-1 RADIATOR UPPER SUPPORT (ASSY) REPLACEMENT BODY PANEL REPLACEMENT F15502 PART NAME [A] Apron Fender Side Extension [B] Cool Air Intake Duct Mounting Bracket (LH Only) BP-2 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding.<br><br> This affects the appearance of the finish. S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts.<br><br> S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F15548 F15548A REMOVAL BODY PANEL REPLACEMENT BP-48 REAR FLOOR PAN EXTENSION (ASSY) REPLACEMENT With the body lower back panel removed. BODY PANEL REPLACEMENT F15549 BP-49 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram.<br><br> (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. S After welding, apply the polyurethane foam to the corresponding parts.<br><br> S After welding, apply body sealer and under-coating to the corresponding parts. S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F15550 F15550A REMOVAL BODY PANEL REPLACEMENT BP-50 REAR FLOOR SIDE REAR MEMBER (ASSY) REPLACEMENT With the body lower back panel removed.<br><br> BODY PANEL REPLACEMENT F15551 BP-51 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.<br><br> S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts. S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.<br><br> F15553 F15553A REMOVAL BODY PANEL REPLACEMENT BP-52 REAR FLOOR NO.2 CROSSMEMBER (ASSY) REPLACEMENT F15554 BODY PANEL REPLACEMENT BP-53 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.<br><br> S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts. S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.<br><br> BODY PANEL REPLACEMENT F15546 F15546A REMOVAL BP-46 REAR FLOOR PAN (ASSY) REPLACEMENT With the body lower back panel removed. BODY PANEL REPLACEMENT F15547 PART NAME [A] Floor Clamp Bracket [D] Jack Up Bracket [E] Spare Wheel Clamp Bracket [B] Fuel Tube Bracket [C] Rear Floor Heat Insulator No.3 Bracket BP-47 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding.<br><br> This affects the appearance of the finish. S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts.<br><br> S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F15532 80mm (31.5in.) F15532A REMOVAL BODY PANEL REPLACEMENT BP-32 ROCKER OUTER PANEL (CUT) REPLACEMENT BODY PANEL REPLACEMENT F15533 POINT 1 Inspect the fitting the front door and rear door, etc., before welding, since this affects the appearance of the finish. BP-33 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram.<br><br> (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. S After welding, apply the polyurethane foam to the corresponding parts.<br><br> S After welding, apply body sealer and under-coating to the corresponding parts. S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT F15530 350mm (13.78in.) F15530A REMOVAL BP-30 ROCKER OUTER PANEL (CUT-P) REPLACEMENT BODY PANEL REPLACEMENT F15531 POINT 1 Inspect the fitting of the front door, etc., before welding, since this affects the appearance of the finish.<br><br> BP-31 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.<br><br> S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts. S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.<br><br> BODY PANEL REPLACEMENT F15557 POINT 1 If reusing the roof panel reinforcement, trim the hemming location using a disc sander, etc. F15557A REMOVAL BP-56 ROOF PANEL (ASSY): w/ sun roof REPLACEMENT F15558 POINT 1 Before temporarily installing the new parts, apply body sealer to the windshield header panel, roof panel rein- forcement and back window frame. HINT: 1) Apply just enough sealer for the new parts to make contact.<br><br> 2 Bend the flange hem with a wooden hammer and dolly. HINT: 1) Perform hemming three steps, being careful not to warp the panel. BODY PANEL REPLACEMENT BP-57 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram.<br><br> (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. S After welding, apply the polyurethane foam to the corresponding parts.<br><br> S After welding, apply body sealer and under-coating to the corresponding parts. S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. BODY PANEL REPLACEMENT F15555 F15555A REMOVAL BP-54 ROOF PANEL (ASSY): w/o sun roof REPLACEMENT BODY PANEL REPLACEMENT F15556 POINT 1 Before temporarily installing the new parts, apply body sealer to the windshield header panel reinforcement and back window frame.<br><br> HINT: 1) Apply just enough sealer for the new parts to make contact. BP-55 INSTALLATION S Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) S Inspect the fitting of the related parts around the new parts before welding.<br><br> This affects the appearance of the finish. S After welding, apply the polyurethane foam to the corresponding parts. S After welding, apply body sealer and under-coating to the corresponding parts.<br><br> S After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. HINT: 1) First wipe off any dirt, grease or oil with a rag soaked in a grease, wax and silicone remover. 2) Cover the surrounding areas with masking paper to avoid coating unnecessary areas.<br><br> If other areas are acci- dently coated, wipe off the coating immediately. 3) Apply the first coating of undercoat to all welded areas and panel joints, then apply a second coat over the entire area. 4) Do not coat parts which become hot, such as the tailpipe, or moving parts, such as the propeller shaft.<br><br> 5) Besides the locations described below, apply undercoating to all weld points under the body to insure corro- sion prevention. 6) Be sure to seal the edge of the flange of the member and bracket with undercoating. 7) If undercoat is damaged by peeling, cracks, etc., be sure to repair as necessary.<br><br> 8) Before the undercoat apply sealer allowing rust prevention to be attained. F15564 REFERENCE Referring to the notes above, undercoating should be applied according to the specifications for your country. PAINT S COATING PC-6 BODY PANEL UNDERCOATING AREAS HINT: 1) Whenever adjusting the doors and hoods, apply anti-rust agent (wax) around the hinges.<br><br> 2) Even if partially repairing a part, apply anti-rust agent (wax) over the entire application area of the part. 3) Wipe off the anti-rust agent immediately with a rag soaked in a grease, wax and silicone remover, if accidently applied to other areas. F15565 PAINT S COATING PC-8 BODY PANEL ANTI-RUST AGENT (WAX) APPLICATION AREAS F15568 HINT: 1) Anti-chipping paint should be applide to some areas before the second coat and to others after the top coat.<br><br> 2) If other areas are accidentally coated, wipe of the paint immediately with a rag soaked in grease, wax and silicone remover. PVC Urethane PAINT S COATING PC-10 BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS HINT: 1) Prior to applying body sealer, clean the area with a rag soaked in grease,wax and silicone remover. 2) If weld-through primer was used, first wipe off any excess and coat with anti-corrosion primer before applying body sealer.<br><br> 3) Wipe off excess body sealer with a rag soaked in a grease, wax and silicone remover. 4) If body sealer is damaged by peeling, cracks, etc., be sure to repair as necessary. F15559 1.<br><br> ENGINE COMPARTMENT Flat Finishing No Flat Finishing PAINT S COATING PC-1 BODY PANEL SEALING AREAS PAINT S COATING F15560 2. INSIDE PC-2 PAINT S COATING F15561 3. REAR LUGGAGE COMPARTMENT PC-3 PAINT S COATING F15562 4.<br><br> DOOR PARTS PC-4 PAINT S COATING F15563 PC-5 The sections shown in the figure below are filled with foamed material to provide noise insullation. After repairing these sections or their peripheries, refill with foamed materials HINT: 1) Use the service holes located on the reverse side of the body panel to refill with foamed materials. 2) When handling foamed material, follow the directions of the material 9s manufacturer.<br><br> F15566 PAINT S COATING PC-7 FOAMED MATERIAL APPLICATION AREAS F15567 non-adhesive sheet PAINT S COATING PC-9 SILENCER SHEET INSTALLATION AREAS BODY DIMENSIONS (Three-Dimensional Distance) Symbol Name Hole dia. Symbol Name Hole dia. mm (in.) A, a B, b C, c D E, e F f G, g Radiator upper support standard hole Front spring support hole-inner Hood hinge installation nut Cowl top outer panel installation nut Air bag sensor installation nut Brake tube installation nut ABS actuator installation nut Radiator upper center support installation nut 12 (0.47) 11 (0.43) 8 (0.31) nut 6 (0.24) nut 8 (0.31) nut 6 (0.24) nut 8 (0.31) nut 6 (0.24) nut H, h I J, j K, k L, l M, m N, n 4 Radiator support standard hole Hood lock support installation nut Front bumper reinforcement installation bolt Front fender mounting bracket standard hole Radiator upper center support installation nut Front fender installation nut Front fender installation nut 4 10x8(0.39x0.31) 6 (0.24) nut 8 (0.31) bolt 10 (0.39) 6 (0.24) nut 6 (0.24) nut 6 (0.24) nut 4 B-D or D-E D-e K-k L-l N-n b-D 523 765 768 1,544 792 1,305 (20.59) (30.12) (30.24) (60.79) (31.18) (51.38) Vehicle Dimensions Left $ Right 332 (13.07) A C N M K J B L G F E H I D k h g l m a b c j e n 1,330 (52.36) 1,352 (53.23) 1,194 (47.01) 697 (27.44) 1,292 (50.87) 720 (28.35) 1,254 (49.37) 545 (21.46) 1,040 (40.94) 206 (8.11) 995 (39.17) 1,001 (39.41) 556 (21.89) 1,262 (49.69) 794 (31.26) 884 (34.80) 988 (38.90) 594 (23.39) 804 (31.65) 548 (21.57) 408 (16.06) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (Seen from rear).<br><br> DI-3 BODY DIMENSION DRAWINGS ENGINE COMPARTMENT (Three-Dimensional Distance) Symbol Name Hole dia. Symbol Name Hole dia. mm (in.) G, g I , i N, n O, o Rocker panel assembly mark Roof side rail assembly mark Center body pillar assembly mark Center body pillar assembly mark 4 4 4 4 P, p Q, q R, r S, s Rocker panel assembly mark Roof side rail assembly mark Quarter panel assembly mark Quarter panel assembly mark 4 4 4 4 N-n O-o P-p Q-q R-r S-s 1,273 1,362 1,365 1,069 1,189 1,363 (50.12) (53.62) (53.74) (42.09) (46.81) (53.66) Vehicle Dimensions Left $ Right G-p I -q N-r N-s O-s P-q R-s or or or or or or or g-P i-Q n-R n-S o-S p-Q r-S 1,632 1,284 1,404 1,568 1,459 1,623 1,506 (64.25) (50.55) (55.28) (61.73) (57.44) (63.90) (59.29) i g q n s o p 677 (26.65) 1,084 (42.68) 851 (33.50) 939 (36.97) 1,052 (41.42) 522 (20.55) r HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (Seen from rear).<br><br> BODY DIMENSIONS DI-5 BODY OPENING AREAS (Side View: Rear) (Three-Dimensional Distance) Symbol Name Hole dia. Symbol Name Hole dia. mm (in.) B, b C, c D, d Back door damper stay installation nut Roof side inner garnish installation bole Quarter panel standard hole 6 (0.24) nut 8.5 (0.335) 10 (0.39) E, e F, f G, g H, h 4 Deck trim side panel installation hole Deck trim rear cover installation hole Rear shock absorber installation hole Center body pillar assembly mark 4 8.5 (0.335) 7 (0.28) 18 (0.71) 4 4 G-H or g-h 1,031 (40.59) A, a Back door hinge installation hole RH: 10.2 (0.402) LH: 13x10.2 (0.51x0.402) h B D A a b c d g e f F E G C 985 (38.78) 1,557 (61.30) 945 (37.20) 747 (29.41) 1,112 (43.78) 1,426 (56.14) 1,069 (42.09) 985 (38.78) 948 (37.32) 507 (19.96) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (Seen from rear).<br><br> BODY DIMENSIONS DI-6 BODY OPENING AREAS (Rear View) (Three-Dimensional Distance) Symbol Name Hole dia. Symbol Name Hole dia. mm (in.) A, a B, b C, c D, d E, e F, f G, g Roof panel corner Cowl top outer panel/Front body pillar adjoining portion Front door hinge installation nut Front door hinge installation nut Front body pillar assembly mark Front body pillar assembly mark Rocker panel assembly mark 4 4 8 (0.31) nut 8 (0.31) nut 4 4 4 H, h I , i J, j K, k L, l M, m 4 Rocker panel assembly mark Roof side rail assembly mark Center body pillar assembly mark Center body pillar assembly mark Rear door hinge installation nut Rear door hinge installation nut 4 E-e F-f G-g H-h I -i J-j K-k 1,265 1,366 1,365 1,365 1,084 1,265 1,362 (49.80) (53.78) (53.74) (53.74) (42.68) (49.80) (53.62) Vehicle Dimensions Left $ Right E-f E-h E-j F-j F-k H-i J-k or or or or or or or e-F e-H e-J f-J f-K h- I j-K 1,482 1,601 1,505 1,760 1,600 1,625 1,427 (58.35) (63.03) (59.25) (69.29) (62.99) (63.98) (56.18) 4 4 4 4 8 (0.31) nut 8 (0.31) nut 4 A B a b c d i j e l k m h f 802 (31.57) 1,039 (40.91) 1,381 (54.37) 1,216 (47.87) 816 (32.13) 1,171 (46.10) 872 (34.33) 914 (35.98) 1,063 (41.85) 1,078 (42,44) 836 (32.91) 1,002 (39.45) g HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (Seen from rear).<br><br> BODY DIMENSIONS DI-4 BODY OPENING AREAS (Side View: Front) BODY DIMENSIONS Three-dimensional distance Center-to-center straight-line distance Two-dimensional distance Center-to-center Horizontal distance in forward/rearward Vertical distance in center Vertical distance in lower surface Imaginary Standard Line Under Surface of The Rocker Panel Imaginary Standard Line DI-1 GENERAL INFORMATION 1. BASIC DIMENSIONS (a) There are two types of dimensions in the diagram. (1) (Three-dimensional distance) S Straight-line distance between the centers of two measuring points.<br><br> (2) (Two-dimensional distance) S Horizontal distance in forward/rearward between the centers of two measuring points. S The height from an imaginary standard line. (b) In cases in which only one dimension is given, left and right are symmetrical.<br><br> (c) The dimensions in the following drawing indicate actual dis- tance. Therefore, please use the dimensions as a refer- ence. (d) The line that connects the places listed below is the imagi- nary standard line when measuring the height.<br><br> (The dimen- sions are printed in the text.) SYMBOL Name 1 The place that was lowered A mm from the under surface of the rocker panel centered on the front jack up point. 2 The place that was lowered B mm from the under surface of the rocker panel centered between 1 and 3. 3 The place that was lowered C mm from the under surface of the rocker panel centered on the rear jack up point.<br><br> Plate Looseness Body Looseness Pointer Looseness Pointer Master Gauge Wrong Correct Pointer BODY DIMENSIONS DI-2 2. MEASURING (a) Basically, all measurements are to be done with a tracking gauge. For portions where it is not possible to use a track- ing gauge, a tape measure should be used.<br><br> (b) Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers. HINT: 1) The height of the left and right pointers must be equal. 2) Always calibrate the tracking gauge before measuring or after adjusting the pointer height.<br><br> 3) Take care not to drop the tracking gauge or otherwise shock it. 4) Confirm that the pointers are securely in the holes. (c) When using a tape measure, avoid twists and bends in the tape.<br><br> BODY DIMENSIONS (Three-Dimensional Distance) Symbol Name Hole dia. Symbol Name Hole dia. mm (in.) A, a B, b C, c D, d E, e F, f Front bumper reinforcement installation bolt Radiator lower support standard hole Front side member standard hole Front suspension member installation nut Front suspension member installation nut Front side member standard hole 8 (0.31) bolt 15 (0.59) 18 (0.71) 12 (0.47) nut 14 (0.55) nut 18 (0.71) G, g H, h I , i J, j K, k L, l Front side member standard hole Front floor under reinforcement standard hole Rear floor side member standard hole Trailing arm installation hole-inner Rear floor side member standard hole Transport hook installation nut 18 (0.71) 18 (0.71) 18 (0.71) 13 (0.51) 18 (0.71) 10 (0.39) nut Imaginary Standard Line RH LH Front 489 (19.25) 1,095 (43.11) 440 (17.32) 988 (38.90) 930 (36.61) 1,031 (40.59) 1,164 (45.83) 885 (34.84) 922 (36.30) 858 (33.78) 300 (11.81) 895 (35.24) 463 (18.23) 256 (10.08) 856 (33.70) 973 (38.31) 1,117 (43.98) 856 (33.70) 968 (38.11) 1,252 (49.29) 856 (33.70) 452 (17.80) 374 (14.72) 1,200 (47.24) 1,080 (42.52) 1,066 (41.97) 697 (27.44) 304 (11.97) 1,451 (57.13) 936 (36.85) 1,269 (49.96) 984 (38.74) 936 (36.85) A,a 388 (15.28) B,b 154 (6.06) C,c 310 (12.20) D,d 295 (11.61) E,e 100 (3.94) F,f 57 (2.24) G,g 57 (2.24) H,h 58 (2.28) I ,i 137 (5.39) J,j 147 (5.79) K,k 287 (11.30) L,l 283 (11.14) 1 2 3 100 100 100 (3.94) (3.94) (3.94) DI-7 UNDER BODY (Two-Dimensional Distance) Symbol Name Hole dia.<br><br> Symbol Name Hole dia. mm (in.) A, a B, b C, c D, d E, e F, f G, g Front bumper reinforcement installation bolt Radiator lower support standard hole Front side member standard hole Front suspension member installation nut Front spring support hole-outer Front suspension member installation nut Front side member standard hole 8 (0.31) bolt 15 (0.59) 18 (0.71) 12 (0.47) nut 11 (0.43) 14 (0.55) nut 18 (0.71) H, h I , i J, j K, k L, l M, m N, n Front side member standard hole Front floor under reinforcement standard hole Rear floor side member standard hole Trailing arm installation hole-inner Rear shock absorber installation hole Rear floor side member standard hole Transport hook installation nut 18 (0.71) 18 (0.71) 18 (0.71) 13 (0.51) 18 (0.71) 18 (0.71) 10 (0.39) nut 1 2 3 100 100 100 (3.94) (3.94) (3.94) Wheel base 2,370 (93.31) RH LH Front Imaginary Standard Line 1,985 (78.15) 1,394 (54.88) 1,167 (45.94) 452 (17.80) 0 520 (20.47) 990 (38.98) 220 (8.66) 443 (17.44) 429 (16.89) 428 (16.85) 428 (16.85) 533 (20.98) 468 (18.43) 494 (19.45) 465 (18.31) 611 (24.06) 428 (16.85) 428 (16.85) 600 (23.62) 535 (21.06) 468 (18.43) 2,069 (81.46) 1,882 (74.09) 1,393 (54.84) 915 (36.02) 0 322 (12.68) 983 (38.70) 1,294 (50.94) A,a 388 (15.28) B,b 154 (6.06) C,c 310 (12.20) D,d 295 (11.61) E,e 752 (29.61) F,f 100 (3.94) G,g 57 (2.24) H,h 57 (2.24) I ,i 58 (2.28) J,j 137 (5.39) K,k 147 (5.79) L,l 659 (25.94) M.m 287 (11.30) N,n 283 (11.14) I BODY DIMENSIONS DI-8 UNDER BODY (Cont 9d)

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