Mazda 6 2009 Bodyshop Manual
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2009-2013
Bodyshop
Manual
FOREWORD
This bodyshop manual is intended for
use by technicians of Authorized Mazda
Dealers to help them service and repair
Mazda vehicles. It can also be useful to
owners and operators of Mazda vehicles in
performing limited repair and maintenance
on Mazda vehicles.
For proper repair and maintenance, a
thorough familiarization with this manual is
important, and it should always be kept in a
handy place for quick and easy reference.
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing.
As modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Mazda dealers. This manual
should be kept up-to-date.
Mazda North American Operations
reserves the right to alter the specifications
and contents of this manual without obliga-
tion or advance notice.
All rights reserved. No part of this book may
be reproduced or used in any form or
by any means, electronic or mechanical
including photocopying and recording and
the use of any kind of information storage
and retrieval system-without permission in
writing.
Mazda North American Operations
HIROSHIMA, JAPAN
CONTENTS
GENERAL INFORMATION
CONSTRUCTION
PANEL REPLACEMENT
WATER-PROOF AND RUST
BODY
PREVENTIVE
STRUCTURE
DIMENSIONS
PLASTIC BODY PARTS
CONSTRUCTION
STANDARD VALVES
APPLICATION:
This manual is applicable to vehicles beginning
with the Vehicle Identification Numbers (VIN),
shown on the following page.
© 2009 Mazda North American Operations
PRINTED IN U.S.A., JULY 2009
Form No. 3442–1U–09G
Part No. 9999–95–099F–09
Title
Section
00
80A
80B
80C
80D
80E
80F

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Summary of Contents for Mazda 6 2009

  • Page 1 This bodyshop manual is intended for use by technicians of Authorized Mazda Dealers to help them service and repair PLASTIC BODY PARTS Mazda vehicles. It can also be useful to owners and operators of Mazda vehicles in CONSTRUCTION performing limited repair and maintenance STANDARD VALVES on Mazda vehicles.
  • Page 2 VEHICLE IDENTIFICATION NUMBERS (VIN) 2009 MY 1YV HP80A✻95 M00001— 1YV HP80H✻95 M00001— 1YV HP81A✻95 M00001— 1YV HP81B✻95 M00001— 1YV HP81H✻95 M00001— 1YV HP82A✻95 M00001— 1YV HP82B✻95 M00001— 1YV HP82H✻95 M00001— 2010 MY 1YV HZ8AA✻A5 M00001— 1YV HZ8AH✻A5 M00001— 1YV HZ8BA✻A5 M00001—...
  • Page 3: Table Of Contents

    GENERAL INFORMATION SECTION 00-00 Toc of SCT GENERAL INFORMATION ..00-00 Toc of SCT 00-00 GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER EFFICIENT REMOVAL OF (VIN) CODE ..... . 00-00–2 BODY PANELS .
  • Page 4: General Information

    Car identifier P= Passenger car Air bag H= With front, side and curtain air bag World manufacturer identification 1YV= Mazda passenger car, produced at AAI *1: Vehicles with the following VIN are equipped with a Hiroshima-manufactured engine. 1YVHP81A095M47734 1YVHP81A295M48111 1YVHP81A595M48085...
  • Page 5: 2010 My

    8= Mazda6 Car identifier Z= Passenger car Air bag H= With front, side and curtain air bag World manufacturer identification 1YV= Mazda passenger car, produced at AAI am6xuw0000287 End Of Sie VEHICLE IDENTIFICATION NUMBERS (VIN) id000000600100 2009 MY 1YV HP80A*95 M00001—...
  • Page 6: How To Use This Manual

    GENERAL INFORMATION HOW TO USE THIS MANUAL id000000600900 Efficient Replacement of Body Panels • This section contains information on the body panels in regard to the welding types, number of spot welds, and cut-and-join locations that are necessary for panel removal and installation. •...
  • Page 7: Body Dimensions (Flat-Plane Dimensions)

    GENERAL INFORMATION Body Dimensions (Flat-plane Dimensions) • Flat-plane dimensions are the dimensions measured by projecting certain reference points onto a plane surface. FRONT FENDER INSTALLATION NUT 00-00 810 {31.89} FLAT-PLANE DIMENSIONS acxuub00000033 00-00–5...
  • Page 8: Body Dimensions (Straight-Line Dimensions)

    GENERAL INFORMATION • When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle. • The hypothetical lines may differ according to the vehicle model. • The schematic diagram shows the vehicle as it is projected from the underbody. Example Shows vehicle section UNDERBODY FLAT-PLANE DIMENSIONS...
  • Page 9 GENERAL INFORMATION FRONT FENDER INSTALLATION NUT 00-00 {32.17} STRAIGHT-LINE DIMENSIONS acxuub00000035 00-00–7...
  • Page 10 GENERAL INFORMATION • When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle. Example ROOM STRAIGHT-LINE DIMENSIONS (1) Shows vehicle section Shows point Shows outline drawing symbol Shows dimension 1,128 {44.41} 1,263...
  • Page 11: Symbols Of Body Dimensions

    GENERAL INFORMATION Symbols of Body Dimensions • The following 8 symbols are used to indicate the standard points. SYMBOL MEANING SYMBOL MEANING 00-00 Bolt tip Center of circular hole (arrow only) Center of rectangular-shaped hole Center elliptical hole Edge of rectangular-shaped hole Notch Panel seam, bead, etc.
  • Page 12: Side Air Bag Module Handling

    GENERAL INFORMATION Side Air Bag Module Handling • Before removing the side air bag module or disconnecting the side air bag module connector, always switch the ignition to off, disconnect the negative battery cable, and then wait for 1 min or more to allow the backup power supply of the SAS control module to deplete its stored power.
  • Page 13: Service Precautions

    GENERAL INFORMATION SERVICE PRECAUTIONS id000000600200 Arrangement of Workshop • Arrangement of the workshop is important for safe and efficient work. Safety Precautions 00-00 • Protective head covering and safety shoes should always be worn. Depending upon the nature of the work, gloves, safety glasses, ear protectors, face shield, etc., should also be used.
  • Page 14: Use Of Pulling Equipment

    GENERAL INFORMATION Use of Pulling Equipment • When using pulling equipment, keep away from the pulling area and use safety wires to prevent accidents. SAFETY WIRES am3uub0000007 Prevent Short Circuits • Turn the ignition switch to the LOCK position. • Disconnect the battery cables. Battery cable acxuub00000042 •...
  • Page 15: Prevention Of Body Deformation

    GENERAL INFORMATION Prevention of Body Deformation • Use a clamp or a jack for removal and reinforce at and around the rough-cutting location to prevent deforming of the body. 00-00 acxuub00000066 Selection of Cut-and-join Locations • For parts where complete replacement is not feasible, careful cutting and joining operations should be followed.
  • Page 16: Welding Notes

    GENERAL INFORMATION Welding Notes • For the number of weld points, welding should be performed in accordance with the following reference standards. SPOT WELDING REPAIR WELD ORIGINAL WELD ORIGINAL NUMBER OF WELDS x 1.3 OR MORE CO 2 ARC WELDING ORIGINAL SPOT WELD IF 3 mm REPAIR WELD...
  • Page 17: Checking Weld Strength

    GENERAL INFORMATION Checking Weld Strength • Installation locations of the engine, chassis, and CHISEL DIMENSIONS seat belts are designated as important safety locations for weld strength. Check weld strength 20° by driving a chisel between the panels at every 25 mm 00-00 fourth or fifth weld spot, and every tenth regular {0.98 in}...
  • Page 18: Installation Preparations

    GENERAL INFORMATION INSTALLATION PREPARATIONS id000000600400 Rough Cutting of New Parts • For cut-and-join areas, allow for an overlap of 30—50 mm {1.2—1.9 in} with the remaining area on the body side and then rough-cut the new parts. 50 mm{1.2 1.9 in} —...
  • Page 19: Application Of Weld-Through Primer

    GENERAL INFORMATION Application of Weld-through Primer • For treatment against corrosion, remove the paint grease, and other material from the portion of new part and body to be welded, and apply weld-through primer. End Of Sie 00-00 acxuub00000068 ANTICORROSION, SOUND INSULATION, AND VIBRATION INSULATION id000000600600 Body Sealing •...
  • Page 20: Application Of Rust Inhibitor

    GENERAL INFORMATION Application of Rust Inhibitor • Apply rust inhibitor (wax, oil, etc.) to the back of the welded areas. acxuub00000061 Application of Floor Silencer • Apply floor silencer by heating with an infrared ray lamp. End Of Sie WM: GENERAL INFORMATION acxuub00000062 BODY COLORS id000000788800...
  • Page 21: Identification Number Locations

    GENERAL INFORMATION IDENTIFICATION NUMBER LOCATIONS id000000800800 Vehicle Identification Number (VIN) 00-00 am6uuw0000051 Engine Identification Number 1YV HP80H*95 M00001—, 1YV HP81H*95 M00001—, 1YV HP82H*95 M00001— 1YV HP80A*95 M00001—, 1YV HP81A*95 M00001—, 1YV HP82A*95 M00001— FRONT am6xuw0000281 FRONT am6xuw0000279 MZI-3.7 FRONT am6xuw0000238 End Of Sie 00-00–19...
  • Page 23 BODY & ACCESSORIES SECTION 09-80A Toc of SCT BODY STRUCTURE BODY STRUCTURE [BODY STRUCTURE] ..09-80A [DIMENSIONS] ... 09-80D BODY STRUCTURE BODY STRUCTURE [PANEL REPLACEMENT] . . . 09-80B [PLASTIC BODY PARTS] .
  • Page 24 BODY STRUCTURE [BODY STRUCTURE] BODY COMPONENTS CONSTRUCTION [BODY STRUCTURE] id098013739700 am6xub0000005 09-80A–2...
  • Page 25 BODY STRUCTURE [BODY STRUCTURE] Ultra high-tension High-tension Thickness (mm Part Name Rust proof steel steel steel {in}) × × Bonnet — 0.7 {0.03} Front bumper bracket — — — 2.6 {0.10} × Shroud side panel — — 2.0 {0.079} × Shroud side member —...
  • Page 26 BODY STRUCTURE [BODY STRUCTURE] Crossmember No.2 — — — 1.2 {0.047} × Front seat bracket — — 1.4 {0.055} × × Front B frame — 1.2 {0.047} × Crossmember No.4 (front) — — 1.2 {0.047} × Crossmember No.4 (rear) — —...
  • Page 27 BODY STRUCTURE [BODY STRUCTURE] 09-80A am6xub0000005 Strength Roof rail reinforcement Part Name (MPa) Front pillar reinforcement Front side frame (inner, front) B-pillar reinforcement (center) Hinge pillar (inner) B-pillar reinforcement (inner) Hinge reinforcement Rear bumper bracket Front pillar (inner) Front B frame Roof rail (inner, rear) Floor reinforcement Side sill (inner)
  • Page 29 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B BODY STRUCTURE [PANEL REPLACEMENT] Symbol Mark ..... 09-80B–18 FRONT BUMPER BRACKET REMOVAL [PANEL REPLACEMENT]... 09-80B–2 Installation Procedure .
  • Page 30: Front Bumper Bracket Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] [PANEL REPLACEMENT] ... 09-80B–58 Symbol Mark ....09-80B–79 Installation Procedure .
  • Page 31: Removal Procedure

    BODY STRUCTURE [PANEL REPLACEMENT] Removal Procedure 1. Grind the 2 locations indicated by (A) shown in the figure. (B)2 09-80B (A)2 FRONT BUMPER BRACKET (B)2 (B)1 am6xub0000001 2. Grind the 5 locations indicated by (B) shown in the figure. 3. Remove the front bumper bracket. End Of Sie 09-80B–3...
  • Page 32: Front Bumper Bracket Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT BUMPER BRACKET INSTALLATION [PANEL REPLACEMENT] id098008743200 Symbol Mark MEANING SYMBOL MARK CONTINUOUS CO 2 ARC WELDING (CUT-AND-JOIN LOCATION) am6zzb0000003 Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 33: Shroud Side Panel Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SHROUD SIDE PANEL REMOVAL [PANEL REPLACEMENT] id098008602700 Symbol Mark SYMBOL MARK MEANING SPOT WELDING am6zzb0000001 09-80B Removal Procedure 1. Drill the 2 locations indicated shown in the figure. SHROUD SIDE PANEL am6zzb0000015 2. Remove the shroud side panel. End Of Sie 09-80B–5...
  • Page 34: Shroud Side Panel Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SHROUD SIDE PANEL INSTALLATION [PANEL REPLACEMENT] id098008602800 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb0000001 Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 35: Shroud Side Member Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SHROUD SIDE MEMBER REMOVAL [PANEL REPLACEMENT] id098008919000 Symbol Mark SYMBOL MARK MEANING SPOT WELDING am6zzb0000001 09-80B Removal Procedure 1. Drill the 6 locations indicated shown in the figure. FRONT FENDER BRACKET am6xub0000001 2. Remove the front fender bracket. 09-80B–7...
  • Page 36 BODY STRUCTURE [PANEL REPLACEMENT] 3. Drill the 7 locations indicated shown in the figure. SHROUD SIDE MEMBER am6xub0000001 4. Remove the shroud side member. End Of Sie 09-80B–8...
  • Page 37: Shroud Side Member Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SHROUD SIDE MEMBER INSTALLATION [PANEL REPLACEMENT] id098008919100 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb0000001 09-80B Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 38 BODY STRUCTURE [PANEL REPLACEMENT] 6. Plug weld the 6 locations indicated shown in the figure. FRONT FENDER BRACKET am6xub0000001 End Of Sie BM: COWL SIDE REINFORCEMENT 09-80B–10...
  • Page 39: Cowl Side Reinforcement Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] COWL SIDE REINFORCEMENT REMOVAL [PANEL REPLACEMENT] id098008741700 Symbol Mark SYMBOL MARK MEANING SPOT WELDING am6zzb0000004 09-80B Removal Procedure 1. Drill the 24 locations indicated shown in the figure. COWL SIDE REINFORCEMENT am6xub0000001 2. Remove the cowl side panel. End Of Sie 09-80B–11...
  • Page 40: Cowl Side Reinforcement Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] COWL SIDE REINFORCEMENT INSTALLATION [PANEL REPLACEMENT] id098008741800 Symbol Mark MEANING SYMBOL MARK PLUG WELDING (CO 2 ARC WELDING) am6zzb0000004 Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 41: Wiper Bracket Component Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] End Of Sie WIPER BRACKET COMPONENT REMOVAL [PANEL REPLACEMENT] BM: WIPER BRACKET id098008750000 Symbol Mark SYMBOL MARK MEANING SPOT WELDING am6zzb0000004 09-80B Removal Procedure 1. Drill the 16 locations indicated shown in the figure. WIPER BRACKET am6xub0000001 2.
  • Page 42: Wiper Bracket Component Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] WIPER BRACKET COMPONENT INSTALLATION [PANEL REPLACEMENT] id098008750100 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb0000004 Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 43: Apron Reinforcement (Upper) Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] APRON REINFORCEMENT (UPPER) REMOVAL [PANEL REPLACEMENT] id098008800000 Symbol Mark SYMBOL MARK MEANING SPOT WELDING am6zzb0000005 09-80B Removal Procedure 1. Drill the 24 locations indicated shown in the figure. APRON REINFORCEMENT (UPPER) am6xub0000002 2. Remove the apron reinforcement (upper). End Of Sie 09-80B–15...
  • Page 44: Apron Reinforcement (Upper) Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] APRON REINFORCEMENT (UPPER) INSTALLATION [PANEL REPLACEMENT] id098008800100 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb0000005 Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 45: Apron Reinforcement (Lower) Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] APRON REINFORCEMENT (LOWER) REMOVAL [PANEL REPLACEMENT] id098008741300 Symbol Mark SYMBOL MARK MEANING SPOT WELDING am6zzb0000005 09-80B Removal Procedure 1. Drill the 14 locations indication shown in the figure. APRON REINFORCEMENT (LOWER) am6xub0000002 2. Remove the apron reinforcement (lower). End Of Sie 09-80B–17...
  • Page 46: Apron Reinforcement (Lower) Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] APRON REINFORCEMENT (LOWER) INSTALLATION [PANEL REPLACEMENT] id098008741400 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb0000005 Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 47: Wheel Apron Panel (Front) Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] WHEEL APRON PANEL (FRONT) REMOVAL [PANEL REPLACEMENT] id098008741100 Symbol Mark SYMBOL MARK MEANING SPOT WELDING am6zzb0000001 09-80B Removal Procedure 1. Drill the 10 locations indicated shown in the figure. WHEEL APRON PANEL (FRONT) am6xub0000002 2. Remove the wheel apron panel (front). 09-80B–19...
  • Page 48 BODY STRUCTURE [PANEL REPLACEMENT] 1. Drill the 22 locations indicated shown in the figure. WHEEL APRON PANEL (FRONT) am6xub0000002 2. Remove the wheel apron panel (front). End Of Sie 09-80B–20...
  • Page 49: Wheel Apron Panel (Front) Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] WHEEL APRON PANEL (FRONT) INSTALLATION [PANEL REPLACEMENT] id098008741200 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb0000001 09-80B Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 50 BODY STRUCTURE [PANEL REPLACEMENT] 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 4.
  • Page 51: Wheel Apron Component Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] WHEEL APRON COMPONENT REMOVAL [PANEL REPLACEMENT] id098008746000 Symbol Mark SYMBOL MARK MEANING SPOT WELDING am6zzb0000006 09-80B Removal Procedure 1. Drill the 36 locations indicated by (A), drill the 8 locations indicated by (B) shown in the figure. (B)2 (A)3 (A)3...
  • Page 52 BODY STRUCTURE [PANEL REPLACEMENT] 1. Drill the 36 locations indicated by (A), drill the 8 locations indicated by (B) shown in the figure. (B)2 (A)3 (A)3 (A)5 (B)3 (B)3 WHEEL APRON COMPONENT (A)22 (A)3 am6xub0000003 Note Drill the 8 locations indicated by (B) from the front wheel housing. 2.
  • Page 53: Wheel Apron Component Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] WHEEL APRON COMPONENT INSTALLATION [PANEL REPLACEMENT] id098008746100 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb0000006 09-80B Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 54 BODY STRUCTURE [PANEL REPLACEMENT] 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2. Drill holes for the plug welding before installing the new parts. 3. After temporarily installing new parts, make sure the related parts fit properly. 4.
  • Page 55: Front Side Frame Component Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME COMPONENT REMOVAL [PANEL REPLACEMENT] id098008741900 Symbol Mark SYMBOL MARK MEANING SPOT WELDING PLUG WELDING (CO 2 ARC WELDING) 09-80B ROUGH CUT LOCATION am6zzb0000006 09-80B–27...
  • Page 56: Removal Procedure

    BODY STRUCTURE [PANEL REPLACEMENT] Removal Procedure 1. Drill the 1 location indicated by (A) shown in the figure. (A)1 FRONT SIDE FRAME COMPONENT (B) 5 (B) 1 (B) 4 (B) 3 am6zzb0000006 Note Drill the 1 location indicated by (A) from the interior. 2.
  • Page 57 BODY STRUCTURE [PANEL REPLACEMENT] 3. Rough cut area indicated by (C) shown in the figure. 09-80B (D) 1 am6zzb0000016 Caution During rough cutting, be careful not to damage the front side frame (rear). 4. Drill the 1 location indicated by (D) shown in the figure. 5.
  • Page 58: Front Side Frame Component Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME COMPONENT INSTALLATION [PANEL REPLACEMENT] id098008742000 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) CONTINUOUS CO 2 ARC WELDING (CUT-AND-JOIN LOCATION) am6zzb0000024 Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 59 BODY STRUCTURE [PANEL REPLACEMENT] 6. Plug weld the 1 location indicated by (C) shown in the figure. 09-80B (C)1 FRONT SIDE FRAME COMPONENT (D) 5 (D) 1 (D) 4 (D) 3 am6zzb0000007 Note Plug weld the 1 location indicated by (C) from the interior. 7.
  • Page 60: Front Side Frame (Partial Cutting) Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME (PARTIAL CUTTING) REMOVAL [PANEL REPLACEMENT] id098008742100 Symbol Mark SYMBOL MARK MEANING SPOT WELDING ROUGH CUT LOCATION am6xub0000003 Removal Procedure Caution The rough cut area indicates the maximum size range of the installation position. 1.
  • Page 61 BODY STRUCTURE [PANEL REPLACEMENT] ROUGH CUT AND CUT-AND-JOIN LOCATION 09-80B (B)8 FRONT SIDE FRAME (OUTER, RH) (B)7 30mm {1.18in} (B)3 FRONT SIDE FRAME (INNER, RH) 85mm {3.35in} ROUGH CUT AND CUT-AND-JOIN LOCATION am6xub0000004 09-80B–33...
  • Page 62 BODY STRUCTURE [PANEL REPLACEMENT] Caution The rough cut area indicates the maximum size range of the installation position. 1. Rough cut area (A), drill the 18 locations indicated by (B), and then remove the front side frame. (A) ROUGH CUT AND CUT-AND-JOIN LOCATION (B)8 FRONT SIDE FRAME (OUTER, LH)
  • Page 63: Front Side Frame (Partial Cutting) Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME (PARTIAL CUTTING) INSTALLATION [PANEL REPLACEMENT] id098008742200 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) CONTINUOUS CO 2 ARC WELDING (CUT-AND-JOIN LOCATION) 09-80B am6xub0000004 Installation Procedure Caution The cut-and-joint area indicates the maximum size range of the installation position. 1.
  • Page 64 BODY STRUCTURE [PANEL REPLACEMENT] 25mm {0.98in} L=30mm x 2 {1.18in} t=2.3mm {0.09in} EXTRUSION BEAD EXTRUSION BEAD REINFORCEMENT L=70mm x 2 10mm 15mm {2.76in} {0.39in} {0.59in} 85mm {3.35in} FRONT SIDE FRAME (INNER, RH) CUT-AND-JOIN LOCATION am6xub0000004 09-80B–36...
  • Page 65 BODY STRUCTURE [PANEL REPLACEMENT] 7. Install the front side frame reinforcement. FRONT SIDE FRAME REINFORCEMENT (RH) 09-80B L=50mm {1.97in} L=50mm {1.97in} am6xub0000004 8. Install the suspension mount reinforcement. 9. Install the suspension mount bolt. Tightening torque 1.0—5.0 N·m {11—50 kgf·cm, 8.9—44 in·lbf} 09-80B–37...
  • Page 66 BODY STRUCTURE [PANEL REPLACEMENT] L=15mm {0.59in} SUSPENSION MOUNT REINFORCEMENT SUSPENSION MOUNT BOLT L=20mm {0.79in} am6xub0000004 09-80B–38...
  • Page 67 BODY STRUCTURE [PANEL REPLACEMENT] 10. Because the front side frame (outer) cannot be welded to the existing parts from the inside of the panel, drill 5 plug weld holes at the locations indicated by (A) on the existing parts. Install the reinforcement and the existing parts by plug welding from the outside, then butt weld the new and existing parts.
  • Page 68 BODY STRUCTURE [PANEL REPLACEMENT] Caution The cut-and-joint area indicates the maximum size range of the installation position. 1. Make a reinforcement panel using the material from the front side frame (inner). 2. To cut and join the new and existing parts, cut the new part at the specified location shown in the figure, and chamfer the joint surfaces of the new and existing parts.
  • Page 69 BODY STRUCTURE [PANEL REPLACEMENT] 6. Install the front side frame (inner). 25mm {0.98in} L=30mm x 2 {1.18in} t=2.3mm {0.09in} 09-80B EXTRUSION BEAD EXTRUSION BEAD REINFORCEMENT L=70mm x 2 10mm 15mm {2.76in} {0.39in} {0.59in} FRONT SIDE FRAME (INNER, LH) 105mm {4.13in} CUT-AND-JOIN LOCATION am6xub0000004...
  • Page 70 BODY STRUCTURE [PANEL REPLACEMENT] 7. Install the front side frame reinforcement. FRONT SIDE FRAME REINFORCEMENT (LH) L=50mm {1.97in} L=50mm {1.97in} am6xub0000004 8. Install the suspension mount reinforcement. 9. Install the suspension mount bolt. Tightening torque 1.0—5.0 N·m {11—50 kgf·cm, 8.9—44 in·lbf} 09-80B–42...
  • Page 71 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B L=15mm {0.59in} SUSPENSION MOUNT REINFORCEMENT SUSPENSION MOUNT BOLT L=20mm {0.79in} am6xub0000004 09-80B–43...
  • Page 72 BODY STRUCTURE [PANEL REPLACEMENT] 10. Because the front side frame (outer) cannot be welded to the existing parts from the inside of the panel, drill 5 plug weld holes at the locations indicated by (A) on the existing parts. Install the reinforcement and the existing parts by plug welding from the outside, then butt weld the new and existing parts.
  • Page 73: Torque Box Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] TORQUE BOX REMOVAL [PANEL REPLACEMENT] id098008607100 Symbol Mark SYMBOL MARK MEANING SPOT WELDING am6zzb0000002 09-80B Removal Procedure 1. Drill the 32 locations indicated shown in the figure. TORQUE BOX am6zzb0000006 2. Remove the torque box. End Of Sie 09-80B–45...
  • Page 74: Torque Box Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] TORQUE BOX INSTALLATION [PANEL REPLACEMENT] id098008607200 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb0000002 Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 75: Front Pillar Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT PILLAR REMOVAL [PANEL REPLACEMENT] id098008744700 Symbol Mark SYMBOL MARK MEANING SPOT WELDING ROUGH CUT LOCATION 09-80B am2zzb0000008 Removal Procedure 1. Rough cut area (A), drill the 77 locations indicated by (B) shown in the figure. 100 mm {3.94 in} (B)13 FRONT PILLAR...
  • Page 76 BODY STRUCTURE [PANEL REPLACEMENT] (B) 3 (B) 1 (B) 2 (B) 26 SIDE FRAME (OUTER) (B) 2 (B) 2 (B) 11 SIDE SILL REINFORCEMENT 90 mm (B) 2 {3.5 in} (B) 4 am6xub0000009 Caution During rough cutting, be careful not to damage the side sill reinforcement. 2.
  • Page 77 BODY STRUCTURE [PANEL REPLACEMENT] 3. Rough cut area (C), drill the 24 locations indicated by (D) shown in the figure. 200 mm {7.87 in} 09-80B FRONT PILLAR REINFORCEMENT HINGE REINFORCEMENT (D) 1 (D) 3 (D) 5 (D) 8 (D) 1 (D) 3 (D) 1 (D) 2...
  • Page 78 BODY STRUCTURE [PANEL REPLACEMENT] 5. Rough cut area (F), drill the 8 locations indicated by (G) shown in the figure. FRONT PILLAR (INNER) 240 mm {9.45 in} (G) 8 am6zzb0000007 6. Remove the front pillar (inner). 7. Remove the spot weld sealer using a disc grinder. End Of Sie 09-80B–50...
  • Page 79: Front Pillar Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT PILLAR INSTALLATION [PANEL REPLACEMENT] id098008744800 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) CONTINUOUS CO 2 ARC WELDING (CUT-AND-JOIN LOCATION) 09-80B am2zzb0000008 Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 80 BODY STRUCTURE [PANEL REPLACEMENT] 5. Cut-and-join area locations indicated by (C) then plug weld the 24 locations indicated by (D) shown in the figure. 140 mm {5.51 in} FRONT PILLAR REINFORCEMENT HINGE REINFORCEMENT (D) 1 (D) 3 (D) 5 (D) 8 (D) 1 (D) 3 (D) 1...
  • Page 81 BODY STRUCTURE [PANEL REPLACEMENT] 7. Cut-and-join area locations indicated by (E) then plug weld the 81 locations indicated by (F) shown in the figure. 70 mm {2.8 in} 09-80B (F) 14 FRONT PILLAR (OUTER) (F) 5 (F) 3 (F) 3 am6zzb0000007 09-80B–53...
  • Page 82 BODY STRUCTURE [PANEL REPLACEMENT] (F) 3 (F) 1 (F) 2 (F) 28 (F) 2 (F) 2 (F) 11 (B) 2 140 mm {5.51 in} (F) 5 am6xub0000009 End Of Sie BM: CENTER PILLAR 09-80B–54...
  • Page 83: Center Pillar Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] CENTER PILLAR REMOVAL [PANEL REPLACEMENT] id098008743900 Symbol Mark SYMBOL MARK MEANING SPOT WELDING ROUGH CUT LOCATION 09-80B am2zzb0000009 Removal Procedure 1. Rough cut area locations indicated by (A) then drill the 77 locations indicated by (B) shown in the figure. ROOF RAIL REINFORCEMENT ROUGH CUT LOCATION...
  • Page 84 BODY STRUCTURE [PANEL REPLACEMENT] 3. Drill the 22 locations indicated by (C) shown in the figure. am6xub0000009 4. Remove the B-pillar reinforcement. 09-80B–56...
  • Page 85 BODY STRUCTURE [PANEL REPLACEMENT] 5. Rough cut area locations indicated by (D) then drill the 10 locations indicated by (E) shown in the figure. 09-80B WELD BOND APPLICATION AREA am6xub0000007 6. Remove the weld bond using a chisel and remove the B-pillar (inner) shown in the figure. 7.
  • Page 86: Symbol Mark

    BODY STRUCTURE [PANEL REPLACEMENT] CENTER PILLAR INSTALLATION [PANEL REPLACEMENT] id098008744000 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) CONTINUOUS CO 2 ARC WELDING (CUT-AND-JOIN LOCATION) am6zzb0000024 Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 87 BODY STRUCTURE [PANEL REPLACEMENT] 4. Cut-and-join area locations indicated by (A) then plug weld the 10 locations indicated by (B) shown in the figure. 5. Plug weld the 19 locations indicated by (C) shown in the figure. 09-80B am6xub0000009 6. After temporarily installing new parts, make sure the related parts fit properly. 09-80B–59...
  • Page 88 BODY STRUCTURE [PANEL REPLACEMENT] 7. Cut-and-join area locations indicated by (D) then plug weld 83 locations indicated (E) shown in the figure. ROOF RAIL REINFORCEMENT CUT-AND-JOIN LOCATION B-PILLAR REINFORCEMENT CENTER PILLAR (OUTER) CENTER PILLAR (OUTER) am6xub0000008 End Of Sie BM: SIDE SILL PANEL 09-80B–60...
  • Page 89: Side Sill Panel Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SIDE SILL PANEL REMOVAL [PANEL REPLACEMENT] id098008743700 Symbol Mark SYMBOL MARK MEANING SPOT WELDING ROUGH CUT LOCATION 09-80B am2zzb0000009 Removal Procedure 1. Rough cut area locations indicated by (A) then drill the 95 locations indicated by (B) shown in the figure. SIDE FRAME (OUTER) WHEEL HOUSE (INNER)
  • Page 90 BODY STRUCTURE [PANEL REPLACEMENT] 3. Rough cut area locations indicated by (C) then drill the 23 locations indicated by (D) shown in the figure. (D) 3 am6zzb0000008 4. Remove the hinge reinforcement and B-pillar reinforcement. 09-80B–62...
  • Page 91 BODY STRUCTURE [PANEL REPLACEMENT] 5. Drill the 61 locations indicated by (E) shown in the figure 09-80B am6zzb0000008 6. Remove the side sill reinforcement. End Of Sie 09-80B–63...
  • Page 92: Side Sill Panel Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] SIDE SILL PANEL INSTALLATION [PANEL REPLACEMENT] id098008743800 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) CONTINUOUS CO 2 ARC WELDING (CUT-AND-JOIN LOCATION) am6zzb0000024 Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 93 BODY STRUCTURE [PANEL REPLACEMENT] 6. Cut-and-join area locations indicated by (B) then plug weld the 23 locations indicated by (C) shown in the figure. 09-80B (C) 3 am6zzb0000025 7. Install the hinge reinforcement and B-pillar reinforcement. 09-80B–65...
  • Page 94 BODY STRUCTURE [PANEL REPLACEMENT] 8. Cut-and-join area locations indicated by (D) then plug weld the 101 locations indicated by (E) shown in the figure. (E) 2 am6zzb0000025 End Of Sie BM: REAR FENDER PANEL 09-80B–66...
  • Page 95: Rear Fender Panel Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FENDER PANEL REMOVAL [PANEL REPLACEMENT] id098008744900 Symbol Mark SYMBOL MARK MEANING SPOT WELDING ROUGH CUT LOCATION 09-80B am6xub0000008 Removal Procedure 1. Rough cut area locations indicated by (A) then drill the 88 locations indicated by (B) shown in the figure. REAR FENDER PANEL SIDE SILL REINFORCEMENT am6xub0000008...
  • Page 96 BODY STRUCTURE [PANEL REPLACEMENT] am6xub0000008 09-80B–68...
  • Page 97 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B am6xub0000008 09-80B–69...
  • Page 98 BODY STRUCTURE [PANEL REPLACEMENT] am6zzb0000009 2. The rear fender panel and the rear pillar (inner) are joined with spot weld sealer at the tire arch line. Use a spatula to separate the rear fender panel from the rear pillar (inner), then remove the rear fender panel. 3.
  • Page 99: Rear Fender Panel Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FENDER PANEL INSTALLATION [PANEL REPLACEMENT] id098008745000 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) CONTINUOUS CO 2 ARC WELDING (CUT-AND-JOIN LOCATION) 09-80B am6xub0000008 Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 100 BODY STRUCTURE [PANEL REPLACEMENT] am6xub0000008 09-80B–72...
  • Page 101 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B am6xub0000008 09-80B–73...
  • Page 102 BODY STRUCTURE [PANEL REPLACEMENT] am6zzb0000010 End Of Sie BM: REAR FENDER RAIN RAIL 09-80B–74...
  • Page 103: Rear Fender Rain Rail And Corner Plate Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FENDER RAIN RAIL AND CORNER PLATE REMOVAL [PANEL REPLACEMENT] id098008611900 Symbol Mark SYMBOL MARK MEANING SPOT WELDING am6xub0000007 09-80B Removal Procedure 1. Drill the 17 locations indicated by (A) shown in the figure. Note When removing the rear fender rain rail and the corner plate separately, drill the 4 locations indicated by (B).
  • Page 104: Rear Fender Rain Rail And Corner Plate Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FENDER RAIN RAIL AND CORNER PLATE INSTALLATION [PANEL REPLACEMENT] id098008612000 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6xub0000007 Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 105: Rear End Panel Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR END PANEL REMOVAL [PANEL REPLACEMENT] id098008744500 Symbol Mark SYMBOL MARK MEANING SPOT WELDING am6zzb0000010 09-80B Removal Procedure 1. Drill the 15 locations indicated shown in the figure. REAR COMBINATION LIGHT BRACKET am6zzb0000018 2. Remove the rear combination light bracket. 3.
  • Page 106 BODY STRUCTURE [PANEL REPLACEMENT] 4. Drill the 52 locations indicated shown in the figure. (A)3 REAR END PANEL am6xub0000002 5. Remove the rear end panel. End Of Sie 09-80B–78...
  • Page 107: Rear End Panel Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR END PANEL INSTALLATION [PANEL REPLACEMENT] id098008744600 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb0000010 09-80B Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 108 BODY STRUCTURE [PANEL REPLACEMENT] 8. Plug weld the 15 locations shown in the figure while install the rear combination light bracket. REAR COMBINATION LIGHT BRACKET am6xub0000008 End Of Sie BM: FLOOR SIDE PANEL 09-80B–80...
  • Page 109: Floor Side Panel Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FLOOR SIDE PANEL REMOVAL [PANEL REPLACEMENT] id098008618700 Symbol Mark SYMBOL MARK MEANING SPOT WELDING am6zzb0000002 09-80B Removal Procedure 1. Drill the 14 locations indicated by (A) shown in the figure. (A) 13 (A) 1 am6xub0000005 09-80B–81...
  • Page 110 BODY STRUCTURE [PANEL REPLACEMENT] 2. Drill the 4 locations indicated by (B) from the rear wheel housing. (B) 4 am6zzb0000010 3. Remove the floor side panel. End Of Sie 09-80B–82...
  • Page 111: Floor Side Panel Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FLOOR SIDE PANEL INSTALLATION [PANEL REPLACEMENT] id098008618800 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb0000002 09-80B Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 112 BODY STRUCTURE [PANEL REPLACEMENT] 5. Plug weld the 4 locations indicated by (B) from the rear wheel housing. (B) 4 am6zzb0000011 End Of Sie BM: TRUNK FLOOR PAN 09-80B–84...
  • Page 113: Rear Floor Pan Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FLOOR PAN REMOVAL [PANEL REPLACEMENT] id098008742700 Symbol Mark SYMBOL MARK MEANING SPOT WELDING adejjb00000042 09-80B Removal Procedure 1. Drill the 114 locations indicated by (A) shown in the figure. (A)5 (A)4 (A)31 (A)4 (A)4 (A)14 (A)20 (A)14 (A)9...
  • Page 114 BODY STRUCTURE [PANEL REPLACEMENT] 2. Drill the 2 locations indicated by (B) from the rear wheel housing. (B)1 (B)1 am6zzb0000011 End Of Sie 09-80B–86...
  • Page 115: Rear Floor Pan Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FLOOR PAN INSTALLATION [PANEL REPLACEMENT] id098008742800 Symbol Mark SYMBOL MARK MEANING PLUG WELDING ( ARC WELDING am2zzb0000003 09-80B Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 116 BODY STRUCTURE [PANEL REPLACEMENT] 6. Plug weld the 6 locations indicated by (A), then install the spare tire bracket. (B)5 (B)4 (B)31 (B)4 (B)4 (B)14 (B)20 (B)14 (B)9 (B)9 (A)6 REAR FLOOR PAN am6xub0000005 7. Plug weld the 114 locations indicated by (B) shown in the figure. 09-80B–88...
  • Page 117 BODY STRUCTURE [PANEL REPLACEMENT] 8. Plug weld the 2 locations indicated by (B) from the rear wheel housing. 09-80B (B)1 (B)1 am6zzb0000019 End Of Sie BM: REAR SIDE FRAME 09-80B–89...
  • Page 118: Rear Side Frame Removal

    BODY STRUCTURE [PANEL REPLACEMENT] REAR SIDE FRAME REMOVAL [PANEL REPLACEMENT] id098008801200 Symbol Mark SYMBOL MARK MEANING ROUGH CUT LOCATION am6zzb0000011 Removal procedure 1. Rough cut and remove the damaged part of the rear side frame. REAR SIDE FRAME am6zzb0000011 End Of Sie 09-80B–90...
  • Page 119: Rear Side Frame Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR SIDE FRAME INSTALLATION [PANEL REPLACEMENT] id098008801300 Symbol Mark SYMBOL MARK MEANING CONTINUOUS CO 2 ARC WELDING (CUT-AND-JOIN LOCATION) am6zzb0000024 Installation Procedure 1. Make a reinforcement panel using the material from the rear side frame. 2. To cut-and-join the new and existing parts, cut at the locations for the new part indicated in the figure below and bevel the locations where the new and existing parts are joined.
  • Page 120: Roof Panel Removal [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] ROOF PANEL REMOVAL [PANEL REPLACEMENT] id098008744300 Symbol Mark SYMBOL MARK MEANING SPOT WELDING am2zzb0000012 Removal Procedure 1. Drill the 72 locations indicated shown in the figure. ROOF PANEL am6xub0000005 2. Remove the roof panel. End Of Sie 09-80B–92...
  • Page 121: Roof Panel Installation [Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] ROOF PANEL INSTALLATION [PANEL REPLACEMENT] id098008744400 Symbol Mark SYMBOL MARK MEANING PLUG WELDING (CO 2 ARC WELDING) am6zzb0000011 Installation Procedure 1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions. 2.
  • Page 122 BODY STRUCTURE [PANEL REPLACEMENT] 4. Plug weld the 72 locations indicated shown in the figure. ROOF PANEL am6xub0000005 End Of Sie 09-80B–94...
  • Page 123: Body Sealing [Water-Proof And Rust Preventive]

    BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] 09-80C BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] BODY SEALING [WATER-PROOF AND RUST PREVENTIVE TREATMENT RUST PREVENTIVE] ....09-80C–1 [WATER-PROOF AND UNDER COATING [WATER-PROOF AND RUST PREVENTIVE] .
  • Page 124 BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] am6xub0000006 09-80C–2...
  • Page 125 BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] 09-80C am6zzb0000012 09-80C–3...
  • Page 126 BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] am6zzb0000012 End Of Sie 09-80C–4...
  • Page 127: Under Coating [Water-Proof And Rust Preventive]

    BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] UNDER COATING [WATER-PROOF AND RUST PREVENTIVE] id098009739900 • The shaded areas indicated under body locations that are undercoated to prevent noise and rusting. 09-80C am6xub0000006 End Of Sie CHIPPING-RESISTANT COATING [WATER-PROOF AND RUST PREVENTIVE] id098009740000 •...
  • Page 128: Rust Preventive Treatment [Water-Proof And Rust Preventive]

    BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] RUST PREVENTIVE TREATMENT [WATER-PROOF AND RUST PREVENTIVE] id098009740100 100 mm {3.94 in} OR MORE 200 mm {7.87 in} OR MORE 100 mm {3.94 in} OR MORE 200 mm {7.87 in} OR MORE 100 mm {3.94 in} OR MORE am6zzb0000028 End Of Sie 09-80C–6...
  • Page 129: Dumping Sheet Replacement [Water-Proof And Rust Preventive]

    BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] DUMPING SHEET REPLACEMENT [WATER-PROOF AND RUST PREVENTIVE] id098009745700 • After repairing the body, attach the dumping sheet to the location shown in the figure for noise insulation. 09-80C am6xub0000006 End Of Sie 09-80C–7...
  • Page 131 BODY STRUCTURE [DIMENSIONS] 09-80D BODY STRUCTURE [DIMENSIONS] UNDERBODY DIMENSIONS FRONT BODY STRAIGHT-LINE [DIMENSIONS] ....09-80D–2 DIMENSIONS (1) [DIMENSIONS] ..09-80D–6 FRONT WHEEL ALIGNMENT FRONT BODY STRAIGHT-LINE [DIMENSIONS] .
  • Page 132: Underbody Dimensions [Dimensions]

    BODY STRUCTURE [DIMENSIONS] UNDERBODY DIMENSIONS [DIMENSIONS] id098010990000 • The following figure is a bottom view. STRAIGHT-LINE RH:539 {21.22} LH:492 {19.37} {13.50} 1,092 {42.99} 1,719 {67.68} 1,188 {46.77} RH:920 {36.22} 1,156 {45.51} 1,046 {41.18} LH:944 {37.17} 994 {39.13} 1,134 {44.65} 1,083 {42.64} 669 {26.34} RH:1,340 {52.76} 1,335 {52.56}...
  • Page 133: Front Wheel Alignment [Dimensions]

    BODY STRUCTURE [DIMENSIONS] 09-80D am6xub0000000 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size (mm {in}) size (mm {in}) φ16 {0.63} Front side frame datum hole Rear suspension member φ7 {0.3} installation hole Front suspension member M14 {0.55}...
  • Page 134: Maximum Steering Angle Adjustment

    BODY STRUCTURE [DIMENSIONS] Maximum Steering Angle Adjustment 1. Loosen the tie-rod end locknuts. 2. Remove the steering gear boot clamp. 3. Turn the tie rods. Standard length L 15.7—22.7 mm {0.619—0.893 in} 4. Turn the tie rods equally to provide the correct maximum steering angle.
  • Page 135: Total Toe-In Adjustment

    BODY STRUCTURE [DIMENSIONS] Total Toe-in Adjustment 1. Loosen the locknut of the lateral link. am6xuw0000243 2. Adjust the toe-in turning the adjusting link. 09-80D Total toe-in • 2±4 mm {0.08±0.16 in} Note • Toe change amount: 0°21′/ one rotation am6xuw0000243 3.
  • Page 136: Front Body Straight-Line Dimensions (1) [Dimensions]

    BODY STRUCTURE [DIMENSIONS] FRONT BODY STRAIGHT-LINE DIMENSIONS (1) [DIMENSIONS] id098010740600 1,110 {43.70} {30.31} 1,536 {60.47} RH:451 {17.76} 1,592 LH:446 {17.56} {62.68} 1,317 1,096 RH:330 {12.99} 1,462 {51.85} {43.15} LH:453 {17.83} {57.56} RH:213 {8.39} 1,218 {14.29} 216 {8.50} 1,051 LH:89 {3.50} {47.95} {31.42} {41.38}...
  • Page 137: Front Body Straight-Line Dimensions (2) [Dimensions]

    BODY STRUCTURE [DIMENSIONS] Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size (mm {in}) size (mm {in}) φ8 {0.3} Hood hinge installation hole LH:φ14 {0.55} Front side frame datum hole RH:φ20 {0.79} LH:Fuse box installation hole φ7 {0.3}...
  • Page 138: Cabin Side Frame Straight-Line Dimensions [Dimensions]

    BODY STRUCTURE [DIMENSIONS] Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size (mm {in}) size (mm {in}) φ8 {0.3} Cowl panel installation hole Front bumper reinforcement φ10 {0.39} installation hole LH:Wiring harness installation hole Front bumper reinforcement...
  • Page 139 BODY STRUCTURE [DIMENSIONS] 09-80D am6xub0000000 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size (mm {in}) size (mm {in}) Front side frame datum bolt M8 {0.3} Rear door hinge installation φ8 {0.3} hole Front fender panel installation...
  • Page 140: Room Straight-Line Dimensions (1) [Dimensions]

    BODY STRUCTURE [DIMENSIONS] ROOM STRAIGHT-LINE DIMENSIONS (1) [DIMENSIONS] id098010743300 1,043 {41.06} 1,054 {41.50} 1,073 {42.24} 1,246 {49.06} 1,082 {42.60} 930 {36.61} 881 {34.69} am6xub0000006 am6xub0000006 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size (mm {in})
  • Page 141: Room Straight-Line Dimensions (2) [Dimensions]

    BODY STRUCTURE [DIMENSIONS] ROOM STRAIGHT-LINE DIMENSIONS (2) [DIMENSIONS] id098010743400 1,098 {43.23} 989 {38.94} 1,407 {55.39} 959 {37.76} 09-80D 1,516 {59.69} 777 {30.59} 1,461 {57.52} 464 {18.27} 479 {18.86} 1,337 {52.64} 1,208 {47.56} 1,227 {48.31} am6xub0000006 am6xub0000006 09-80D–11...
  • Page 142: Room Straight-Line Dimensions (3) [Dimensions]

    BODY STRUCTURE [DIMENSIONS] Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size (mm {in}) size (mm {in}) Center pillar innner datum Crossmember No.3 datum φ8 {0.3} φ6 {0.2} hole hole φ8 {0.3} Front seat belt adjust C-pillar trim installation hole...
  • Page 143: Rear Body Straight-Line Dimensions (1) [Dimensions]

    BODY STRUCTURE [DIMENSIONS] Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size (mm {in}) size (mm {in}) φ8.6 {0.34} Crossmember No.3 datum C-pillar trim installation hole φ6 {0.2} hole Trunk lid striker installation φ7 {0.3} φ8.6 {0.34} C-pillar trim installation hole...
  • Page 144 BODY STRUCTURE [DIMENSIONS] am6xub0000007 Hole diameter Hole diameter Point Point Designation or bolt or nut Designation or bolt or nut symbol symbol size (mm {in}) size (mm {in}) Roof panel notch Rear bumper installation 14×20 square hole {0.55×0.79} Rear package tray seamless location Trunk lid striker installation φ7 {0.3}...
  • Page 145 BODY STRUCTURE [PLASTIC BODY PARTS] 09-80E BODY STRUCTURE [PLASTIC BODY PARTS] PLASTIC PARTS HEAT RESISTING Repairable Bumpers ....09-80E–2 TEMPERATURE POLYPROPYLENE BUMPER REPAIR [PLASTIC BODY PARTS] ... 09-80E–1 [PLASTIC BODY PARTS].
  • Page 146 BODY STRUCTURE [PLASTIC BODY PARTS] REPAIRABLE RANGE OF POLYPROPYLENE BUMPERS [PLASTIC BODY PARTS] id098011600100 The three types of damaged bumpers shown below are considered repairable. Although a bumper which has been damaged greater than this could also be repaired, it should be replaced with a new one because such repair would detract from the looks and quality of the bumper.
  • Page 147 BODY STRUCTURE [PLASTIC BODY PARTS] POLYPROPYLENE BUMPER REPAIR [PLASTIC BODY PARTS] id098011600200 Scratch on paint only Hole or crack through surface Crack more than 100 mm {3.94 in} long or completely broken Bumper Bumper Remove paint surface surface not visible visible Smooth damaged area 09-80E...
  • Page 148 BODY STRUCTURE [PLASTIC BODY PARTS] PROCEDURE [PLASTIC BODY PARTS] id098011600300 Repair of polypropylene bumpers having damage that has reached the surface of the polypropylene and are too serious to be restored by painting only. Hole Flaw Crack B-B, D-D Section A-A Section Section Top coat layer...
  • Page 149 BODY STRUCTURE [PLASTIC BODY PARTS] 2. Weld the damaged area. • For repair of a cracked area, melt the crack together with a heat gun and a melting attachment. Heat gun Melt together B-B,C-C Section painted surface Attachment for Section after melting Polypropylene surface melting am8rrb00000052...
  • Page 150 BODY STRUCTURE [PLASTIC BODY PARTS] 4. Sand the surface of the polypropylene gradually as it is easily melted by the abrasion heat. Sand the area to which repair agent will be applied. Sand gradually Sand repair area Paint am8rrb00000056 5. Uniformly apply polypropylene primer with a brush to an area larger than the repaired area. Allow to dry about 10 minutes at 20 °C {68 °F}.
  • Page 151 BODY STRUCTURE [PLASTIC BODY PARTS] 7. Sand the area with #180—240 sandpaper. Note • If excessive force is applied to the area when sanding, the surface will be damaged. • If fuzz remains around the repaired area, melt it with a heat gun. 09-80E am8rrb00000062 8.
  • Page 152 BODY STRUCTURE [PLASTIC BODY PARTS] 11. Add the softener to the urethane primer surfacer and spray it on the repaired area. a. Mixing method Urethane primer surfacer + Softener ..Mixture A Mixture A + hardener ..Mixture B Dilute mixture B with thinner to spray on bumper b.
  • Page 153 BODY STRUCTURE [CONSTRUCTION STANDARD VALUES] 09-80F BODY STRUCTURE [CONSTRUCTION STANDARD VALUES] CONSTRUCTION STANDARD VALUES Front View ..... . . 09-80F–1 [CONSTRUCTION STANDARD Rear View .
  • Page 154 BODY STRUCTURE [CONSTRUCTION STANDARD VALUES] Standar Maximu Minimu Side by Maximu Minimu Side by Standar Measure Measure d values m values m values differenc d values m values m values differenc ment ment e (mm e (mm part part {in}) {in}) {in}) {in})
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