Ford 2006 Escape J87R Bodyshop Manual
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Ford 2006 Escape J87R Bodyshop Manual

Ford 2006 Escape J87R Bodyshop Manual

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Summary of Contents for Ford 2006 Escape J87R

  • Page 2 The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and Ford Motor Company reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation.
  • Page 3 PRIMARY COLOR MIXTURE CHART FOR use by technicians of Authorized Ford BODY COLORS Dealers to help them service and repair Ford vehicles. It can also be useful to © 2006 Mazda Motor Corporation owners and operators of Ford vehicles in MARCH 2006 performing limited repair and maintenance on F342–20–06C...

  • Page 5: Table Of Contents

    Driver, Passenger and Side air bag Y= 4001—5000 lbs {1814—2268 kg}, with Driver and Passenger air bag Gross vehicle weight and Air bags LFA= Ford Lio Ho World manufacturer identification aesffb00000001 End Of Sie VEHICLE IDENTIFICATION NUMBERS (VIN) id000000600100 LFA CKZTNX*2 000001—...

  • Page 6: General Information

    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 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 810 {31.89} FLAT-PLANE DIMENSIONS acxuub00000033 • When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle.
  • Page 8 GENERAL INFORMATION Example Shows vehicle section When there are no specific indications, all of UNDERBODY FLAT-PLANE DIMENSIONS units are in millimeters (mm). The dimensions on the left and right in regard to the center mm {in} Shows outline drawing of the vehicle are different. Shows dimension Shows point symbol...
  • Page 9 GENERAL INFORMATION Body Dimensions (Straight-line Dimensions) • Straight-line dimensions are the actual dimensions between two standard points. FRONT FENDER INSTALLATION NUT {32.17} STRAIGHT-LINE DIMENSIONS acxuub00000035 • When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle.

  • Page 10: Service Precautions

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

  • Page 11: Efficient Removal Of Body Panels

    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 acxuub00000041 Prevent Short Circuits • Turn the ignition switch to the LOCK position. • Disconnect the battery cables. Battery cable acxuub00000042 •...
  • Page 12 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. acxuub00000066 Selection of Cut-and-join Locations • For parts where complete replacement is not feasible, careful cutting and joining operations should be followed.

  • Page 13: 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 {1.18—1.97 in} with the remaining area on the body side and then rough-cut the new 30-50mm{1.18-1.97in} 30-50mm{1.18-1.97in} parts. Over lap Over lap Body side rough cut location New part rough cut location...

  • Page 14: Efficient Installation Of Body Panels

    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 acxuub00000068 EFFICIENT INSTALLATION OF BODY PANELS id000000600500 Checking Preweld Measurements And Watching •...
  • Page 15 GENERAL INFORMATION Spot Welding Notes • The shape of the spot welder tip is D=(2×t)+3. If the upper panel thickness is different from that of 70 - 120° the under panel, adjust to the thinner one. acxuub00000054 • Because the weld strength is affected by the shape of the spot welder tip, the optimum condition of the tip should always be maintained.
  • Page 16 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 25mm fourth or fifth weld spot, and every tenth regular {0.98in} weld location.

  • Page 17: Anticorrosion, Sound Insulation, And Vibration Insulation

    GENERAL INFORMATION ANTICORROSION, SOUND INSULATION, AND VIBRATION INSULATION id000000600600 Body Sealing • Apply body sealer where necessary. • For locations where application of body sealer is difficult after installation, apply it before installation. acxuub00000059 Application of Undercoating • Apply an undercoat to the required location of the body.

  • Page 18: Abbreviation

    GENERAL INFORMATION ABBREVIATION id000000600700 Control module Center Dynamic stability control Front Hydraulic unit Left Metallic Mica Right Rear End Of Sie 00-00–14...
  • Page 19 BODY & ACCESSORIES SECTION Toc of SCT BODY STRUCTURE BODY STRUCTURE [CONSTRUCTION] ..09-80A [DIMENSIONS] ... . 09-80D BODY STRUCTURE[PANEL BODY STRUCTURE REPLACEMENT]..09-80B [PLASTIC BODY PARTS].
  • Page 20 BODY STRUCTURE [CONSTRUCTION] BODY COMPONENTS CONSTRUCTION[CONSTRUCTION] id098007739700 R.H.D. MODELS atraab00000004 09-80A–2...
  • Page 21 BODY STRUCTURE [CONSTRUCTION] x:Applied -:Not applied Thickness Part Name High- tension steel Rust proof steel (mm) {in} Bonnet 0.70 {0.028} Shroud upper panel 0.90 {0.035} Lamp bracket 1.20 {0.047} Shroud side stay 1.20 {0.047} 2.00 {0.079} Front bumper bracket 2.30 {0.091} Bonnet lock stay 1.00 {0.039} Crossmember No.1 (front)
  • Page 22 BODY STRUCTURE [CONSTRUCTION] Thickness Part Name High- tension steel Rust proof steel (mm) {in} Side sill (inner) 2.00 {0.079} Front B frame 1.40 {0.055} Crossmember No.3 2.00 {0.079} Crossmember No.4 1.40 {0.055} Crossmember No.2 0.80 {0.031} Front floor pan 0.80 {0.031} Crossmember No.2.5 0.80 {0.031} Crossmember No.3 (upper)
  • Page 23 BODY STRUCTURE [CONSTRUCTION] L.H.D. MODELS atraab00000005 09-80A–5...
  • Page 24 BODY STRUCTURE [CONSTRUCTION] x:Applied -:Not applied Thickness Part Name High- tension steel Rust proof steel (mm) {in} Bonnet 0.70 {0.028} Shroud upper panel 0.90 {0.035} Lamp bracket 1.20 {0.047} Shroud side stay 1.20 {0.047} Front bumper bracket 2.30 {0.091} Bonnet lock stay 1.00 {0.039} Crossmember No.1 (front) 1.00 {0.039}...
  • Page 25 BODY STRUCTURE [CONSTRUCTION] Thickness Part Name High- tension steel Rust proof steel (mm) {in} Crossmember No.4 1.40 {0.055} Crossmember No.2 0.80 {0.031} Front floor pan 0.65 {0.026} Crossmember No.2.5 0.80 {0.031} Crossmember No.3 (upper) 0.80 {0.031} Seat bracket 0.70 {0.028} Rear side frame 1.40 {0.055} Hook bracket...
  • Page 27 BODY STRUCTURE [PANEL REPLACEMENT] 09-80B BODY STRUCTURE [PANEL REPLACEMENT] RADIATOR SHROUD PANEL FRONT PILLAR INSTALLATION COMPONENT REMOVAL [PANEL REPLACEMENT] ... 09-80B–16 [PANEL REPLACEMENT]... 09-80B–2 CENTER PILLAR REMOVAL RADIATOR SHROUD PANEL [PANEL REPLACEMENT] .

  • Page 28: Radiator Shroud Panel Component Removal

    BODY STRUCTURE [PANEL REPLACEMENT] RADIATOR SHROUD PANEL COMPONENT REMOVAL[PANEL REPLACEMENT] id098008614700 1. Drill the 13 weld locations indicated by (A), and remove the radiator shroud panel component. Note • When removing the shroud panel, lamp bracket, and the shroud side stay separately, drill the 8 locations indicated by (B) and the 5 weld locations (C).

  • Page 29: Crossmember No.1 Removal

    BODY STRUCTURE [PANEL REPLACEMENT] CROSSMEMBER No.1 REMOVAL[PANEL REPLACEMENT] id098008603500 1. Remove the crossmember No.1. BUE0980B004 End Of Sie CROSSMEMBER No.1 INSTALLATION[PANEL REPLACEMENT] id098008603600 1. When installing new parts, position each part so that the section measurement aligns to the body dimension. 2.

  • Page 30: Apron Reinforcement And Cowl Side Reinforcement Removal

    BODY STRUCTURE [PANEL REPLACEMENT] APRON REINFORCEMENT AND COWL SIDE REINFORCEMENT REMOVAL[PANEL REPLACEMENT] id098008615100 1. Remove the apron reinforcement. 2. Remove the cowl side reinforcement (front) and cowl side reinforcement (rear). Caution • Be careful not to damage the windshield when drilling the 2 locations indicated by (A). 3.

  • Page 31: Apron Reinforcement And Cowl Side Reinforcement Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] APRON REINFORCEMENT AND COWL SIDE REINFORCEMENT INSTALLATION[PANEL REPLACEMENT] id098008615000 1. When installing new parts, position each part so that the section measurement aligns with the body dimension. 2. Drill holes for plug welds before installing new parts. 3.

  • Page 32: Wheel Apron Panel Component Removal

    BODY STRUCTURE [PANEL REPLACEMENT] WHEEL APRON PANEL COMPONENT REMOVAL[PANEL REPLACEMENT] id098008614900 1. Drill the 59 weld locations indicated by (A), and remove the wheel apron panel component. Note • When removing the wheel apron panel (front) and the suspension housing separately, drill 14 locations indicated by (B).

  • Page 33: Wheel Apron Panel Component Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] WHEEL APRON PANEL COMPONENT INSTALLATION[PANEL REPLACEMENT] id098008614800 1. When installing new parts, position each part so that the section measurement aligns to the dimension. 2. Drill holes for plug welds before installing new parts. 3. Plug welding of 7 weld locations indicated by (A), during installation of the cowl side reinforcement. 4.

  • Page 34: Front Side Frame Component Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME COMPONENT REMOVAL[PANEL REPLACEMENT] id098008741900 1. When the front side frame is being removed, the frame reinforcement may interfere with the front frame (rear) and make removal difficult. Therefore, drill 11 locations indicated by (A), then open the front frame (rear) outward.

  • Page 35: Front Side Frame Component Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME COMPONENT INSTALLATION[PANEL REPLACEMENT] id098008742000 1. When installing new parts, position each part so that the section measurement aligns to the body dimension. 2. After temporarily installing new parts, make sure the related parts fit properly. FRONT SIDE FRAME RH:13 LH:9...

  • Page 36: Front Side Frame (Partial Cutting) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME (PARTIAL CUTTING) REMOVAL[PANEL REPLACEMENT] id098008742100 1. To facilitate rough cutting of the outer, drill the 3 weld locations indicated by (A) and bend the wheel apron panel (front) upward. 2. Rough cut at the locations shown in the figure to remove damaged parts. INNER ROUGH CUT LOCATION 185mm...

  • Page 37: Front Side Frame (Partial Cutting) Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT SIDE FRAME (PARTIAL CUTTING) INSTALLATION[PANEL REPLACEMENT] id098008742200 Caution • The cut-and-joint area indicates the maximum size range of the installation position. 1. Make reinforcement panel using the material of the front side frame. 2. To cut-and-join the new part, cut at the locations indicated in the figure below and bevel the cut-and-join locations of the new parts.

  • Page 38: Front Frame (Rear) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT FRAME (REAR) REMOVAL[PANEL REPLACEMENT] id098008742500 1. Drill the 20 weld locations indicated by (A), 9 locations indicated by (B), and 12 RH and 11 LH weld locations indicated by (C) from the room side. Note •...

  • Page 39: Front Frame (Rear) Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT FRAME (REAR) INSTALLATION[PANEL REPLACEMENT] id098008742600 1. When installing new parts, position each part so that the section measurement aligns to the body dimension. 2. Drill holes for plug welds before installing new parts. 3. Plug welding of 2 weld location indicated by (E), during installation of the front side frame. 4.

  • Page 40: Front Pillar Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT PILLAR REMOVAL[PANEL REPLACEMENT] id098008744700 1. Rough cut area (A), drill the 30 RH and 31 LH weld locations indicated by (B), then remove the lower part of the front pillar (outer). Caution • Avoid cutting with a blowtorch or similar tools as the insulator (shaded area) is flammable. 2.

  • Page 41: End Of Toc

    BODY STRUCTURE [PANEL REPLACEMENT] ROUGH CUT LOCATION FOR THE FRONT PILLAR REINFORCEMENT 130mm {5.11in} (C) ROUGH CUT LOCATION FOR THE SIDE SILL REINFORCEMENT (C) 6 (C) 2 INSULATOR (C) 6 90mm {3.54in} (D) 4 BUE0980B017 End Of Sie 09-80B–15...

  • Page 42: Front Pillar Installation

    BODY STRUCTURE [PANEL REPLACEMENT] FRONT PILLAR INSTALLATION[PANEL REPLACEMENT] id098008744800 1. When joining the new and old parts, temporarily install and fit the new part in position, measure each dimension according to the body dimension, then adjust the position to align it to the standard dimensions. 2.
  • Page 43 BODY STRUCTURE [PANEL REPLACEMENT] CUT-AND-JOIN LOCATION FOR THE FRONT PILLAR (OUTER) CUT-AND-JOIN LOCATION FOR THE FRONT PILLAR (INNER) 50mm {1.96in} 50mm {1.96in} CUT-AND-JOIN LOCATION FOR THE FRONT PILLAR REINFORCEMENT CUT-AND-JOIN LOCATION FOR THE SIDE SILL REINFORCEMENT RH:16 LH:15 90mm {3.54in} CUT-AND-JOIN LOCATION FOR THE FRONT PILLAR (OUTER) 80mm...

  • Page 44: Center Pillar Removal

    BODY STRUCTURE [PANEL REPLACEMENT] CENTER PILLAR REMOVAL[PANEL REPLACEMENT] id098008743900 1. Rough cut area (A), and drill the 38 weld locations indicated by (B), then remove the lower part of the center pillar (outer). Caution • Avoid cutting with a blowtorch or similar tools as the insulator (shaded area) is flammable. 2.

  • Page 45: Center Pillar Installation

    BODY STRUCTURE [PANEL REPLACEMENT] CENTER PILLAR INSTALLATION[PANEL REPLACEMENT] id098008744000 1. When joining the new and old parts, temporary install and fit the new part in position, measure each dimension according to the body dimension, the adjust the position to align it to the standard dimensions. 2.

  • Page 46: Side Sill Panel Removal

    BODY STRUCTURE [PANEL REPLACEMENT] SIDE SILL PANEL REMOVAL[PANEL REPLACEMENT] id098008615300 1. Removal the side sill panel. Caution • Avoid cutting with a blowtorch or similar tools as the insulator (shaded area) is flammable. 2. Remove the side sill reinforcement. ROUGH CUT CUT-AND-JOIN LOCATION LOCATION...

  • Page 47: Side Sill Panel Installation

    BODY STRUCTURE [PANEL REPLACEMENT] SIDE SILL PANEL INSTALLATION[PANEL REPLACEMENT] id098008615200 1. When joining the new and old parts, temporarily install and fit the new part in position, measure each dimension according to the body dimension, then adjust the position to align it to the standard dimensions. 2.

  • Page 48: Rear Fender Panel Removal

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FENDER PANEL REMOVAL[PANEL REPLACEMENT] id098008744900 Caution • Avoid cutting with a blowtorch or similar tools as the insulator (shaded area) is flammable. 1. The rear fender panel and the rear pillar (inner) are joined with glue at the wheel arch line. Use a chisel or similar tool to separate the rear fender panel from the rear pillar (inner), then remove the rear fender panel.

  • Page 49: Rear Fender Panel Installation

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FENDER PANEL INSTALLATION[PANEL REPLACEMENT] id098008745000 1. When joining the new and old parts, temporarily install and fit the new part in position, measure each dimension according to the body dimension, then adjust the position to align it to the standard dimensions. 2.

  • Page 50: Rear End Panel And

    BODY STRUCTURE [PANEL REPLACEMENT] REAR END PANEL AND CROSSMEMBER No.5 REMOVAL[PANEL REPLACEMENT] id098008615700 1. Remove the rear end panel. 2. Remove the rear end side member. 3. Remove the bumper bracket, drill each weld location, and remove the crossmember No.5 while pulling it from above.

  • Page 51: Rear End Panel And

    BODY STRUCTURE [PANEL REPLACEMENT] REAR END PANEL AND CROSSMEMBER No.5 INSTALLATION[PANEL REPLACEMENT] id098008615600 1. When installing new parts, position each part so that the section measurement aligns to the body dimension. 2. Drill holes for plug welds before installing new parts. 3.

  • Page 52: Rear Pillar (Outer) And Rear Pillar Reinforcement Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR PILLAR (OUTER) AND REAR PILLAR REINFORCEMENT REMOVAL[PANEL REPLACEMENT] id098008615500 1. Remove the rear pillar (outer). 2. Remove the rear pillar reinforcement. Caution • Avoid cutting with a blowtorch or similar tools as the insulator (shaded area) is flammable. 3.

  • Page 53: Rear Pillar (Outer) And Rear Pillar Reinforcement Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR PILLAR (OUTER) AND REAR PILLAR REINFORCEMENT INSTALLATION[PANEL REPLACEMENT] id098008615400 1. When joining the new and old parts, temporarily install and fit the new part in position, measure each dimension according to the body dimension, then adjust the position to align it to the standard dimensions. 2.

  • Page 54: Rear Floor Pan Removal

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FLOOR PAN REMOVAL[PANEL REPLACEMENT] id098008742700 1. Remove the rear floor pan. Caution • During rough cutting, be careful not to damage the seat bracket indicated by dotted lines in the figure. ROUGH CUT LOCATION ROUGH CUT LOCATION 100mm {3.93in} OVERLAP OF OLD AND...

  • Page 55: Rear Floor Pan Installation

    BODY STRUCTURE [PANEL REPLACEMENT] REAR FLOOR PAN INSTALLATION[PANEL REPLACEMENT] id098008742800 1. Drill holes for plug welds before installing new parts. 2. Apply body sealer to the joints of old and new parts for waterproofing and rust protection. 3. After temporarily installing new parts, make sure the related parts fit properly. 50mm {1.96in} PARTS...

  • Page 56: Rear Side Frame (Partial Cutting) Removal[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] REAR SIDE FRAME (PARTIAL CUTTING) REMOVAL[PANEL REPLACEMENT] id098008608100 1. Rough cut and remove the damaged part of the rear side frame. 50mm {1.96in} CUT-AND-JOIN LOCATION ROUGH CUT LOCATION BUE0980B032 End Of Sie REAR SIDE FRAME (PARTIAL CUTTING) INSTALLATION[PANEL REPLACEMENT] id098008608200 1.

  • Page 57: Roof Panel Removal

    BODY STRUCTURE [PANEL REPLACEMENT] ROOF PANEL REMOVAL[PANEL REPLACEMENT] id098008744300 1. Remove the roof panel. BRAZE WELDING BUE0980B034 End Of Sie 09-80B–31...

  • Page 58: Roof Panel Installation[Panel Replacement]

    BODY STRUCTURE [PANEL REPLACEMENT] ROOF PANEL INSTALLATION[PANEL REPLACEMENT] id098008744400 1. Drill holes for plug welds before installing new parts. 2. After temporarily installing new parts, make sure the related parts fit properly. BRAZE WELDING BUE0980B035 End Of Sie 09-80B–32...
  • Page 59 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–2 [WATER-PROOF AND RUST UNDER COATING[WATER-PROOF AND PREVENTIVE] .
  • Page 60 BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] BODY SEALING[WATER-PROOF AND RUST PREVENTIVE] id098009739800 Sealant is applied to the parts where the panels meet and to the hemmed parts of the door panel and bonnet panel to provide water proofing and rust proofing. R.H.D.
  • Page 61 BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] BUE0980B037 09-80C–3...
  • Page 62 BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] BONNET DOOR LIFTGATE BUE0980B038 09-80C–4...
  • Page 63 BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] L.H.D. models BUE0980B071 09-80C–5...
  • Page 64 BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] BUE0980B072 End Of Sie 09-80C–6...
  • Page 65 BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] UNDER COATING[WATER-PROOF AND RUST PREVENTIVE] id098009739900 The shaded areas indicated under body locations that are underacted to prevent noise and rusting. R.H.D. models BUE0980B039 09-80C–7...
  • Page 66 BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] L.H.D. models BUE0980B073 End Of Sie 09-80C–8...
  • Page 67 BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE] RUST PREVENTIVE TREATMENT[WATER-PROOF AND RUST PREVENTIVE] id098009740100 The carting locations are indicated by the shaded areas. R.H.D. models (Rust prventive oil is not applied on the L.H.D. models) BUE0980B041 End Of Sie 09-80C–9...
  • Page 69 BODY STRUCTURE [DIMENSIONS] 09-80D BODY STRUCTURE [DIMENSIONS] UNDERBODY FLAT-PLANE CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS[DIMENSIONS] ..09-80D–2 DIMENSIONS[DIMENSIONS] ..09-80D–8 UNDERBODY STRAIGHT-LINE ROOM STRAIGHT-LINE DIMENSIONS DIMENSIONS[DIMENSIONS] ..09-80D–5 (1)[DIMENSIONS].

  • Page 70: Underbody Flat-Plane Dimensions[Dimensions]

    BODY STRUCTURE [DIMENSIONS] UNDERBODY FLAT-PLANE DIMENSIONS[DIMENSIONS] id098010740400 R.H.D. models mm {in} 1,240 {19.27} {28.21} {48.82} {12.40} {16.73} {7.28} {3.86} {12.62} {2.17} BUE0980B042 Hole diameter Hole diameter Point or bolt size or Point or bolt size or Designation Designation symbol nut size mm symbol nut size mm {in}...
  • Page 71 BODY STRUCTURE [DIMENSIONS] Except L.H.D. Face-lifted model mm {in} 1,240 {22.04} {28.21} {48.82} {12.40} {16.73} {4.53} {3.86} {12.62} {2.17} BUE0980B074 Hole diameter Hole diameter Point or bolt size or Point or bolt size or Designation Designation symbol nut size mm symbol nut size mm {in}...
  • Page 72 BODY STRUCTURE [DIMENSIONS] L.H.D. Face-lifted model mm {in} 3,900 {153.54} CUE0980B151 End Of Sie 09-80D–4...

  • Page 73: Underbody Straight-Line Dimensions[Dimensions]

    BODY STRUCTURE [DIMENSIONS] UNDERBODY STRAIGHT-LINE DIMENSIONS[DIMENSIONS] id098010740500 BUE0980B043 BUE0980B044 Measured Measured Dimensions mm {in} Dimensions mm {in} location location RH:214 {8.42}, R.H.D. models 425 {16.73} R.H.D. models LH:215 {8.46} L.H.D. models 428 {16.85} L.H.D. models 156 {6.14} R.H.D. models 1,229 {48.38} RH:1,023 {40.27}, L.H.D.

  • Page 74: Front Body Straight-Line Dimensions (1)[Dimensions]

    BODY STRUCTURE [DIMENSIONS] FRONT BODY STRAIGHT-LINE DIMENSIONS (1)[DIMENSIONS] id098010740600 BUE0980B045 BUE0980B046 Measured Measured Dimensions mm {in} Dimensions mm {in} location location 1,114 {43.87} R.H.D. models 324 {12.76} R.H.D. models 647 {25.47} L.H.D. models 326 {12.84} L.H.D. models 644 {25.36} 1,333 {52.48} R.H.D.

  • Page 75: Front Body Straight-Line Dimensions (2)[Dimensions]

    BODY STRUCTURE [DIMENSIONS] FRONT BODY STRAIGHT-LINE DIMENSIONS (2)[DIMENSIONS] id098010740700 BUE0980B047 BUE0980B048 Measured Measured Dimensions mm {in} Dimensions mm {in} location location 1,410 {55.51} 728 {28.67} 1,438 {56.61} 1,581 {62.25} 1,079 {42.48} 180 {7.11} 1,428 {56.22} 455 {17.92} 1,370 {53.94} 1,298 {51.10} 69 {2.74} 436 {17.17} 1,426 {56.14}...

  • Page 76: Cabin Side Frame Straight-Line Dimensions[Dimensions]

    BODY STRUCTURE [DIMENSIONS] CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS[DIMENSIONS] id098010743600 R.H.D. models BUE0980B049 BUE0980B050 Measured Measured Dimensions mm {in} Dimensions mm {in} location location 864 {34.01} 1,337 {52.63} 921 {36.25} 1,107 {43.58} 1,272 {50.07} 1,017 {40.03} 1,169 {46.02} 658 {25.90} 591 {23.26} 902 {35.52} 765 {30.11} 990 {38.97}...
  • Page 77 BODY STRUCTURE [DIMENSIONS] L.H.D. models BUE0980B075 BUE0980B076 Measured Measured Dimensions mm {in} Dimensions mm {in} location location 868 {34.17} 1,009 {39.72} 925 {36.42} 1,095 {43.11} 1,275 {50.20} 777 {30.59} 1,171 {46.10} 583 {22.95} 1,039 {40.91} 1,270 {45.00} 1,062 {41.81} 806 {31.73} 1,097 {43.19} 396 {15.59} End Of Sie...

  • Page 78: Room Straight-Line Dimensions (1)[Dimensions]

    BODY STRUCTURE [DIMENSIONS] ROOM STRAIGHT-LINE DIMENSIONS (1)[DIMENSIONS] id098010743300 BUE0980B051 F (R.H.D. MODELS) F (L.H.D. MODELS) BUE0980B052 Measured Measured Dimensions mm {in} Dimensions mm {in} location location 1,180 {46.47} RH:827 {32.55}, R.H.D. models 1,114 {43.86} LH:909 {35.78} 852 {33.55} RH:864 {34.02}, L.H.D.

  • Page 79: Room Straight-Line Dimensions

    BODY STRUCTURE [DIMENSIONS] End Of Sie ROOM STRAIGHT-LINE DIMENSIONS (2)[DIMENSIONS] id098010743400 BUE0980B053 B,C (R.H.D. MODELS) E (R.H.D. MODELS) B,C (L.H.D. MODELS) E (L.H.D. MODELS) BUE0980B054 Measured Measured Dimensions mm {in} Dimensions mm {in} location location RH:1,186 {46.69}, RH:1,506 {59.29}, R.H.D. models R.H.D.

  • Page 80: Rear Body Straight-Line Dimensions (1)[Dimensions]

    BODY STRUCTURE [DIMENSIONS] End Of Sie BM: REAR BODY REAR BODY STRAIGHT-LINE DIMENSIONS (1)[DIMENSIONS] id098010746300 BUE0980B055 A (L.H.D. MODELS) A (R.H.D. MODELS) BUE0980B056 Measured Measured Dimensions mm {in} Dimensions mm {in} location location R.H.D. models 725 {28.54} 799 {31.47} L.H.D. models 731 {28.78} 762 {30.00} 1,600 {63.00}...
  • Page 81 BODY STRUCTURE [PLASTIC BODY PARTS] 09-80E BODY STRUCTURE [PLASTIC BODY PARTS] PLASTIC PARTS HEAT RESISTING POLYPROPYLENE BUMPER REPAIR TEMPERATURE[PLASTIC [PLASTIC BODY PARTS]... . 09-80E–3 BODY PARTS] ....09-80E–1 PROCEDURE REPAIRABLE RANGE OF [PLASTIC BODY PARTS].
  • Page 82 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 83 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 {3.94in} long or completely broken Bumper Remove paint Bumper surface surface not visible visible Smooth damaged area Apply aluminium tape to reverse side of bumper Plastic weld damaged area...
  • Page 84 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 Primer surface layer...
  • Page 85 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 ZUA9818B003...
  • Page 86 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 YMU980PCX 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 87 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. YMU980PD0 8.
  • Page 88 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 89 BODY STRUCTURE [PRIMARY COLOR MIXTURE CHART FOR BODY COLOS] 09-80F BODY STRUCTURE [PRIMARY COLOR MIXTURE CHART FOR BODY COLOS] PRIMARY COLOR MIXTURE CHART FOR BODY COLORS[PRIMARY COLOR MIXTURE CHART FOR BODY COLOS] ....09-80F–1 End of Toc PRIMARY COLOR MIXTURE CHART FOR BODY COLORS[PRIMARY COLOR MIXTURE CHART FOR BODY BM: BODY COLORS...

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