Page 1  BODY REPAIR MANUAL  Page 1. Foreword ........................3 2. Airbag Operating Instructions ..................11 3. Jack/Lift Points ......................17 4. Vehicle Identification ....................21 5. Assembly of Exterior Parts..................25 6. Panel Components.....................48 7. Galvanized Sheet Metal .....................60 8. Body Construction......................61 9. Body Reference Points....................65 10.
Page 2: Table Of Contents
11-33. Rear Floor Side (total replacement) ............258 11-34. Rear Side Frame Lower Rear (total replacement)........264 11-35. Side Sill Inner Rear (total replacement) .............268 11-36. Rear Side Frame Upper (total replacement) ..........276 11-37. Rear Side Frame (total replacement) ............280 11-38. Roof Panel (total replacement)..............290 11-39.
Page 3: Foreword
Foreword 1. Foreword A: USE OF THIS MANUAL This manual explains the points to be observed during removal and installation of parts separately by loca- tion. 1. ILLUSTRATION EXAMPLE • Symbols and number of points indicate the welding method and the number of welding points. Text in brackets indicates the direction for removal of welded parts, and numbers indicate the number of plates to be drilled in panels of welded parts to be removed.
Page 4 Foreword 2. REMOVAL DIRECTION Division is made into the four groups of inside, outside, top, and bottom, and these directions are defined as shown in the following figure. Outside Inside Outside Inside Inside Inside Inside Inside Outside Outside Bottom BS-02459 BS - 4...
Page 5 Foreword 3. NUMBER OF PANELS TO BE DRILLED 4. HOLE DRILLING FOR PLUG WELDING Depending on the number of panels, drilling is done (1) Drilling of holes for plug welding in service parts through one panel or two panels, and this number is listed together with the removal direction.
Page 6 Foreword 5. MEANING OF SYMBOLS • Cutting BS-00352 BS-00267 • Spot welding Two over- lapping parts BS-00655 BS-00656 Three or more over- lapping parts BS-00659 BS-00660 BS-00657 BS-00658 • Carbon dioxide gas arc welding (MIG welding) Plug welding BS-00661 BS-00663 BS-00662 Continuous welding BS-00664...
Page 7 Foreword • Bolt, nut tightening portion Bolt BS-04481 BS-04483 (1) Bolt BS-04482 (2) Nut B: CAUTION Since there is a possibility that the required strength will not be obtained, an inverter welder must be used for spot-welding at locations where high-strength steel is used. BS - 7...
Page 8 Foreword C: NOTE 1. About high-tensile steel sheets of 980 MPa class or more To drill high-strength steel sheets of 980 MPa class and 1,500 MPa class, use a tool that can machine objects of 500 Hv or more hardness (e.g., C-20VR made by Cyuotokenzai). It is recommended to perform the weldings using 980 MPa class and 1,500 MPa class high-strength steel un- der the following conditions.
Page 9 Foreword 3. Repair work using foam CAUTION: • Do not perform welding or other work involving high temperatures. • Do not use an open flame at the time of disassembly. • Remove residual foam before injecting the new material. • After completion of work, confirm that there is no danger of igniting the material. •...
Page 10 Foreword Cross section C — C Cross section D — D :(a) :(a) BRM00086 BRM00085 (a) Urethane foam injection locations (a) Urethane foam injection locations Cross section E — E Cross section F — F :(a) :(a) BRM00087 BS-08853 (a) Urethane foam injection locations (a) Urethane foam injection locations Cross section G —...
Page 11: Airbag Operating Instructions
Airbag Operating Instructions 2. Airbag Operating Instructions A: CAUTION 1. BEFORE STARTING ALL WORKS • Before performing vehicle maintenance, turn the ignition switch to OFF and wait for 60 seconds or more after disconnecting the negative terminal from battery. • The airbag system (including pretensioner) is fitted with a backup power supply. After disconnecting the battery ground cable, the airbag may operate if you do not wait for 60 seconds or more before starting the service of airbag system.
Page 12 Airbag Operating Instructions – Front part of the vehicle including the front wheel apron, front fender and radiator panel side • Front impact sensor • Wiring harness – Side or its vicinity of the vehicle including the side sill, center pillar, front doors, rear doors and rear fend- •...
Page 13 Airbag Operating Instructions • After removing each parts of the airbag system, keep them with the pad side facing upward on a dry, clean and flat surface away from heat, light sources, moisture and dust. AB-03711 • Observe the following; the airbag system component or the internal parts of seat belt pretensioner may be damaged or the reliability may be greatly lowered.
Page 14 Airbag Operating Instructions • Driver's airbag module AB-02316 • Passenger's airbag module and side airbag module AB-02317 • Do not disassemble the airbag modules and pretensioners. AB-03713 • The removed front seat with airbag module must be kept at least 200 mm (8 in) away from walls and other objects.
Page 15 Airbag Operating Instructions 3. BEFORE STARTING TROUBLESHOOTING • Even if any part must be replaced as the result of troubleshooting, do not use an airbag part or pretensioner part from other vehicles. Always replace the defective parts with new parts. •...
Page 16 Airbag Operating Instructions • Do not check the continuity of airbag modules and pretensioners. AB-03714 BS - 16...
Page 17: Jack/Lift Points
Jack/Lift Points 3. Jack/Lift Points A: CAUTION When using a lift or shop jack to raise a vehicle or using rigid rack to support a vehicle, always follow instruc- tions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in in- jury.
Page 18 Jack/Lift Points • SUPPORT LOCATIONS NT-10144 Jack-up point • PANTOGRAPH JACK NT-10143 Jack-up point BS - 18...
Page 19 Jack/Lift Points • LIFT NT-00271 CAUTION: For models with spoiler garnish, use a spacer or an attachment to lift up the vehicle securely at jack up point without the side garnish contacting the lift. • RIGID RACK NT-10107 Attachment BS - 19...
Page 20 Jack/Lift Points • PLATE LIFT NT-10145 Jack-up point Attachment • JACK-UP POINT (WHEN USING A GARAGE JACK) NT-10149 Front Rear Front crossmember support Rear differential CAUTION: If jacking up the front side of the vehicle, make sure that the jack is attached at the center of the jack- up plate not at the sides.
Page 21: Vehicle Identification
Vehicle Identification 4. Vehicle Identification A: IDENTIFICATION 1. IDENTIFICATION NUMBER & LABEL LOCATIONS The V.I.N. (Vehicle Identification Numbers) is used to classify the vehicle. Positioning of the plate label for identification ID-10293 PLATE COMPLIANCE (for KA) Tire inflation pressure label VIN plate (driver's side) VIN (Vehicle Identification Number)...
Page 22 The starting and ending brackets ( ] [ ) are stop marks. Digits Code Meaning Details 1 — 3 Manufacturer body area JF1: Passenger car, SUBARU CORPORATION made (for EH and ES) JF2: Multipurpose passenger car, SUBARU CORPORATION made (for KS) Car line S: Forester Body type K: Wagon Displacement class 7: 2.0 L AWD...
Page 23 Vehicle Identification 3. MODEL NUMBER LABEL The model number label indicates: the applied model, the option code, the trim code, the engine type, the transmission type, and the exterior color code. This information is helpful when placing orders for parts. FOR EUROPE/GENERAL (EXCEPT FOR EH AND ES MODELS) SK7AK2L Digits...
Page 24 Vehicle Identification (3) SK74L1H Digits Code Meaning Details Series S: Forester Body type K: Wagon Total engine displace- 7: 2.0 L AWD non-turbo ment / drive system E: 2.0 L AWD HEV Grade 4: 2.0 i-Limited-C 5: 2.0 i-Limited-C EyeSight G: 2.0 i-Sport-C H: 2.0 i-Sport-C EyeSight Fuel feed system /...
Page 25: Assembly Of Exterior Parts
Assembly of Exterior Parts 5. Assembly of Exterior Parts NOTE: • The alphabet mark beside the clips in the figure indicates the colors of the clips. • The clips with the same shape may have different engaging forces depending on their colors. Always use the specified parts when installing.
Page 26: Mud Guard
Assembly of Exterior Parts 2. MUD GUARD C21:x9 C21:x9 C21:x10 C21:x11 C01:x3 C01:x3 (10) C21:x3 C21:x3 C01:x2 C21:x3 C21:x4 C01:x2 C21:x4 C21:x3 EI-11346 Mud guard front RH Cover mud guard LH Mud guard rear LH Cover mud guard RH Plate air flap front LH (10) Plate air flap rear LH Plate air flap front RH Mud guard rear RH...
Page 27 Assembly of Exterior Parts 3. FLOOR UNDER PROTECTOR C30:x8 C30:x8 EI-11359 Under cover rear RH Under cover rear LH Tightening torque: N·m (kgf-m, ft-lb) Protector tank RH Protector tank LH T1: 7.5 (0.8, 5.5) T2: 18 (1.8, 13.3) BS - 27...
Page 28 Assembly of Exterior Parts 4. FUEL TANK PROTECTOR • Except for ES BRM00679 Fuel tank band RH Fuel tank protector LH Tightening torque: N·m (kgf-m, ft-lb) Fuel tank band LH Clip T: 18 (1.8, 13.3) Fuel tank protector RH BS - 28...
Page 29 Assembly of Exterior Parts • For ES BRM00680 Fuel tank band RH Fuel tank protector LH Tightening torque: N·m (kgf-m, ft-lb) Fuel tank band LH Clip T: 18 (1.8, 13.3) Fuel tank protector RH BS - 29...
Page 30: Front Bumper
Assembly of Exterior Parts 5. FRONT BUMPER C01:x3 C01:x4 C07:x2 (22) (23) (21) (20) C01:x2 (18) (17) (16) (19) (15) C01:x12 (14) (11) (12) (13) (10) C01:x7 EI-11347 Grille ASSY front LWR (11) Light ASSY fog LH (LED type) (21) Air guide LH Bumper face front (12) Energy absorber LWR (22) Bracket grille front...
Page 31 Assembly of Exterior Parts 6. FRONT HOOD C41(L):x9 EI-11374 Ornament front Bracket grille UPR Tightening torque: N·m (kgf-m, ft-lb) Grille ASSY front UPR Panel COMPL front hood T: 4.5 (0.5, 3.3) BS - 31...
Page 32: Rear Bumper
Assembly of Exterior Parts 7. REAR BUMPER C01:x2 (13) C06:x2 C01:x2 (11) (12) C01:x7 (10) EI-11368 Bumper beam COMPL rear Reflex reflector LH/rear fog & reflex Tightening torque: N·m (kgf-m, ft-lb) (except for KA model) reflector (LHD model with rear fog T1: 7.5 (0.8, 5.5) light) T2: 70 (7.1, 51.6)
Page 33: Cowl Panel
Assembly of Exterior Parts 8. COWL PANEL • Models without EyeSight C29:x2 C51:x6 EI-11370 Cowl panel side RH Cover joint Hose windshield washer Cowl panel Cover cowl panel Protector cowl panel Cowl panel side LH Nozzle windshield washer Seal cowl panel BS - 33...
Page 34 Assembly of Exterior Parts • Models with EyeSight C29:x2 (10) C51:x6 EI-11349 Cowl panel side RH Cover cowl panel Protector cowl panel Cowl panel Joint washer hose (10) Seal cowl panel Cowl panel side LH Nozzle windshield washer Cover joint Hose windshield washer BS - 34...
Page 35 Assembly of Exterior Parts 9. ROOF MOLDING EI-11376 Cap lid Fastener Tightening torque: N·m (kgf-m, ft-lb) Molding roof RH Self-locking nut T: 7.5 (0.8, 5.5) Rivet Molding roof LH Carrier BRKT BS - 35...
Page 36: Roof Rail
Assembly of Exterior Parts 10.ROOF RAIL • Type A (13) (10) (12) (11) (14) EI-11360 Roof rail ASSY RH Molding roof RH (13) Protector rear LH Seal washer Rivet (14) Molding roof LH Protector front RH Fastener Protector center RH (10) Roof rail ASSY LH Tightening torque: N·m (kgf-m, ft-lb) Protector rear RH...
Page 37 Assembly of Exterior Parts 11.SIDE GARNISH & SIDE SPOILER C42:x3 C86:x5 C83:x6 C83:x6 C83:x9 C46(G) C83:x9 C41(B) C46(W):x9 C82:x4 EI-11361 Garnish ASSY fender LH Garnish ASSY front door LH Garnish ASSY rear quarter (type B) Garnish ASSY front door LH Garnish ASSY rear door LH...
Page 38 Assembly of Exterior Parts 12.REAR GATE GARNISH C42(V):x2 C95(W):x2 C42(V):x2 C41(W):x9 C95(W):x2 (10) EI-11350 Garnish bracket side LH Protector UPR Tightening torque: N·m (kgf-m, ft-lb) Garnish INN SUB ASSY LH Garnish ASSY rear gate T: 4.5 (0.5, 3.3) Opener switch (model with lock/ Protector unlock button)/opener switch (model without lock/unlock button)
Page 39 Assembly of Exterior Parts 13.ROOF SPOILER C41(W):x3 C41(Or):x4 C41(W):x4 C41(W):x4 EI-11362 Spoiler ASSY roof CTR Stop light ASSY high-mounted Tightening torque: N·m (kgf-m, ft-lb) Spoiler ASSY roof side LH T1: 4.5 (0.5, 3.3) Spoiler ASSY roof side RH T2: 7.5 (0.8, 5.5) 14.HEAT SHIELD COVER EX-10372 Center exhaust cover...
Page 40 Assembly of Exterior Parts 15.FRONT HOOD (10) EB-10446 Panel COMPL front hood Stay ASSY front hood Tightening torque: N·m (kgf-m, ft-lb) Striker ASSY front hood Grommet hood stay T1: 18 (1.8, 13.3) Hinge COMPL front hood Clamp front hood stay T2: 25 (2.5, 18.4) Cover fender UPR Bracket hood stay...
Page 41 Assembly of Exterior Parts 16.FRONT FENDER EB-10447 Fender front Garnish ASSY fender Tightening torque: N·m (kgf-m, ft-lb) Cover A pillar ASSY T: 9 (0.9, 6.6) BS - 41...
Page 42 Assembly of Exterior Parts 17.FRONT DOOR (15) (10) (13) (13) (11) (12) (14) EB-10448 Weather strip outer door front Plate door Tightening torque: N·m (kgf-m, ft-lb) Cover B pillar ASSY front (10) Sealing cover door front T1: 7.5 (0.8, 5.5) Molding door sash front (11) Pad front door inner T2: 25 (2.5, 18.4)
Page 43 Assembly of Exterior Parts 18.REAR DOOR (10) (14) (12) (11) (12) (13) EB-10451 Weather strip outer door rear Cover B pillar inner door rear Tightening torque: N·m (kgf-m, ft-lb) Cover B pillar ASSY rear Checker ASSY door rear T1: 7.5 (0.8, 5.5) Cover C pillar ASSY rear (10) Sealing cover door rear T2: 25 (2.5, 18.4)
Page 44 Assembly of Exterior Parts 19.REAR GATE (11) (10) EB-10452 Hinge ASSY door rear gate Buffer body side Tightening torque: N·m (kgf-m, ft-lb) Panel COMPL rear gate Molding side ASSY rear gate T1: 7.5 (0.8, 5.5) Latch & actuator ASSY rear gate Clip T2: 13 (1.3, 9.6) Striker rear gate...
Page 45 Assembly of Exterior Parts 20.WEATHER STRIP EB-10453 Panel COMPL door front Weather strip door front Weather strip door rear lower Weather strip door front side sill Panel COMPL door rear Weather strip door rear Weather strip door front lower Weather strip door rear side sill BS - 45...
Page 46 Assembly of Exterior Parts EB-10454 Hood seal rubber Clip Seal cowl panel Weather strip body side flange front Weather strip body arch rear Weather strip body side flange rear Weather strip door rear gate BS - 46...
Page 47 Assembly of Exterior Parts 21.BODY REINFORCING PARTS BRM00090 Plate pitching stopper COMPL Tightening torque: N·m (kgf-m, ft-lb) Panel bulkhead front COMPL T1: 45 (4.59, 33.19) T2: 18 (1.84, 13.28) T3: Secure 18 (1.84, 13.28) or more. The bolts should be seated and not broken.
Page 48: Panel Components
Panel Components 6. Panel Components A: COMPONENTS 1. TOE BOARD & FRONT PANEL • LHD :(a) BRM00240 High-strength tensile steel (440 — 590 MPa class) Panel complete, front Duct complete, front Crossmember, toe board inner Reinforcement, front panel side Toe board complete BS - 48...
Page 49 Panel Components • RHD :(a) BRM00241 High-strength tensile steel (440 — 590 MPa class) Panel complete, front Duct complete, front Toe board complete Reinforcement, front panel side BS - 49...
Page 50 Panel Components 2. RADIATOR PANEL :(a) BRM00243 High-strength tensile steel (440 — 590 MPa class) Panel complete, radiator Panel complete, radiator upper left Frame complete, radiator panel lower Panel complete, radiator upper Panel complete, radiator side Frame complete, radiator lower Panel complete, radiator upper Stay complete, hood lock right...
Page 51 Panel Components 3. FRONT WHEEL APRON (16) (14) :(a) (10) (15) :(b) (11) (13) (12) (14) (10) (11) BRM00605 High-strength tensile steel High-strength tensile steel (440 — 590 MPa class) (1,500 MPa class) Front side frame front Wheel apron complete, front (13) Plate, pitching stopper upper...
Page 52 Panel Components 4. FRONT SIDE FRAME :(a) BRM00245 High-strength tensile steel (440 — 590 MPa class) Frame side complete Gusset complete, front frame Tie down complete, front Frame side front complete, front Bracket complete, beam Wheel apron, extension light Plate, front frame front Closing plate Bracket complete, battery BS - 52...
Page 53 Panel Components 5. FRONT FLOOR PANEL :(a) (11) (13) (11) (12) (10) (13) (12) BRM00247 High-strength tensile steel (440 — 590 MPa class) Crossmember, center floor Floor pan, front (11) Frame, front floor rear Crossmember complete, A Crossmember complete, filler front (12) Pillar, front inner lower Frame, front floor front...
Page 54 Panel Components 6. REAR FLOOR PANEL & REAR SKIRT :(a) :(b) BRM00249 High-strength tensile steel High-strength tensile steel (440 — 590 MPa class) (980 MPa class) Crossmember complete Reinforcement, damper Bracket, spare tire Floor pan complete, rear Frame side, rear upper Floor side, rear Frame complete, rear upper Floor pan complete, rear rear...
Page 55 Panel Components 7. REAR FLOOR SIDE FRAME :(a) BRM00250 High-strength tensile steel (440 — 590 MPa class) Crossmember complete, A Frame complete, floor side rear Frame complete, rear floor rear Crossmember B complete, rear Bracket complete, rear suspen- Bracket, bumper rear floor sion Side sill complete, inner rear...
Page 56 Panel Components 8. ROOF :(a) BRM00251 High-strength tensile steel (440 — 590 MPa class) Rail complete, front roof Plate complete, T stud Brace complete, roof center Rail complete, rear roof Panel complete, roof BS - 56...
Page 57 Panel Components 9. SIDE PANEL INNER :(a) (10) (11) (12) BRM00253 High-strength tensile steel (440 — 590 MPa class) Pillar complete, front inner upper Reinforcement, side sill front outer Pillar, D inner lower Side rail, inner Rear quarter complete, inner (10) Reinforcement, D pillar Pillar complete, front center inner...
Page 58 Panel Components 10.SIDE PANEL OUTER :(a) :(b) (12) (11) (10) (13) (14) BRM00404 High-strength tensile steel High-strength tensile steel (440 — 590 MPa class) (980 MPa class) Gusset, front pillar Extension complete, D pillar (11) Pillar complete, center outer Reinforcement complete, front pil- Rear quarter end complete (12) Rear quarter complete, outer...
Page 59 Panel Components B: REPAIR PART SIZE 1. SIDE PANEL OUTER BRM00256 Part name Measuring point Datum dimension mm (in) 51 (2.01) Front pillar outer 81 (3.19) 68 (2.68) 96 (3.78) 201 (7.91) Center pillar outer 98 (3.86) 650 (25.59) 690 (27.17) 98 (3.86) Rear quarter outer 433 (17.05)
Page 60: Galvanized Sheet Metal
Galvanized Sheet Metal 7. Galvanized Sheet Metal A: SPECIFICATION :(1) BRM00094 Galvanized sheet metal (both sides) The fuel flap is made of plastic. BS - 60...
Page 61: Body Construction
Body Construction 8. Body Construction A: SPECIFICATIONS BRM00098 Cross section A — A Cross section B — B BRM00100 BRM00099 (1) Plate closing plate FF (1) Frame lower A (2) Frame side FF (2) Frame lower B (3) Separator FF A (4) Closing plate FF (5) Gusset battery (6) Gusset battery lower...
Page 62 Body Construction Cross section C — C Cross section D — D BRM00101 BRM00102 (1) Reinforcement front suspension upper (1) Bracket front suspension lower (2) Frame side FF (2) Frame side FF (3) Closing plate FF (3) Closing plate FF (4) Reinforcement front suspension lower (4) Reinforcement FF rear (5) Bracket front suspension lower...
Page 63 Body Construction Cross section I — I Cross section J — J BRM00107 BRM00108 (1) Panel side outer (1) Panel side outer (2) Extension D pillar (2) Reinforcement pillar front outer (3) Reinforcement D pillar lower (3) Gusset frame side upper (4) Pillar D inner center (4) Pillar front inner lower (5) Quarter panel rear inner...
Page 64 Body Construction Cross section O — O Cross section P — P BRM00113 BRM00114 (1) Panel side outer (1) Panel side outer (2) Reinforcement sill side outer front (2) Arch rear inner (3) Reinforcement sill side rear (3) Wheel apron rear (4) Reinforcement sill side inner (5) Side sill inner front Cross section Q —...
Page 65: Body Reference Points
Body Reference Points 9. Body Reference Points A: DIMENSIONS 1. LOWER SURFACE (73) (74) (73) (74)(75) (73) (74) (73) (74)(75) (74)(75) (74)(75) (75) (75) (92) (92) (92) (92) (92) (92) (73) (73) (91) (91) (91) (91) (91) (91) (72) (72) (72) (72) (72)
Page 66 Body Reference Points (71) Under cover front mounting hole (80) Under cover rear mounting hole (89) Rear suspension support sub (symmetrical) (symmetrical) frame mounting hole (symmetrical) (72) Gauge hole (symmetrical) (81) Under cover rear mounting hole (90) Rear suspension crossmember (symmetrical) mounting hole (symmetrical), front side...
Page 67 Body Reference Points Datum Projected Datum Projected Measuring point dimension mm dimensions mm Measuring point dimension mm dimensions mm (in) (in) (in) (in) (82)R — (82)L 387 (15.24) — (72)L — (83)R 1,766 (69.53) 1,750 (68.90) (83)R — (83)L 908 (35.75) —...
Page 68 Body Reference Points 2. FRONT 1 (13) (12) (13) (13) (13) (12) (12) (12) (14) (14) (14) (15) (15) (15) (18) (18) (18) (19) (19) (19) (20) (17) (17) (17) BRM00466 Body repair reference hole Extension fender front mounting (17) Gauge hole (symmetrical) hole (symmetrical) , rear side Headlight mounting hole...
Page 69 Body Reference Points Measuring point Datum dimension mm (in) Measuring point Datum dimension mm (in) (8)R — (8)L 1,525 (60.04) (1) — (13)R 1,267 (49.88) (8)R — (9)L 1,551 (61.06) (1) — (14)R 875 (34.45) (8)L — (14)R 1,082 (42.60) (1) —...
Page 70 Body Reference Points 3. FRONT 2 (16) (16) (16) (13) (13) (13) (16) (16) (16) (11) (11) (11) (10) (10) (10) (15) (15) (15) (13) (13) (13) (11) (11) (11) (10) (10) (10) (14) (14) (14) BRM00347 Frame radiator upper side mount- Extension fender front mounting (15) Gauge hole (center)
Page 71 Body Reference Points Measuring point Datum dimension mm (in) Measuring point Datum dimension mm (in) (8)R — (13)R 526 (20.71) (2)R — (14)L 1,045 (41.14) (9)R — (13)R 285 (11.22) (2)R — (15) 958 (37.72) (10)R — (10)L 1,163 (45.79) (2)L —...
Page 72 Body Reference Points 4. INSIDE 1 (47) (47) (47) (46) (46) (46) (45) (45) (45) (45) (45) (35) (35) (35) (26) (26) (26) (44) (44) (44) (28) (28) (28) (29) (29) (29) (36) (36) (36) (43) (43) (43) (23) (23) (23) (26) (26)
Page 73 Body Reference Points Measuring point Datum dimension mm (in) Measuring point Datum dimension mm (in) (35)R — (44)R 994 (39.13) (18)L — (22)L 1,146 (45.12) (35)R — (47)R 554 (21.81) (18)L — (24)L 1,146 (45.12) (36)R — (44)R 866 (34.09) (19)L —...
Page 74 Body Reference Points 5. INSIDE 2 (34) (33) (33) (33) (35) (35) (35) (21) (21) (21) (32) (32) (32) (36) (36) (36) (31) (31) (31) (40) (40) (40) (41) (41) (41) (37) (37) (37) (25) (25) (25) (21) (21) (21) (40) (40) (40)
Page 75 Body Reference Points Measuring point Datum dimension mm (in) Measuring point Datum dimension mm (in) (34)R — (37)R 1,088 (42.83) (21)R — (21)L 1,511 (59.49) (40)R — (40)L 1,441 (56.73) (25)R — (25)L 1,524 (60.00) (40)L — (41)L 689 (27.13) (31)R —...
Page 76 Body Reference Points 6. INSIDE of REAR (48) (48) (49) (48) (49) (49) (50) (50) (50) (46) (46) (46) (51) (51) (51) (45) (45) (45) (52) (52) (52) (44) (44) (44) (53) (53) (53) (52) (52) (52) (58) (58) (58) (55) (55) (55)
Page 77 Body Reference Points (44) Apron trim mounting hole (50) D pillar trim mounting hole (54) Gauge hole (left side only) (symmetrical) (symmetrical) (45) D pillar trim mounting hole (51) Apron trim mounting hole (55) Gauge hole (symmetrical) (symmetrical) (symmetrical) (46) C pillar trim mounting hole...
Page 78 Body Reference Points 7. REAR (59) (59) (59) (59) (59) (59) (60) (61) (53) (53) (53) (62) (60) (62) (61) BRM00468 (59) Rear gate stay mounting hole (61) Gauge hole (symmetrical) (62) Rear bumper beam mounting hole (symmetrical), upper side (symmetrical) (60) Rear combination light mounting...
Page 79 Body Reference Points (51) (51) (51) (59) (59) (59) (52) (52) (52) (56) (56) (56) (53) (53) (53) (57) (57) (57) (54) (54) (54) (60) (60) (60) (55) (55) (55) (61) (61) (61) (62) (62) (62) (58) (58) (58) BS-09955 BS-09953 BS - 79...
Page 80: Measurement For Combined Parts
Measurement for Combined Parts 10.Measurement for Combined Parts A: DIMENSIONS 1. SUSPENSION MOUNT (SUB FRAME  SUSPENSION MOUNT) &ENGINE MOUNT (10) (10) (10) (57) (57) (57) (74) (75) (74) (75) (75) (74) (91) (91) (91) (90) (90) (90) (79) (79) (79) (10) (10)
Page 81 Measurement for Combined Parts Measuring point Datum dimension mm (in) Measuring point Datum dimension mm (in) (75) — (79) 718 (28.27) Datum line — (10) 632 (24.88) (75) — (90) 2,424 (95.43) Datum line — (57) 393 (15.47) (90) — (91) 573 (22.56) Datum line —...
Page 82: Panel Replacement
Panel Replacement 11.Panel Replacement 11-1. Radiator Panel (total replacement) A: REMOVAL • Overall view BS-09736 1 point (outside  1) 1 point (bolt) 2 points (bolt) 2 points (top  1) BS - 82...
Page 83 Panel Replacement • Views A BS-09737 2 points (top  1) BS - 83...
Page 84 Panel Replacement • Views B BS-09738 1 point (outside  1) 2 points (outside  1) 3 points (outside  1) BS - 84...
Page 85 Panel Replacement • Views C BS-09739 2 points (inside  1) BS - 85...
Page 86 Panel Replacement • Views D BS-09740 1 point (outside  1) 2 points (outside  1) BS - 86...
Page 87 Panel Replacement B: INSTALLATION • Overall view BS-09741 1 point 1 point (bolt) 2 points (bolt) 2 points BS - 87...
Page 88 Panel Replacement • Views A BS-09742 2 points BS - 88...
Page 89 Panel Replacement • Views B BS-09743 1 point 2 points 3 points (service) BS - 89...
Page 90 Panel Replacement • Views C BS-09744 2 points BS - 90...
Page 91 Panel Replacement • Views D BS-09745 1 point (service) 2 points (service) BS - 91...
Page 92: Radiator Core Support (Total Replacement)
Panel Replacement 11-2. Radiator Core Support (total replacement) A: REMOVAL • Overall view BS-09747 1 point (outside  1) Rough cutting BS - 92...
Page 93 Panel Replacement • Views A BS-09748 1 point (top  1) 3 points (top  1) Rough cutting 2 points (top  1) BS - 93...
Page 94 Panel Replacement • Views B BS-09749 1 point (bottom  1) 2 points (bottom  1) Rough cutting BS - 94...
Page 95 Panel Replacement B: INSTALLATION • Overall view BS-09750 1 point BS - 95...
Page 96 Panel Replacement • Views A BS-09751 1 point BS - 96...
Page 97 Panel Replacement • Views B BS-09752 1 point (service) BS - 97...
Page 98 Panel Replacement • Views C BS-09753 1 point 10 points 20 points 2 points BS - 98...
Page 99: Side Upper Frame (Total Replacement)
Panel Replacement 11-3. Side Upper Frame (total replacement) A: REMOVAL • Overall view BS-09754 1 point (outside  1) 3 points (outside  1) 1 point (outside  2) 2 points (outside  1) 4 points (outside  1) 1 point (outside  1 belt sander) BS - 99...
Page 100 Panel Replacement • Views A BS-09755 2 points (outside  1) BS - 100...
Page 101 Panel Replacement • Views B BRM00469 1 point (bottom  1) 3 points (bottom  1) 1 point (bottom  1 belt sander) 2 points (bottom  1) 1 point (bottom  2) BS - 101...
Page 102 Panel Replacement B: INSTALLATION • Overall view BS-09757 1 point 3 points 1 point (continuous welding) [6 mm (0.24 in)] 2 points 4 points (service) BS - 102...
Page 103 Panel Replacement • Views A BS-09758 2 points BS - 103...
Page 104 Panel Replacement • Views B BS-09759 1 point 2 points 3 points BS - 104...
Page 105: Front Wheel Apron (Total Replacement)
Panel Replacement 11-4. Front Wheel Apron (total replacement) A: REMOVAL • Overall view BS-09760 1 point (outside  1) 1 point (inside  2) 4 points (inside  1) 1 point (outside  2) 2 points (outside  1) 6 points (inside  1) 1 point (inside ...
Page 106 Panel Replacement • Views A BS-09761 1 point (bottom  1) 2 points (bottom  1) 3 points (bottom  1) 1 point (top  2) 2 points (top  2) BS - 106...
Page 107 Panel Replacement • Views B (LH) BRM00470 1 point (top  1) 2 points (top  1) 3 points (inside  1) 1 point (inside  1) 2 points (inside  1) 5 points (inside  1) 1 point (top  2) 3 points (top ...
Page 108 Panel Replacement • Views B (RH) BRM00471 1 point (inside  1) 2 points (inside  2) 3 points (inside  1) 2 points (inside  1) 3 points (top  1) BS - 108...
Page 109 Panel Replacement • Views C (LHD) BRM00473 1 point (outside  1) 7 points (outside  1) 1 point (outside  1 belt sander) 3 points (outside  1) BS - 109...
Page 110 Panel Replacement • Views C (RHD) (LH) BRM00474 1 point (outside  1) 8 points (outside  1) 1 point (outside  1 belt sander) 3 points (outside  1) BS - 110...
Page 111 Panel Replacement • Views C (RHD) (RH) BRM00475 1 point (outside  1) 7 points (outside  1) 1 point (outside  1 belt sander) 3 points (outside  1) BS - 111...
Page 112 Panel Replacement B: INSTALLATION • Overall view BS-09765 1 point 4 points (service) 6 points (service) 2 points BS - 112...
Page 113 Panel Replacement • Views A BS-09766 1 point 2 points 3 points BS - 113...
Page 114 Panel Replacement • Views B (LH) BRM00476 1 point 3 points 3 points (service) 2 points 1 point (service) 5 points (service) BS - 114...
Page 115 Panel Replacement • Views B (RH) BRM00477 1 point 3 points 2 points (service) 2 points 1 point (service) 3 points (service) BS - 115...
Page 116 Panel Replacement • Views C (LHD) BS-09769 1 point (service) 3 points (service) 7 points (service) BS - 116...
Page 117 Panel Replacement • Views C (RHD) (LH) BS-09990 1 point (service) 3 points (service) 8 points (service) BS - 117...
Page 118 Panel Replacement • Views C (RHD) (RH) BS-09991 1 point (service) 3 points (service) 7 points (service) BS - 118...
Page 119: Toe Board Reinforcement (Total Replacement)
Panel Replacement 11-5. Toe Board Reinforcement (total replacement) A: REMOVAL • Overall view BRM00479 1 point (outside  1) 2 points (outside  1) 7 points (outside  1) 1 point (inside  1) 2 points (inside  1 belt sander) 1 point (inside ...
Page 120 Panel Replacement • Overall view (RHD) (RH) BRM00481 1 point (outside  1) 2 points (outside  1) 6 points (outside  1) 1 point (inside  1) 2 points (inside  1 belt sander) 1 point (inside  1 belt sander) BS - 120...
Page 121 Panel Replacement • Views A BS-09771 1 point (bottom  1) 4 points (bottom  1) 5 points (bottom  1) 2 points (bottom  1) BS - 121...
Page 122 Panel Replacement B: INSTALLATION • Overall view [f](3) [f](3) [c](1) [f](3) [c](2) [f](4) BS-09772 1 point 1 point (service) 7 points (service) 2 points 2 points (service) [c] Spot welding Compression: 4.0 kN, Current: 7.0 kA, Welding time: 20 cyc [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %)
Page 123 Panel Replacement • Overall view (RHD) (RH) [f](3) [f](3) [c](2) [f](3) [c](1) [f](4) BS-09993 1 point 1 point (service) 6 points (service) 2 points 2 points (service) [c] Spot welding Compression: 4.0 kN, Current: 7.0 kA, Welding time: 20 cyc [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %)
Page 124 Panel Replacement • Views A [f](1) [f](2) BS-09773 1 point (service) 4 points (service) 5 points (service) 2 points (service) [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %) BS - 124...
Page 125: Closing Plate Lh (Partial Replacement)
Panel Replacement 11-6. Closing Plate LH (partial replacement) A: REMOVAL • Overall view BRM00483 217 mm [8.54 in] 52 mm [2.05 in] 1 point (outside  1) 5 points (outside  1) Cut position where the damage is small 1 point (outside  2) 12 points (outside ...
Page 126 Panel Replacement • Views A BRM00485 1 point (outside  1) 2 points (outside  1) BS - 126...
Page 127 Panel Replacement • Views B BRM00487 1 point (top  2) 3 points (top  1) 1 point (inside  1) 2 points (top  1) 5 points (inside  1) BS - 127...
Page 128 Panel Replacement • Views C BS-09777 1 point (bottom  1) BS - 128...
Page 129 Panel Replacement B: INSTALLATION • Overall view BRM00489 217 mm [8.54 in] 52 mm [2.05 in] 1 point 12 points 1 point (service) 2 points Tailored line 5 points 1 point (continuous welding) BS - 129...
Page 130 Panel Replacement • Views A BRM00491 1 point 2 points BS - 130...
Page 131 Panel Replacement • Views B BRM00493 1 point 3 points 5 points 2 points BS - 131...
Page 132 Panel Replacement • Views C BS-09781 1 point BS - 132...
Page 133: Closing Plate Rh (Partial Replacement)
Panel Replacement 11-7. Closing Plate RH (partial replacement) A: REMOVAL • Overall view BS-09782 217 mm [8.54 in] 52 mm [2.05 in] 1 point (outside  1) 5 points (outside  1) Tailored line 1 point (outside  2) 7 points (outside  1) Cut position where the damage is small 2 points (outside ...
Page 134 Panel Replacement • Views A BRM00495 1 point (outside  1) 2 points (outside  1) 3 points (top  1) 1 point (outside  2) BS - 134...
Page 135 Panel Replacement • Views B BS-09784 1 point (bottom  1) BS - 135...
Page 136 Panel Replacement B: INSTALLATION • Overall view BS-09785 217 mm [8.54 in] 52 mm [2.05 in] 1 point 7 points 1 point (continuous welding) 2 points 12 points 1 point (service) 5 points Tailored line BS - 136...
Page 137 Panel Replacement • Views A BRM00498 1 point 2 points 3 points BS - 137...
Page 138 Panel Replacement • Views B BS-09787 1 point BS - 138...
Page 139: Front Side Frame Lh (Partial Replacement)
Panel Replacement 11-8. Front Side Frame LH (partial replacement) A: REMOVAL • Overall view BS-09788 55 mm [2.17 in] 1 point (inside  1) 5 points (inside  1) Tailored line 1 point (inside  2) 10 points (inside  1) Cut position BS - 139...
Page 140 Panel Replacement • Views A BS-09789 1 point (outside  1) 1 point (top  1) 2 points (outside  1) BS - 140...
Page 141 Panel Replacement B: INSTALLATION • Overall view BS-09790 55 mm [2.17 in] 1 point 5 points (service) Tailored line 5 points 10 points 1 point (continuous welding) BS - 141...
Page 142 Panel Replacement • Views A BS-09791 1 point 2 points BS - 142...
Page 143: Front Side Frame Rh (Partial Replacement)
Panel Replacement 11-9. Front Side Frame RH (partial replacement) A: REMOVAL • Overall view BS-09792 60 mm [2.36 in] 1 point (inside  1) 7 points (inside  1) Cut position 1 point (inside  2) 10 points (inside  1) 5 points (inside ...
Page 144 Panel Replacement • Views A BS-09793 1 point (outside  1) 1 point (top  1) 2 points (outside  1) BS - 144...
Page 145 Panel Replacement B: INSTALLATION • Overall view BS-09794 60 mm [2.36 in] 1 point 7 points Tailored line 5 points 10 points 1 point (continuous welding) BS - 145...
Page 146 Panel Replacement • Views A BS-09795 1 point 2 points BS - 146...
Page 147: Front Side Frame (Total Replacement)
Panel Replacement 11-10. Front Side Frame (total replacement) A: REMOVAL • Overall view BRM00551 1 point (outside  1) 1 point (outside  2) 5 points (outside  1) BS - 147...
Page 148 Panel Replacement • Views A BRM00553 1 point (top  1) BS - 148...
Page 149 Panel Replacement • Views B BS-09798 1 point (bottom  1) 2 points (bottom  1) 3 points (bottom  2) 1 point (inside  2) 2 points (inside  1) 2 points (outside  1) 3 points (bottom  1) BS - 149...
Page 150 Panel Replacement B: INSTALLATION • Overall view [f](2) [f](1) [f](1) BRM00554 1 point (service) 5 points (service) [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %) BS - 150...
Page 151 Panel Replacement • Views A BRM00556 1 point (service) BS - 151...
Page 152 Panel Replacement • Views B [f](2) [f](1) [f](3) [f](1) [f](2) [f](3) BS-09801 1 point (service) 2 points (service) 3 points (service) [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %) BS - 152...
Page 153: Front Pillar Outer (Partial Replacement)
Panel Replacement 11-11. Front Pillar Outer (partial replacement) A: REMOVAL • Overall view 1 BRM00657 1 point (outside  1) 3 points (outside  1) BS - 153...
Page 154 Panel Replacement • Views A BRM00559 2 points (outside  1) BS - 154...
Page 155 Panel Replacement • Views B BRM00560 1 point (top  2) 3 points (top  1) BS - 155...
Page 156 Panel Replacement • Overall view 2 BRM00561 270 mm [10.63 in] 1 point (outside  1) 3 points (outside  1) 12 points (outside  1) 2 points (outside  1) 5 points (outside  1) Cut position BS - 156...
Page 157 Panel Replacement • Views C BRM00563 1 point (top  1) 2 points (top  1) 3 points (outside  2) 1 point (top  2) 3 points (top  1) The part that can be reused. BS - 157...
Page 158 Panel Replacement • Views D BRM00564 260 mm [10.24 in] 1 point (top  1) 2 points (top  1) Cut position 2 points (outside  1) 3 points (top  1) BS - 158...
Page 159 Panel Replacement • Views E BRM00565 1 point (outside  1) 2 points (outside  1) 3 points (outside  1) BS - 159...
Page 160 Panel Replacement B: INSTALLATION • Overall view 1 BRM00659 1 point (service) 3 points (service) BS - 160...
Page 161 Panel Replacement • Views A BRM00568 2 points (service) BS - 161...
Page 162 Panel Replacement • Views B BRM00569 1 point 3 points BS - 162...
Page 163 Panel Replacement • Overall view 2 [e](3) [d](1) [c](1) [c](1) [d](1) [c](1) [c](3) BRM00570 310 mm [12.20 in] 1 point 2 points (service) 5 points (service) 1 point (service) 3 points 12 points 2 points 5 points 1 point (continuous welding) [c] Spot welding Compression: 4.0 kN, Current: 7.0 kA, Welding time: 20 cyc [d] Spot welding...
Page 164 Panel Replacement • Views C BRM00572 1 point 3 points The part that can be reused. 3 points (service  matching ) 2 points BS - 164...
Page 165 Panel Replacement • Views C (RHD) (LH) BRM00573 1 point 3 points The part that can be reused. 3 points ( service  matching) 2 points Spotting sealer : Spotting sealer application location (spotting sealer or sealing [Three Bond 4101 (004403063)]) Note: Cover the gap between the reinforcement front panel side and reinforcement front bulk upper.
Page 166 Panel Replacement • Views D [e](3) BRM00574 260 mm [10.24 in] 1 point 2 points 3 points 1 point (service) 2 points (service) 1 point (continuous welding) [e] Spot welding Compression: 4.0 kN, Current: 8.5 kA, Welding time: 20 cyc BS - 166...
Page 167 Panel Replacement • Views E BRM00575 1 point (service) 2 points (service) 3 points (service) BS - 167...
Page 168 Panel Replacement • Views F BRM00331 55 mm [2.17 in] 169 mm [6.65 in] A point B point Spotting sealer : Spotting sealer application location (spotting sealer or sealing [Three Bond 4101 (004403063)]) Note: • Check for protrusion between (a) and (b). BS - 168...
Page 169: Front Pillar Reinforcement (Total Replacement)
Panel Replacement 11-12. Front Pillar Reinforcement (total replacement) A: REMOVAL • Overall view BRM00576 1 point (outside  1) 2 points (outside  1) 5 points (outside  1) 1 point (outside  2) 3 points (outside  1) 12 points (outside  1) BS - 169...
Page 170 Panel Replacement • Views A BS-09818 1 point (top  1) 3 points ( top  1) BS - 170...
Page 171 Panel Replacement • Views B BS-09819 1 point (top  2) 2 points ( outside  2) 3 points ( outside  1) 2 points (top  1) BS - 171...
Page 172 Panel Replacement • Views C BS-09820 2 points (outside  1) 6 points ( outside  1) BS - 172...
Page 173 Panel Replacement B: INSTALLATION • Overall view [f](2) [f](7) [c](1) [b](1) BRM00578 1 point ( service  matching) 1 point 5 points 2 points 12 points 2 points (service) 3 points 1 point (service) [b] Spot welding Compression: 3.0 kN, Current: 8.0 kA, Welding time: 23 cyc [c] Spot welding Compression: 4.0 kN, Current: 7.0 kA, Welding time: 20 cyc [f] Plug welding...
Page 174 Panel Replacement • Views A [f](1) BS-09822 1 point 3 points [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %) BS - 174...
Page 175 Panel Replacement • Views B [f](1) [f](1) [f](1) [f](2) [f](2) [f](2) [f](3) [f](4) BS-09823 1 point (service  matching) 2 points (service  matching) 3 points (service) 2 points (service) [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %) BS - 175...
Page 176 Panel Replacement • Views C [f](1) [f](1) [f](1) BS-09824 2 points (service) 6 points (service) [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %) BS - 176...
Page 177: Front Pillar Reinforcement (Partial Replacement)
Panel Replacement 11-13. Front Pillar Reinforcement (partial replacement) A: REMOVAL • Overall view BS-09825 100 mm [3.94 in] 80 mm [3.15 in] 1 point (outside  1) 2 points (top  1) Cut position 1 point (top  1) 3 points (outside  1) Half-cut position, outer panel 2 points (outside ...
Page 178 Panel Replacement • Views A BS-09826 1 point (outside  1) 6 points (outside  1) Cut position 2 points (outside  1) BS - 178...
Page 179 Panel Replacement B: INSTALLATION • Overall view [f](4) [c](1) [b](1) [f](2) [f](3) [f](6) BS-09827 2 points (service  matching) 1 point 6 points 1 point (service  matching) 3 points 1 point (continuous welding) 2 points (service) 3 points (service) [b] Spot welding Compression: 3.0 kN, Current: 8.0 kA, Welding time: 23 cyc [c] Spot welding...
Page 180 Panel Replacement • Views A [f](3) [f](3) [f](3) BS-09828 1 point 2 points (service) 1 point (continuous welding) 2 points 6 points (service) [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %) BS - 180...
Page 181: Center Pillar (Partial Replacement)
Panel Replacement 11-14. Center Pillar (partial replacement) A: REMOVAL • Overall view BS-09829 130 mm [5.12 in] 120 mm [4.72 in] 1 point (outside  1) 4 points (outside  1) Cut position 2 points (outside  1) 5 points (outside  1) 3 points (outside ...
Page 182 Panel Replacement B: INSTALLATION • Overall view [e](4) [e](3) [f](1) [f](1) [e](7) [e](4) [f](1) [f](1) [e](6) [e](5) [f](1) [f](1) [e](5) [e](3) [f](1) [e](5) [f](1) [f](1) BS-09830 150 mm [5.91 in] 95 mm [3.74 in] 100 mm [3.94 in] 1 point (service) 2 points 5 points 2 points (service)
Page 183: Center Pillar Reinforcement (Total Replacement)
Panel Replacement 11-15. Center Pillar Reinforcement (total replacement) A: REMOVAL • Overall view BS-09831 1 point (outside  1) 4 points (outside  1) 10 points (outside  1) 2 points (outside  1) 5 points (outside  1) Rough cutting 3 points (outside ...
Page 184 Panel Replacement • Views A BS-09832 1 point (outside  1) 4 points (outside  1) 5 points (outside  1) 3 points (outside  1) BS - 184...
Page 185 Panel Replacement • Views B BS-09833 2 points (outside  1) 4 points (outside  1) 5 points (outside  1) 3 points (outside  1) BS - 185...
Page 186 Panel Replacement B: INSTALLATION • Overall view [f](1) [f](1) [f](4) [a](1) [f](3) [a](1) [a](1) [a](3) [a](2) [a](1) [a](1) [a](7) [a](5) [a](1) [a](1) [a](3) [b](2) BS-09834 1 point 4 points 10 points 2 points 5 points 1 point (continuous welding) 3 points 8 points [a] Spot welding Compression: 4.0 kN, Current: 7.5 kA, Welding time: 17 cyc...
Page 187 Panel Replacement • Views A [f](4) [f](1) [f](1) BS-09835 1 point (service) 4 points 5 points (service) 3 points [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %) BS - 187...
Page 188 Panel Replacement • Views B [f](2) [f](4) [f](3) [f](3) [f](1) [f](3) BS-09836 2 points (service) 4 points (service) 5 points (service) 3 points (service) [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %) BS - 188...
Page 189: Center Pillar Inner (Total Replacement)
Panel Replacement 11-16. Center Pillar Inner (total replacement) A: REMOVAL • Overall view BS-09837 1 point (inside  1 belt sander) 2 points (outside  1) 9 points (outside  1) BS - 189...
Page 190 Panel Replacement • Views A BRM00531 2 points (inside  1) 3 points (inside  1) 1 point (inside  1) BS - 190...
Page 191 Panel Replacement B: INSTALLATION • Overall view BS-09838 1 point (continuous welding) 2 points 9 points (service) (41 mm [1.61 in]) 1 point (continuous welding) (15 mm [0.59 in]) BS - 191...
Page 192 Panel Replacement • Views A BRM00533 2 points 3 points 1 point BS - 192...
Page 193: Side Sill Outer Panel (Partial Replacement)
Panel Replacement 11-17. Side Sill Outer Panel (partial replacement) A: REMOVAL • Overall view BS-09841 30 mm [1.18 in] 90 mm [3.54 in] 55 mm [2.17 in] 1 point (outside  1) 6 points (outside  1) 2 points (outside  1) 5 points (outside ...
Page 194 Panel Replacement • Views A BRM00588 1 point (outside  1) 3 points (outside  1) Cut position 2 points (outside  1) BS - 194...
Page 195 Panel Replacement • Views B BRM00589 1 point (outside  1) 3 points (outside  1) Cut position 2 points (outside  1) 6 points (outside  1) BS - 195...
Page 196 Panel Replacement • Views C BS-09844 1 point (outside  1) 2 points (outside  1) Cut position BS - 196...
Page 197 Panel Replacement B: INSTALLATION • Overall view [c](1) [c](1) BS-09845 60 mm [2.36 in] 120 mm [4.72 in] 85 mm [3.35 in] 1 point 6 points 1 point (continuous welding) 5 points 2 points [c] Spot welding Compression: 4.0 kN, Current: 7.0 kA, Welding time: 20 cyc BS - 197...
Page 198 Panel Replacement • Views A [d](1) [c](3) [c](1) [c](1) [c](1) [c](1) [c](1) [c](3) [c](3) [c](3) [c](1) [d](1) BRM00590 1 point 2 points 1 point (continuous welding) 1 point (service) 3 points [c] Spot welding Compression: 4.0 kN, Current: 7.0 kA, Welding time: 20 cyc [d] Spot welding Compression: 4.0 kN, Current: 8.0 kA, Welding time: 20 cyc BS - 198...
Page 199 Panel Replacement • Views B [c](1) BRM00592 1 point 3 points 1 point (continuous welding) 2 points (service) 6 points 1 point (service) [c] Spot welding Compression: 4.0 kN, Current: 7.0 kA, Welding time: 20 cyc BS - 199...
Page 200 Panel Replacement • Views C BS-09848 1 point (service) 2 points (service) 1 point (continuous welding) BS - 200...
Page 201: Side Sill Reinforcement Outer Rear (Total Replacement)
Panel Replacement 11-18. Side Sill Reinforcement Outer Rear (total replacement) A: REMOVAL • Overall view BS-09849 1 point (outside  1) 2 points (outside  1) 3 points (outside  1) BS - 201...
Page 202 Panel Replacement • Views A BS-09850 1 point (outside  1) 2 points (top  1) BS - 202...
Page 203 Panel Replacement • Views B BS-09851 1 point (bottom  1) BS - 203...
Page 204 Panel Replacement B: INSTALLATION • Overall view [b](1) [e](1) [b](1) [f](4) [b](1) [f](2) [b](1) BS-09852 1 point 2 points 3 points 1 point (service) 2 points (service) [b] Spot welding Compression: 3.0 kN, Current: 8.0 kA, Welding time: 23 cyc [e] Spot welding Compression: 4.0 kN, Current: 8.5 kA, Welding time: 20 cyc [f] Plug welding...
Page 205 Panel Replacement • Views A [f](1) [f](2) BS-09853 1 point (service) 2 points (service) [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %) BS - 205...
Page 206 Panel Replacement • Views B [f](1) BS-09854 1 point (service) [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %) BS - 206...
Page 207: Side Sill Reinforcement Outer (Total Replacement)
Panel Replacement 11-19. Side Sill Reinforcement Outer (total replacement) A: REMOVAL • Overall view BRM00580 1 point (outside  1) 2 points (outside  1) 6 points (outside  1) BS - 207...
Page 208 Panel Replacement • Views A BS-09856 1 point (outside  1) 3 points (outside  1) 7 points (outside  1) 2 points (outside  1) BS - 208...
Page 209 Panel Replacement • Views B BS-09857 1 point (outside  1) 2 points (outside  1) BS - 209...
Page 210 Panel Replacement B: INSTALLATION • Overall view [f](2) [b](3) [b](1) [b](3) BRM00582 1 point 6 points 2 points 2 points (service) [b] Spot welding Compression: 3.0 kN, Current: 8.0 kA, Welding time: 23 cyc [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %) BS - 210...
Page 211 Panel Replacement • Views A [c](1) [b](2) [f](5) [b](2) [a](1) [a](1) [b](4) [a](1) [a](1) [a](1) [b](3) [c](1) [c](3) [c](1) [b](2) [b](1) [b](1) [b](1) [b](1) [c](1) BS-09860 1 point 3 points 1 point (service) 2 points 7 points [a] Spot welding Compression: 4.0 kN, Current: 7.5 kA, Welding time: 17 cyc [b] Spot welding Compression: 3.0 kN, Current: 8.0 kA, Welding time: 23 cyc...
Page 212 Panel Replacement • Views B [c](1) [b](2) [b](1) [b](2) [b](1) [a](1) [a](1) [a](1) [b](1) [b](1) [b](2) BS-09861 1 point 2 points [a] Spot welding Compression: 4.0 kN, Current: 7.5 kA, Welding time: 17 cyc [b] Spot welding Compression: 3.0 kN, Current: 8.0 kA, Welding time: 23 cyc [c] Spot welding Compression: 4.0 kN, Current: 7.0 kA, Welding time: 20 cyc BS - 212...
Page 213: Rear Quarter Panel (Partial Replacement)
Panel Replacement 11-20. Rear Quarter Panel (partial replacement) A: REMOVAL • Overall view (10) BRM00501 360 mm [14.17 in] 13.5 mm [5.31 in] 510 mm [20.08 in] 1 point (outside  1) 6 points (outside  1) 1 point (outside  2) 2 points (outside ...
Page 214 Panel Replacement • Views A BS-09864 2 points (outside  1) 3 points (outside  1) 5 points (outside  1) 2 points (outside  2) 3 points (outside  2) Cut position BS - 214...
Page 215 Panel Replacement B: INSTALLATION • Overall view BRM00502 380 mm [14.96 in] 115 mm [4.53 in] 490 mm [19.29 in] 1 point 3 points 7 points 1 point (service) 4 points 22 points 2 points (service) 6 points 1 point (continuous welding) BS - 215...
Page 216 Panel Replacement • Views A BS-09866 2 points (service) 3 points (service) 5 points (service) 2 points (service  matching) 3 points (service  matching) 1 point (continuous welding) BS - 216...
Page 217 Panel Replacement • Views B BRM00332 53.2 mm [2.09 in] A point B point Spotting sealer : Spotting sealer application location (spotting sealer or sealing [Three Bond 4101 (004403063)]) Note: Fill spotting sealer between the panel side out and arch rear inner. •...
Page 218: Rear Pillar Reinforcement Outer (Total Replacement)
Panel Replacement 11-21. Rear Pillar Reinforcement Outer (total replacement) A: REMOVAL • Overall view BS-09868 1 point (outside  1) 2 points (outside  1) 6 points (top  1) BS - 218...
Page 219 Panel Replacement B: INSTALLATION • Overall view BS-09869 1 point 2 points 6 points (service) 1 point (service) 2 points (service) BS - 219...
Page 220: Arch Rear Inner Lh (Total Replacement)
Panel Replacement 11-22. Arch Rear Inner LH (total replacement) A: REMOVAL • Overall view BS-09870 1 point (outside  1) 2 points (inside  1) 4 points (outside  1) 1 point (inside  1 belt sander) 3 points (outside  1) 6 points (outside ...
Page 221 Panel Replacement B: INSTALLATION • Overall view BS-09871 1 point 3 points 6 points (service) 7 points (service  matching) 1 point (service) 4 points 2 points 6 points 1 point (continuous welding) [22 mm (0.87 in)] BS - 221...
Page 222: Arch Rear Inner Rh (Total Replacement)
Panel Replacement 11-23. Arch Rear Inner RH (total replacement) A: REMOVAL • Overall view BS-09872 1 point (outside  1) 3 points (outside  1) 6 points (outside  1) 1 point (inside  1 belt sander) 3 points (outside  2) 2 points (outside ...
Page 223 Panel Replacement B: INSTALLATION • Overall view (10) BS-09873 1 point 3 points (service) 6 points (service) 3 points (service  matching) 1 point (service) (10) 1 point (continuous welding) [22 mm (0.87 in)] 2 points 4 points 3 points 6 points BS - 223...
Page 224: Rear Quarter Inner Lh (Partial Replacement)
Panel Replacement 11-24. Rear Quarter Inner LH (partial replacement) A: REMOVAL • Overall view a(4) BRM00520 200 mm [7.87 in] 530 mm [20.87 in] 1 point (outside  1) 2 points (outside  1) 5 points (outside  1) 1 point (outside  2) 3 points (outside ...
Page 225 Panel Replacement • Views A a(2) BS-09875 2 points (outside  1) 2 points (outside  1 belt sander) Note: Welding points in part "a" vary depending on each vehicle model (spot or arc welding). BS - 225...
Page 226 Panel Replacement • Views B BS-09876 1 point (outside  1) 1 point (inside  1 belt sander) 5 points (outside  1) 1 point (outside  2) 2 points (outside  2) BS - 226...
Page 227 Panel Replacement B: INSTALLATION • Overall view a(5) BRM00521 200 mm [7.87 in] 530 mm [20.87 in] 1 point 2 points 4 points (service) 1 point (service) 2 points (service) 5 points (service) 1 point (continuous welding) 3 points (service) 1 point (continuous welding) (22 mm [0.87 in]) Note: Welding points in part "a"...
Page 228 Panel Replacement • Views A a(3) BS-09878 2 points 2 points (service) 3 points (continuous welding) (5 mm [0.20 in]) Note: Welding points in part "a" vary depending on each vehicle model (spot or arc welding). BS - 228...
Page 229 Panel Replacement • Views B BS-09879 1 point 1 point (continuous welding) 5 points (5 mm [0.20 in]) 1 point (service) 2 points (service) BS - 229...
Page 230: Rear Quarter Inner Rh (Partial Replacement)
Panel Replacement 11-25. Rear Quarter Inner RH (partial replacement) A: REMOVAL • Overall view a(4) BRM00522 200 mm [7.87 in] 530 mm [20.87 in] 1 point (outside  1) 2 points (outside  1) 5 points (outside  1) 1 point (outside  2) 3 points (outside ...
Page 231 Panel Replacement • Views A a(2) BS-09881 2 points (outside  1) 2 points (outside  1 belt sander) Note: Welding points in part "a" vary depending on each vehicle model (spot or arc welding). BS - 231...
Page 232 Panel Replacement • Views B BS-09882 1 point (outside  1) 1 point (inside  1 belt sander) 2 points (outside  2) 1 point (outside  2) 2 points (outside  1) 6 points (outside  1) BS - 232...
Page 233 Panel Replacement B: INSTALLATION • Overall view a(5) BRM00523 200 mm [7.87 in] 530 mm [20.87 in] 1 point 2 points 4 points (service) 1 point (service) 2 points (service) 5 points (service) 1 point (continuous welding) 3 points (service) 1 point (continuous welding) 22 mm [0.87 in]) Note: Welding points in part "a"...
Page 234 Panel Replacement • Views A a(3) BS-09884 2 points 2 points (service) 2 points (continuous welding) (5 mm [0.20 in]) Note: Welding points in part "a" vary depending on each vehicle model (spot or arc welding). BS - 234...
Page 235 Panel Replacement • Views B BS-09885 1 point 1 point (continuous welding) 2 points (service) (5 mm [0.20 in]) 1 point (service) 2 points 6 points BS - 235...
Page 236: D Pillar Extension (Partial Replacement)
Panel Replacement 11-26. D Pillar Extension (partial replacement) A: REMOVAL • Overall view BS-09886 160 mm [6.30 in] 5 points (outside  1) 6 points (outside  1) Cut position BS - 236...
Page 237 Panel Replacement B: INSTALLATION • Overall view BS-09887 140 mm [5.51 in] 5 points (service) 6 points 1 point (continuous welding) BS - 237...
Page 238: Rear Quarter End Panel (Total Replacement)
Panel Replacement 11-27. Rear Quarter End Panel (total replacement) A: REMOVAL • Overall view BS-09888 1 point (outside  1) 4 points (outside  1) 6 points (outside  1) BS - 238...
Page 239 Panel Replacement B: INSTALLATION • Overall view BS-09889 1 point 4 points 6 points BS - 239...
Page 240: D Pillar Reinforcement (Partial Replacement)
Panel Replacement 11-28. D Pillar Reinforcement (partial replacement) A: REMOVAL • Overall view BS-09890 1 point (outside  1) 3 points (outside  1) 5 points (inside  2) 1 point (inside  2) BS - 240...
Page 241 Panel Replacement • Views A BRM00524 1 point (inside  1) 2 points (inside  1) 4 points (inside  1) 1 point (inside  2) 3 points (inside  1) BS - 241...
Page 242 Panel Replacement B: INSTALLATION • Overall view BS-09892 1 point 3 points 5 points BS - 242...
Page 243 Panel Replacement • Views A BRM00525 1 point (service) 3 points (service) 2 points (service) 2 points 4 points (service) BS - 243...
Page 244: Rear Skirt (Total Replacement)
Panel Replacement 11-29. Rear Skirt (total replacement) A: REMOVAL • Overall view BS-09894 1 point (outside  1) 2 points (outside  1) 4 points (outside  1) 1 point (top  1) 2 points (outside  2) 5 points (top  1) 1 point (outside ...
Page 245 Panel Replacement • Views A BRM00619 1 point (outside  2) 1 point (outside  1) 2 points (outside  2) BS - 245...
Page 246 Panel Replacement B: INSTALLATION • Overall view BS-09896 1 point 3 points 5 points 2 points 4 points BS - 246...
Page 247 Panel Replacement • Views A BRM00526 1 point 2 points BS - 247...
Page 248: Rear Side Frame Upper Rear Lh (Total Replacement)
Panel Replacement 11-30. Rear Side Frame Upper Rear LH (total replacement) A: REMOVAL • Overall view BS-09898 1 point (top  1) 3 points (top  1) 9 points (top  1) 1 point (top  2) 4 points (top  1) 2 points (top ...
Page 249 Panel Replacement • Views A BRM00527 1 point (top  1) 1 point (inside  1) BS - 249...
Page 250 Panel Replacement B: INSTALLATION • Overall view BS-09900 1 point (service) 3 points 9 points (service) 1 point (service  matching) 4 points (service) 2 points (service  matching) 5 points (service) BS - 250...
Page 251 Panel Replacement • Views A BRM00529 1 point BS - 251...
Page 252: Rear Side Frame Upper Rear Rh (Total Replacement)
Panel Replacement 11-31. Rear Side Frame Upper Rear RH (total replacement) A: REMOVAL • Overall view BS-09902 1 point (top  1) 3 points (top  1) 9 points (top  1) 1 point (top  2) 4 points (top  1) 2 points (top ...
Page 253 Panel Replacement • Views A BRM00535 1 point (top  1) 1 point (inside  1) BS - 253...
Page 254 Panel Replacement B: INSTALLATION • Overall view BS-09904 1 point (service) 3 points 9 points (service) 1 point (service  matching) 4 points (service) 2 points (service  matching) 5 points (service) BS - 254...
Page 255 Panel Replacement • Views A BRM00537 1 point BS - 255...
Page 256: Rear Floor Pan (Partial Replacement)
Panel Replacement 11-32. Rear Floor Pan (partial replacement) A: REMOVAL • Overall view BRM00539 455 mm [17.91 in] 170 mm [6.69 in] 1 point (top  1) 4 points (top  1) Cut position 1 point (inside  1 belt sander) 5 points (top ...
Page 257 Panel Replacement B: INSTALLATION • Overall view BRM00540 475 mm [18.70 in] 140 mm [5.51 in] 1 point 2 points (service) 5 points (service) 1 point (service) 4 points (service) 8 points (service) Note: Apply sealing agent to the floor pan fitting parts (front and rear) of section "a". BS - 257...
Page 258: Rear Floor Side (Total Replacement)
Panel Replacement 11-33. Rear Floor Side (total replacement) A: REMOVAL • Overall view BS-09924 1 point (top  1) LH: 2 points (top  2) 8 points (top  1) RH: 1 point (top  2) 1 point (inside  1) BS - 258...
Page 259 Panel Replacement • Views A (LH) BS-09925 1 point (inside  1) 1 point (outside  2) 5 points (inside  1) BS - 259...
Page 260 Panel Replacement • Views A (RH) BS-09926 1 point (inside  1) 2 points (inside  1) 2 points (outside  1) 1 point (outside  2) BS - 260...
Page 261 Panel Replacement B: INSTALLATION • Overall view BS-09927 LH: 2 points (service  matching) 1 point 8 points (service) RH: 1 point (service  matching) 1 point (service) BS - 261...
Page 262 Panel Replacement • Views A (LH) BS-09928 1 point (service  matching) 1 point 5 points BS - 262...
Page 263 Panel Replacement • Views A (RH) BRM00541 1 point (service  matching) 1 point 2 points BS - 263...
Page 264: Rear Side Frame Lower Rear (Total Replacement)
Panel Replacement 11-34. Rear Side Frame Lower Rear (total replacement) A: REMOVAL • Overall view BRM00542 1 point (top  1) 1 point (bottom  2) 2 points (inside  1 belt sander) 1 point (inside  1 belt sander) BS - 264...
Page 265 Panel Replacement • Views A BS-09957 1 point (inside  1 belt sander) 2 points (inside  1 belt sander) 3 points (inside  1 belt sander) BS - 265...
Page 266 Panel Replacement B: INSTALLATION • Overall view BRM00544 1 point 2 points 1 point (service) BS - 266...
Page 267 Panel Replacement • Views A BRM00545 1 point 2 points 3 points BS - 267...
Page 268: Side Sill Inner Rear (Total Replacement)
Panel Replacement 11-35. Side Sill Inner Rear (total replacement) A: REMOVAL • Overall view 1 BS-09960 1 point (outside  1) 3 points (outside  1) Rough cutting 2 points (outside  1) BS - 268...
Page 269 Panel Replacement • Overall view 2 BRM00661 1 point (outside  1) 2 points (outside  1) 4 points (outside  1) 1 point (outside  2) 2 points (outside  2) 1 point (inside  2) 3 points (outside  1) BS - 269...
Page 270 Panel Replacement • Views A BS-09962 1 point (top  1) 2 points (top  1) 4 points (top  1) 1 point (top  2) 3 points (top  1) Structural adhesive : Structural adhesive application location BS - 270...
Page 271 Panel Replacement • Views B BS-09963 1 point (bottom  1) 2 points (bottom  1) 5 points (bottom  1) 1 point (bottom  2) BS - 271...
Page 272 Panel Replacement B: INSTALLATION • Overall view 1 BS-09964 1 point 3 points 1 point (continuous welding) 2 points BS - 272...
Page 273 Panel Replacement • Overall view 2 [f](6) [f](6) [f](6) [f](3) BRM00663 1 point 2 points 3 points 1 point (service) 2 points (service) 3 points (service) 1 point (service  matching) 2 points (service  matching) 4 points (service) [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %) BS - 273...
Page 274 Panel Replacement • Views A [f](2) [f](1) BS-09966 1 point 2 points (service) 4 points 1 point (service  matching) 3 points (service) Structural adhesive : Structural adhesive application location [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %) BS - 274...
Page 275 Panel Replacement • Views B BS-09967 1 point 2 points (service) 5 points 1 point (service  matching) BS - 275...
Page 276: Rear Side Frame Upper (Total Replacement)
Panel Replacement 11-36. Rear Side Frame Upper (total replacement) A: REMOVAL • Overall view BS-09968 1 point (top  1) 2 points (top  2) 5 points (top  1) 1 point (top  2)) 3 points (top  1) LH: 2 points (top ...
Page 277 Panel Replacement • Views A BRM00338 1 point (inside  1) 6 points (outside  1) 2 points (inside  1) 2 points (outside  2) BS - 277...
Page 278 Panel Replacement B: INSTALLATION • Overall view [f](1) [f](1) [f](3) [f](3) BS-09970 1 point LH: 2 points (service) 4 points (service) RH: 1 point (service) 1 point (service) 2 points (service) 5 points (service) 1 point (service  matching) 3 points (service) [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %)
Page 279 Panel Replacement • Views A BRM00339 1 point 2 points 6 points BS - 279...
Page 280: Rear Side Frame (Total Replacement)
Panel Replacement 11-37. Rear Side Frame (total replacement) A: REMOVAL • Overall view BRM00340 1 point (top  1) 7 points (top  1) Structural adhesive 5 points (top  1) : Structural adhesive application location BS - 280...
Page 281 Panel Replacement • Views A BS-09973 1 point (outside  1) BS - 281...
Page 282 Panel Replacement • Views B BRM00341 1 point (bottom  1) 1 point (bottom  2) 3 points (outside  1) BS - 282...
Page 283 Panel Replacement • Views C BS-09975 1 point (bottom  1) 3 points (bottom  1) 1 point (bottom  2) 2 points (outside  1) BS - 283...
Page 284 Panel Replacement • Views D BS-09976 1 point (bottom  1) 2 points (bottom  1) 3 points (outside  1) 1 point (bottom  2) BS - 284...
Page 285 Panel Replacement B: INSTALLATION • Overall view BRM00343 1 point 7 points Structural adhesive 5 points : Structural adhesive application location BS - 285...
Page 286 Panel Replacement • Views A BS-09978 1 point (service) BS - 286...
Page 287 Panel Replacement • Views B BRM00344 1 point (service  matching) 1 point (service) 3 points (service) BS - 287...
Page 288 Panel Replacement • Views C BS-09980 1 point (service  matching) 1 point 3 points 2 points 1 point (service) BS - 288...
Page 289 Panel Replacement • Views D BS-09981 1 point (service) 2 points 3 points 1 point (service  matching) BS - 289...
Page 290: Roof Panel (Total Replacement)
Panel Replacement 11-38. Roof Panel (total replacement) A: REMOVAL • Overall view (model without Sunroof) BS-09982 1 point (top  1) 3 points (top  1) 8 points (top  1) 2 points (top  1) 7 points (top  1) 12 points (top ...
Page 291 Panel Replacement • Overall view (model with Sunroof) BS-09983 1 point (top  1) 2 points (top  2) 7 points (top  1) 2 points (top  1) 5 points (top  1) 8 points (top  1) BS - 291...
Page 292 Panel Replacement • Views A BS-09984 1 point (top  1) 3 points (top  1) 4 points (top  1) 2 points (outside  1 belt sander) BS - 292...
Page 293 Panel Replacement B: INSTALLATION • Overall view (model without Sunroof) (10) [f](6) [f](2) BS-09985 1 point (service) 8 points (service) 3 points 2 points (service) 12 points (service) (10) 4 points 3 points (service) 1 point 7 points (service) 2 points : Application of adhesive [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2...
Page 294 Panel Replacement • Overall view (model with Sunroof) [f](3) [f](4) [f](2) BS-09986 1 point (service) 7 points (service) 2 points 2 points (service) 8 points (service) 4 points 5 points (service) 1 point : Application of adhesive [f] Plug welding A Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW12, Gas: CO2 B Plug diameter: 8.5 mm (0.33 in) or more, Wire: YGW16, Gas: Gas mixture (argon: 80 %, CO2: 20 %) BS - 294...
Page 295 Panel Replacement • Views A BS-09987 1 point 2 points (service) 4 points 2 points 3 points BS - 295...
Page 296: T Stud Installation
Panel Replacement 11-39. T Stud Installation 78.4 148.9 139.1 269.5 270.6 169.3 267.5 (3.09) (5.86) (5.48) (10.61) (10.65) (6.67) (10.53) BRM00116 • T stud welding • T stud basic cross section (0.94) BRM00118 BS-05067  Arc welding for both plate ends Panel side outer 5.2 mm (0.20 in) hole...
Page 297: Body Sealing
Body Sealing 12.Body Sealing A: SPECIFICATIONS Used material: Three Bond 4101 (004403063) : Sealer application location : Sealer application location (Application of 50 m thick wax is allowable.) BRM00192 Front hood Rear door Rear gate Front door View A View B BRM00194 BRM00197 RHD models only...
Page 298 Body Sealing View C View D BRM00200 BRM00204 Wax is allowable Wax is allowable Only for models with increased anticorrosion protection RHD models only Only for models with increased anticorrosion protection View E View F BRM00214 BRM00209 Only for models with increased anticorrosion protection Wax is allowable Only for models with increased anticorrosion protection View G...
Page 299 Body Sealing View K View L BRM00230 BRM00232 View M View N BRM00235 BRM00234 (1) Do not block the water drain holes. View O View P BRM00236 BRM00237 (1) Do not block the water drain holes. (1) Do not block the water drain holes. CAUTION: Sealer has already been applied to hood, door and rear gate that are in replacement condition.
Page 300: Anticorrosion Wax
Anticorrosion Wax 13.Anticorrosion Wax A: SPECIFICATIONS Used material: Rust-stop aerosol (K0877YA015) : Application area • Door (Application thickness = 50 m or more) : (a) : (b) A – A BRM00122 Rust-stop aerosol To be filled into the plate joint Wax application work openings 10 mm (0.39 in) Adherence of mist is allowable...
Page 301 Anticorrosion Wax • Front door hinge upper side • Rear door hinge upper side (Application thickness = 15 m or more)  (Application thickness = 15 m or more) Apply to the contact surface (indicated area) on the body side in Apply to the contact surface (indicated area) on the body side in two locations on the left and right.
Page 302 Anticorrosion Wax • Overall view :(a) :(b) BRM00406 Rust-stop aerosol Rust-stop aerosol   (Application thickness = 15 m or (Application thickness = 50 m or more) more) The panel joints shall be covered The panel joints on the inside of the engine compartment shall be covered (Only for models with increased (Only for models with increased anticorrosion protection) anticorrosion protection)
Page 303 Anticorrosion Wax • View / Cross section  Enlarged view :(a) :(a) :(c) :(b) D – D BRM00407 Rust-stop aerosol To be filled into the plate joint  (Application thickness = 50 m or more) Securely cover the contact surface of the toe board, front suspension bracket(Sealing is allowable),Wrap the sealing and wax securely.
Page 304 Anticorrosion Wax :(a) :(a) F – F BRM00146  (a) Rust-stop aerosol (Application thickness = 50 m or more) BRM00147 (1) 20 mm (0.79 in) (Only for models with increased anticorro- sion protection) (2) Adherence of mist is allowable  (a) Rust-stop aerosol (Application thickness = 150 m or more)
Page 305 Anticorrosion Wax • Bottom view 1 (General rust-proofing model) :(a) :(b) BRM00130 Rust-stop aerosol Rust-stop aerosol   (Application thickness = 50 m or (Application thickness = 150 more) or more) Apply wax so that the suspension arm bush and exhaust pipe are not waxed. Sealing is allowable BS - 305...
Page 306 Anticorrosion Wax • Bottom view 2 (Models with increased anticorrosion protection) :(a) :(b) J J J BRM00131 Rust-stop aerosol Rust-stop aerosol Rust-stop aerosol    (Application thickness = 50 m or (Application thickness = 150 (Application thickness = 50 m or more) or more)
Page 307 Anticorrosion Wax :(a) BRM00134  (a) Rust-stop aerosol (Application thickness = 150 m or more) :(a) K – K BRM00135  (a) Rust-stop aerosol (Application thickness = 150 m or more) (1) If an air pocket occurs, completely cover the air pocket area. BS - 307...
Page 308 Anticorrosion Wax :(a) :(b) L – L BRM00136  (a) Rust-stop aerosol (Application thickness = 50 m or more)  (b) Rust-stop aerosol (Application thickness = 150 m or more) (1) 20 mm (0.79 in) (2) The wax application thickness should be 50 m or more BS - 308...
Page 309 Anticorrosion Wax :(a) M – M BRM00408  (a) Rust-stop aerosol (Application thickness = 50 m or more) :(a) N – N BRM00139  (a) Rust-stop aerosol (Application thickness = 50 m or more) BS - 309...
Page 310 Anticorrosion Wax :(a) O – O BRM00409  (a) Rust-stop aerosol (Application thickness = 50 m or more) (1) 20 mm (0.79 in) BS - 310...
Page 311 Anticorrosion Wax :(a) BRM00141  (a) Rust-stop aerosol (Application thickness = 150 m or more) (1) 20 mm (0.79 in) (2) 22 mm (0.87 in) BS - 311...
Page 312: Undercoat
Undercoat 14.Undercoat A: SPECIFICATIONS Repair material: PVC (NT guardcoat 5900FL) CAUTION: Be careful not to let the PVC be attached to any parts not indicated below and to the following loca- tions. • High-temperature parts related to the exhaust pipe •...
Page 313 Undercoat • Rear wheel apron side view : (a) BRM00151 300 m — 500 m 10 mm (0.39 in) BS - 313...
Page 314 Undercoat • Bottom view : (a) : (b) : (c) H H H J J J BRM00410 300 m — 500 m 200 m or more 600 m — 800 m Cover the plug with the PVC. View A Cross section B — B : (a) : (a) BRM00153...
Page 315 Undercoat View C Cross section D — D : (a) : (a) : (b) : (c) BRM00157 BRM00156 (a) 200 m or more (a) 300 m — 500 m (b) 300 m — 500 m (c) 600 m — 800 m (1) 10 mm (0.39 in) (Adherence of mist is allowable) (1) Cover the grommet seat with the PVC.
Page 316 Undercoat Cross section I — I View J : (a) : (a) BRM00163 (a) 300 m — 500 m BRM00164 (a) 300 m — 500 m BS - 316...
Page 317: Damping Seat
Damping Seat 15.Damping Seat A: SPECIFICATIONS CAUTION: • Use an adhesive agent to paste the silencer. Apply an adhesive agent to whole surface of the si- lencer. • When the silencer thickness does not meet the standard value, laminate the silencer until its thick- ness meets the standard.
Page 318 Damping Seat • Upper view 2 :(a) :(b) :(c) BRM00665 Thickness of the silencer:  Thickness of the silencer:  Thickness of the silencer:  3.0 mm (0.12 in) 4.5 mm (0.18 in) 5.5 mm (0.22 in) BS - 318...
Page 319: Insulator
Insulator 16.Insulator A: SPECIFICATIONS 1. UPPER VIEW : (a) BRM00166 View A View B : (a) : (a) BRM00168 BRM00463 Insulator BS - 319...
Page 320 Insulator 2. BOTTOM VIEW : (a) BRM00171 Insulator 3. FRONT HOOD : (a) BRM00172 Insulator BS - 320...
Page 321: Gauge Values For Fitting
Gauge Values for Fitting 17.Gauge Values for Fitting A: DIMENSIONS 1. FRONT HOOD EB-10449 Part Standard Panel COMPL front hood to Bumper face front 6.5+1.5 ,-1 mm (0.3+0.1,-0.04 in) Panel COMPL front hood to Light assembly head 4.51.7 mm (0.20.07 in) Panel COMPL front hood to Fender front 3.51 mm (0.10.04 in) Surface level gap: Panel COMPL front hood to Fender front...
Page 322 Gauge Values for Fitting 2. FRONT DOOR EB-10450 Part Standard Fender front to Panel COMPL door front 3.90.9 mm (0.150.04 in) Panel side outer to Molding door sash front 5+1.5,-1 mm (0.2+0.06, 0.04 in) *1 3.11.6 mm (0.120.06 in) Surface level gap: Panel side outer to Molding door sash front 3.61.6 mm (0.140.06 in) Cover B pillar assembly front to Cover B pillar assembly rear 5.51.5 mm (0.220.06 in)
Page 323 Gauge Values for Fitting 3. REAR DOOR EB-10455 Part Standard Panel COMPL door front to Panel COMPL door rear 41 mm (0.160.04 in) Cover B pillar assembly front to Cover B pillar assembly rear 5.51.5 mm (0.220.06 in) Panel side outer to Molding door sash rear 5+1.5,-1 mm (0.2+0.06, 0.04 in) 3.11.5 mm (0.120.06 in) Surface level gap: Panel side outer to Molding door sash rear...
Page 324 Gauge Values for Fitting 4. REAR GATE EB-10456 Part Standard Panel COMPL rear gate to Panel side outer 61 mm (0.240.04in) 0.5+0.5, -1.5 mm Surface level gap: Panel COMPL rear gate to Panel side outer (0.02+0.02, -0.06 in) Panel COMPL rear gate to Finisher assembly rear 1.51 mm (0.060.04 in) Panel COMPL rear gate to Bumper face rear 71.8 mm (0.280.07 in)
Page 325: Wheel Alignment Standard Values
Wheel Alignment Standard Values 18.Wheel Alignment Standard Values A: SPECIFICATION 1. FRONT ALIGNMENT (INSPECTION VALUE) Suspension height mm (in) 64 (2.52) +12 mm +0.47 in (Tolerance: –24 mm –0.94 in Camber (tolerance: 0°30 Differences between RH and LH: 35 or less) -0°05...
Page 326: Plastic Parts And Materials
Plastic Parts and Materials 19.Plastic Parts and Materials A: SPECIFICATIONS (27) (24) (18) (29) (20) (23) (17) (21) (10) (26) (30) (22) (11) (14) (32) (25) (15) (12) (13) (19) (31) (28) (16) BRM00672 BS - 326...
Page 327 Plastic Parts and Materials Headlight (LED) (12) Air flap rear (23) Rear mudguard Front fog light (13) Rear bumper (24) Roof rail Front bumper (14) Rear gate garnish (25) Side garnish Cowl panel (15) Ornament rear (26) Head light washer Front grill (16) Rear combination light...
Page 328 Plastic Parts and Materials Part name Material Lens Body PP-TD30 Extension A Extension B Reflector (turn light) PPS-MD20 Inner lens A Inner lens B SRH provided, model with Headlight (LED) Inner lens C Inner lens D Inner lens E PMMA Cover Base A Base B...
Page 329 Plastic Parts and Materials Part name Material Outer lens PMMA Reflex reflector Housing Rear fog light Inner lens Fog light LED socket Packing EPDM Molding DAM rubber EPDM Front window molding Seal upper side EPDM Seal A EPDM Body Unit bracket Cover stay A Cover stay B Packing stay...
Page 330 Plastic Parts and Materials Part name Material Outer lens PMMA Inner lens A Inner lens B PMMA (16) Rear combination light Turn light reflector Extension Housing Packing EPDM Frame handle bar, outer PA6-GF30 (17) Door handle Handle bar, outer PC+PBT-MD10 Cover handle bar, outer Molding Clip...
Page 331 Plastic Parts and Materials Part name Material Cylinder Piston Seal A EPDM Seal B EPDM Valve case Cap B Head light washer nozzle Check valve EPDM (26) Head light washer Nozzle holder Nozzle Bracket Spacer Hose S Joint Nozzle cover T joint Hose Assy Cord clamp...
Page 332: List Of Plastic Material Notations
List of Plastic Material Notations 20.List of Plastic Material Notations A: SPECIFICATIONS Notation Notation Material name Material name symbol symbol ABS resin Polyethylene (acrylonitrile/butadiene/styrene resin) Acrylonitrile/ethylene/styrene Polyethylene terephthalate Polyethylene terephthalate Acrylonitrile/strene/acrylate PET-GF45 (45 % glass fiber content) ELASTOMER Elastomer PMMA Polymethyl methacrylate Epoxy resin Polyacetal...

Subaru Forester 2019 Repair Manual

1 Foreword

2 Airbag Operating Instructions

3 Jack/Lift Points

4 Vehicle Identification

5 Assembly of Exterior Parts

6 Panel Components

7 Galvanized Sheet Metal

8 Body Construction

9 Body Reference Points

10 Measurement for Combined Parts

11 Panel Replacement

12 Body Sealing

13 Anticorrosion Wax

14 Undercoat

15 Damping Seat

16 Insulator

17 Gauge Values for Fitting

18 Wheel Alignment Standard Values

19 Plastic Parts and Materials

20 List of Plastic Material Notations

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