Escolar Documentos
Profissional Documentos
Cultura Documentos
1. Foreword
A: USE OF THIS MANUAL
This manual explains important points for removal and installation of parts per location.
1. ILLUSTRATION EXAMPLE
• Symbols and number of points indicate the welding method and the number of welding points.Text in
brackets indicate the direction of removal for welded parts, and numbers indicate the number of panels to be
drilled to remove welded sections of panels.
• Areas enclosed by a broken line indicates work from the opposite side (rear side).
• Always apply anticorrosion wax to the welding locations when replacing panels.
(1) (2)
(3)
(3)
(6)
(3)
G (5)
20
(4)
0m
(5)
m
F
(A)
E (B)
(3)
(3)
(7)
(8)
(1)
(9) (7)
(1)
a (2)
(1)
(1)
(3) D (1)
(8)
(5) C
A
(3)
(7)
(C)
(1) (2)
B (4)
b (2)
(1)
(4)
(5)
(5)
(1) Rough cutting (130 mm) (6) Rough cutting (170 mm) (11) 1 point (outside . 1), hidden hit point
(2) 2 points (outside . 1) (7) 5 points (outside . 1) (12) 9 points (outside . 1)
(3) 1 point (outside . 1) (8) 8 points (outside . 1) (13) 2 points (outside . 2)
(4) 3 points (outside . 1) (9) 12 points (outside . 1) (5)
(5) 4 points (outside . 1) (10) 1 point (outside . 2) (4)
(3)
· Rear quarter removal condition
· Detach the hidden hit point between the rear door catcher bracket and side sill reinforcement. (6)
· When replacing the D-pillar, there are two weld locations a and b (hidden hit point).
BS-00649
BS - 2
Foreword
2. REMOVAL DIRECTION
Areas are divided into four groups of inside, outside, top, and bottom, and these directions are defined as
shown in the following figure.
Outside
Inside
Outside Top Inside
Inside
Inside
Inside
Inside
Outside
Outside
Bottom
BS-00650
BS - 3
Foreword
Inside Outside
BS-00653
Inside Outside
(1)
(C) (D)
BS-00654
(C) (Inside 2)
(D) (Outside 2)
BS - 4
Foreword
5. MEANING OF SYMBOLS
• Cutting
BS-00352 BS-00267
• Spot welding
Two
overlapping
parts
BS-00655 BS-00656
Three
overlapping
parts
BS - 5
Foreword
• Brazing
BS-00667 BS-00668
BS - 6
Panel Components
2. Panel Components
A: COMPONENTS
1. TOE BOARD & FRONT PANEL
(4) (1)
(4)
(5) (2)
FRONT
(5)
(3)
BS-00669
BS - 7
Panel Components
(11)
(6)
(10)
(1) (9)
(8)
(2)
(10)
(7)
(3) (2)
FRONT
(9)
(4)
(5) (12)
(11)
(7)
BS-00670
(1) Upper frame (5) Lower frame B (9) Front wheel apron
(2) Radiator side panel (6) Front suspension bracket (10) Front wheel apron upper
(3) Hood lock stay (7) Closing plate (11) Side upper frame
(4) Lower frame A (8) Fender bracket (12) Gusset battery
BS - 8
Panel Components
(8) (10)
FRONT (9)
(1)
(8)
(2) (3)
(4)
(11)
(12)
(5) (9) (11)
(13)
(6)
(4)
(7)
(1)
(5) (2)
(7) (3)
(6)
BS-00671
(1) Front side frame front (6) Front plate (10) Front floor crossmember
(2) Tie-down hook (7) Front gusset C (11) Toe board crossmember side
(3) Bumper bracket front (8) Front side frame rear (12) Pitching stopper bracket
(4) Separator B (9) Toe board lower reinforcement (13) Toe board crossmember center
(5) Front gusset
BS - 9
Panel Components
(11)
(10)
(8)
(12)
(9)
(6)
(7)
FRONT (5)
(14)
(13)
(3)
(2) (10)
(6)
(1) (9) (11)
(5)
(8)
(3)
(4)
BS-00672
(1) Panel inner bracket (6) Front side frame rear (11) Side sill separator B
(2) Floor crossmember C (7) Front floor pan (12) Crossmember front seat rear
(3) Front side frame inner (8) Side sill inner (13) Crossmember front seat front
(4) Floor crossmember rear (9) Side sill inner front (14) H/B cable bracket
(5) Toe board upper reinforcement (10) Side sill separator A
BS - 10
Panel Components
(10)
(7) (11)
(8)
FRONT (6) (10)
(3)
(9)
(12)
(1) (6)
(2)
<A>
(15)
(4)
(3)
(13)
(5)
(2) (14)
(1)
(12)
<B>
BS-00673
(1) Closing plate (6) Rear floor side (11) Rear skirt
(2) Front closing plate (7) Spare tire bracket (12) Tractive plate
(3) Rear floor pan doubler front (8) Floor patch (13) Rear skirt inner
(4) NS (Rear floor pan front) (9) Rear floor pan rear (14) Bumper bracket
(5) NS (Crossmember A front) (10) Muffler bracket center (15) Rear skirt outer
BS - 11
Panel Components
FRONT
(4)
(1) (5)
(2)
(6)
(3) (4)
(2) (1)
(7)
(3)
BS-00674
(1) Rear floor side frame (4) Rear floor side frame rear (6) Crossmember B
(2) Rear damper bracket (5) Crossmember C (7) NS (Crossmember A rear)
(3) Side sill inner rear
BS - 12
Panel Components
7. ROOF
• Wagon
(2) (2)
FRONT
(1) (3)
(1) (3)
BS-00675
(1) Front roof rail (2) Rear roof rail (3) Roof panel
BS - 13
Panel Components
• Sedan
(2) (2)
FRONT
(1)
(1) (3)
(3)
BS-00676
(1) Front roof rail (2) Rear roof rail (3) Roof panel
BS - 14
Panel Components
8. SIDE PANEL
• Wagon
1) Inner panel
(1)
(9)
FRONT (8)
(2)
(7) (10)
(11)
(4)
(6)
(3)
(5)
BS-00677
(1) Side rail inner (5) Side sill reinforcement front (9) Rear quarter inner lower
(2) Front pillar inner upper (6) Side sill reinforcement rear (10) C-pillar reinforcement
(3) Cowl panel side (7) Center pillar inner (11) Rear arch inner
(4) Front pillar inner lower (8) Rear quarter inner
2) Outer panel
(6)
(7)
(3)
FRONT
(2)
(1)
(4)
(5)
BS-00678
(1) Front pillar outer (4) Center pillar outer (6) Rear quarter end
(2) Side rail outer (5) Side sill outer (7) Rear quarter outer
(3) Drip rail
BS - 15
Panel Components
• Sedan
1) Inner panel
(8)
(1)
FRONT
(2) (7)
(10)
(9)
(11)
(3) (6)
(5)
(4)
BS-00679
(1) Side rail inner (5) Side sill reinforcement front (9) Rear quarter inner
(2) Front pillar inner upper (6) Side sill reinforcement rear (10) Rear pillar reinforcement
(3) Cowl panel side (7) Center pillar inner (11) Rear arch inner
(4) Front pillar inner lower (8) Rear panel
2) Outer panel
(2) (7)
(3) (6)
FRONT
(1)
(4)
(5)
BS-00680
(1) Front pillar outer (4) Center pillar outer (6) Rear quarter end
(2) Side rail outer (5) Side sill outer (7) Rear quarter outer
(3) Drip rail
BS - 16
Galvanized Sheet Metal
(1)
(2)
BS-02639
(1) Galvanized on both sides (2) Only for the OUTBACK hood,
steel sheet galvanized on both
sides is used
BS - 17
Aluminium Sheet Metal
(1)
BS-02640
BS - 18
Body Construction
5. Body Construction
A: SPECIFICATION
• Wagon / sedan common parts
F N
J N O
J O
K
F
K M
M
G L
G L
E
D
C H
I
E H
CD
I
B
A
A
B
BS-00681
BS - 19
Body Construction
(2) (3)
(2)
BS-00682
(1) Radiator lower frame A
(2) Radiator lower frame B
Cross section C — C
(1) (4)
(2) (5)
(3)
(4)
BS-00683
(1) Front gusset front A
BS-00684 (2) Front side frame front
(1) Front wheel apron (3) Hook reinforcement
(2) Front side frame front (4) Bumper bracket
(3) Closing plate (5) Radiator lower frame B
(4) Frame inner reinforcement A
Cross section D — D Cross section E — E
(1)
(1)
(2)
(4) (2)
(3)
(3)
(5)
(6)
BS-00685 BS-00686
(1) Front wheel apron (1) Cover toe board
(2) Front suspension lower reinforcement (2) Toe board
(3) Front suspension lower bracket (3) Toe board center crossmember
(4) Frame inner reinforcement A
(5) Front side frame front
(6) Closing plate
BS - 20
Body Construction
(3)
(4)
(3)
BS-00687 BS-00688
(1) Side rail outer (1) Front pillar inner doubler
(2) Roof panel (2) Front pillar outer
(3) Side rail inner (3) Front pillar inner upper
(4) Drip rail
Cross section H — H Cross section I — I
(1)
(1)
(2)
(2)
(3)
(3)
BS-00689 (4) BS-00690
(1) Front pillar inner lower (1) Side sill reinforcement
(2) Front pillar outer reinforcement (2) Side sill inner front
(3) Front pillar outer (3) Front floor pan
(4) Side sill outer
Cross section J — J Cross section K — K
(1)
(1) (2)
(2)
(3)
BS-00691 BS-00692
(1) Roof panel (1) Center pillar inner
(2) Sunroof frame front (2) Center pillar reinforcement
(3) Center pillar outer
BS - 21
Body Construction
(2)
(3)
BS-00693 BS-00694
(1) Center pillar inner (1) Rear wheel apron
(2) Center pillar reinforcement (2) Rear arch inner
(3) Center pillar outer (3) Rear quarter panel outer
Cross section N — N Cross section O — O
(3)
(2) (4)
BS-00695 BS-00696
(1) Rear quarter panel inner A (1) Rear wheel apron reinforcement
(2) Rear quarter panel outer (2) Rear quarter panel inner A
(3) Rear quarter panel outer
(4) C-pillar reinforcement
Cross section P — P
(2)
(1)
(3)
BS-00697
(1) Rear quarter panel inner B
(2) D-pillar reinforcement
(3) Rear quarter panel outer
BS - 22
Body Construction
• Sedan-only parts
S
Q
S
Q
R
R
BS-00698
BS - 23
Body Construction
(2)
(3)
(4)
(2)
BS-00699 BS-00700
(1) Side rail outer (1) Rear pillar inner
(2) Roof panel (2) Rear quarter panel outer
(3) Side rail inner
(4) Drip rail
Cross section S — S
(1)
(2)
BS-00701
(1) Rear pillar inner
(2) Rear quarter panel outer
BS - 24
Gauge Values for Fitting
(A)
(D)
(B) (C)
(1)
(2)
(6)
(4)
(5) (4) (8)
(7)
(D) (E),(F) (G)
EB-00176
(1) Front hood panel (4) Rear door panel (7) Side sill
(2) Front fender panel (5) Rear quarter panel (8) Rear quarter lower protector
(3) Front door panel (6) Door panel
BS - 25
Gauge Values for Fitting
2. FRONT
(2)
(C) (E)
(A) (B)
(D)
(1)
(A)
(3)
(3)
C2
C1
(1) (4) (C)
(B)
(5)
(4) (1)
(1) Front bumper (3) Front hood panel (5) Front fender panel
(2) Front grille (4) Headlight
BS - 26
Gauge Values for Fitting
(6)
(F)
(D)
(C) (G)
(B)
(A)
(E)
(3)
(A)
F2
(4)
(2)
(6) (2) (5)
(1)
(B) (C)
F1
(4)
(4)
(1) (F)
(4)
(4) (5) (4)
(3)
G1 G2
(D) (E) (G)
EB-00178
(1) Trunk lid panel (3) Rear bumper (5) Fuel filler flap lid
(2) Rear combination light (4) Rear fender panel (6) Trunk lid garnish
BS - 27
Gauge Values for Fitting
(E) (1)
(5)
(D)
(C)
(G)
(H)
(B)
(3)
(A) (F) (2)
(A) (C)
G2
(7)
(6)
(3)
(5)
(8)
(1) G1
(D)
(B)
(7)
(7)
(G)
(9)
(4)
H1 H2
EB-00179
(1) Rear gate panel (4) Roof panel (7) Rear fender panel
(2) Rear bumper (5) Rear gate glass (8) Fuel filler flap lid
(3) Rear combination light (6) Rear quarter glass (9) Roof spoiler
BS - 28
Plastic Parts and Materials
(8)
(23)
(6) (7)
(5)
(14)
(15)(16)
(12) (11)
(13)
(22)
(1) (21)
(3) (4)
(2)
(17) (18)
(19) (20) (24)
(29)
(25)
(26) (30)
(27)
(28)
BS-01497
BS - 29
Plastic Parts and Materials
BS - 30
Plastic Parts and Materials
• Sedan-only parts
No. Part name Material
(25) Trunk garnish PC + PET
Lens PMMA
(26) License light
Housing ASA
Face PP
(27) Rear bumper
EA form Foamed PP
Lens PMMA
Inner lens PC
(28) Rear combination light Housing ASA
Reflex reflector PMMA
Cover ASA
(29) Rear window molding PVC
(30) Six light molding ABS
Lens PC
High mount stop light Case PP
Reflector PBT + PET
BS - 31
List of Plastic Material Notations
BS - 32
Body Sealing
9. Body Sealing
A: SPECIFICATION
Used material: Three Bond 4101 (004403063)
: Sealer application location
• Common parts for wagon and sedan
(2)
I
H
Y
P
O
(1)
J
D
N
C
E K
L T
M U
V
X
G
A R
B
F W
Q
S
(3)
(4)
BS-00731
BS - 33
Body Sealing
View A View B
Ft
Ft
BS-00732 BS-00733
View C View D
Ft
Ft
BS-00734 BS-00735
View E View F
Ft
Ft
BS-00736 BS-00737
View G View H
Ft
Ft
BS-00738 BS-00739
BS - 34
Body Sealing
View I View J
Ft
Ft
BS-00740 BS-00741
View K View L
Ft
Ft
BS-00742 BS-00743
View M View N
Ft
Ft
BS-00744 BS-00745
View O View P
Ft
Ft
BS-00746 BS-00747
BS - 35
Body Sealing
View Q View R
Ft
Ft
BS-00748 BS-00749
View S View T
Ft
Ft
BS-00750 BS-00751
View U
Ft
BS-00752
BS - 36
Body Sealing
View V View W
(1)
BS-00754
(1) Do not block the water drain holes.
View X
(1)
(2)
(2)
(1) BS-02513
(1) Application not required.
(2) 40 mm (1.57 in)
BS-00755
(1) Do not block the water drain holes.
View Y
BS-00756
CAUTION:
Sealer already has been applied to hood, door and rear gate in replacement condition.
BS - 37
Body Sealing
• Sedan-only parts
GG
(1)
HH
CC
DD
AA
EE
FF
BB
BS-00757
(1) Trunk
BS - 38
Body Sealing
View AA View BB
Ft
Ft
BS-00758 BS-00759
View CC View DD
Ft
Ft
BS-00760 BS-00761
View EE View FF
Ft
Ft
BS-00762 BS-00763
View GG
View HH
(1)
(2) BS-00764
(1) Block the holes.
(2) Do not block the water drain holes.
CAUTION:
Sealer already has been applied to trunk in replacement condition.
BS - 39
Anticorrosion Wax
10.Anticorrosion Wax
A: SPECIFICATION
Used material:
Rust-stop aerosol (K0877YA015)
• Front hood
:(a)
:(b)
(2)
(1)
A-A
BS-02514
:(a)
:(b)
(1) (1)
B B
(2) (4)
B B (3) (2)
B-B
BS-02515
(1) Wax application work openings (3) 50 mm (1.97 in) (4) 90 mm (3.54 in)
(2) 10 mm (0.39 in)
BS - 40
Anticorrosion Wax
• Rear gate
:(a)
:(b)
(1)
C (2)
(2) (3)
C-C
BS-02516
(1) Wax application work openings (2) 10 mm (0.39 in) (3) 40 mm (1.57 in)
• Trunk
:(a)
:(b)
(1)
D
(3)
D (2)
(2)
D-D
BS-02517
(1) Wax application work openings (2) 10 mm (0.39 in) (3) 40 mm (1.57 in)
BS - 41
Anticorrosion Wax
:(a)
BS-02518
• Door hinge
Apply to the installation outer circumference at two
locations at the top and bottom (eight locations in
all).
:(a)
BS-02519
:(a)
BS-02520
BS - 42
Anticorrosion Wax
• Overall view
B A
(A) (B)
F
(1)
(C)
(2) (3)
(4)
(5) (5)
BS-02521
(1) Apply to the mating surface (2) Closing plate (4) Reinforcement
between the front suspension (3) Front side frame front (5) 10 mm (0.39 in)
bracket and duct. (15 Pm or more)
BS - 43
Undercoat
11.Undercoat
A: SPECIFICATION
Repair material:
THREE BOND 6115
1) Application thickness is 0.4 mm or more.
2) Be careful that the undercoat does not become attached to locations other than where indicated in the fig-
ure, and on the following locations.
• High-temperature parts related to the exhaust pipe
• Hoses, tubes, and harness parts
• Installation surfaces of rear suspension, transmission, subframe etc.
3) Application area
and : Undercoat application location
• Side view
:(a)
A
E
B
D
B
A
C
BS-01507
BS - 44
Undercoat
• Bottom view/1
:(a)
:(b)
F
I
H I J
G
G J
H
(1)
BS-02638
(1) Undercoat is not required in this (a), (b) Undercoat application location
area for vehicles equipped with an
undercover.
:(a) :(a)
BS-01429 BS-01430
View C View D
:(a)
Ft
BS-01431 BS-02523
BS - 45
Undercoat
Ft
BS-02524 BS-02525
Cross section G — G (rotated 90q) Cross section C — C (rotated 90q)
:(a) :(a)
BS-01432 BS-01433
Cross section I — I Cross section J — J (rotated 90q)
:(a) :(a)
BS-01512 BS-01434
BS - 46
Body Reference Points
(C)
(17)
(B)
(55)
(102) (103)
(81) (101) (104)
(80) (82) (99) (100)
(93)
(84) (89) (88) (90) (92) (94) (97) (98)
(A)
(85) (86)
(93)
(90) (94)
(82) (84)
(89)
(98)
(80) (81)
(88) (104)
BS-01530
• Diagonal dimensions are the actual dimensions between reference points. The values in brackets are
projected dimensions for reference.
BS - 47
Body Reference Points
CAUTION:
For reference point 17 strut mount mounting hole (symmetrical), refer to the "Datum dimension". (Re-
fer to the figure "FRONT STRUCTURE, DIMENSIONS, Body Reference Points" on page 51.)
For reference point 55 rear suspension mounting hole (symmetrical), refer to the "Datum dimen-
sion". (Refer to the figure "INSIDE, DIMENSIONS, Body Reference Points" on page 54.)
(A) Standard line (B) Side sill (C) Upper face
(80) Gauge hole (symmetrical) (89) Transmission crossmember (97) Fuel protector mounting hole
(81) Front crossmember mounting hole mounting hole (symmetrical) (symmetrical)
(symmetrical), lower face rear (90) Gauge hole (symmetrical) (98) Trailing arm mounting hole
(82) Strut mount mouning hole (91) Under cover mounting hole (symmetrical)
(symmetrical) (symmetrical) (99) Trailing arm mounting hole
(83) Strut mount mounting hole (92) Under cover mounting hole (symmetrical)
(symmetrical) (symmetrical) (100) Rear suspension crossmember
(84) Strut mount mounting hole (93) Center bearing mounting hole mounting hole (symmetrical)
(symmetrical) (symmetrical) (101) Canister hose mounting hole
(85) Transmission crossmember (94) Exhaust cover mounting hole (symmetrical)
mounting hole (symmetrical) (symmetrical) (102) Rear suspension crossmember
(86) Drain hose mounting hole (95) Weight reduction hole mounting hole (symmetrical)
(symmetrical) (symmetrical) (103) Gauge hole (symmetrical)
(87) Under cover mounting hole (96) Under cover mounting hole (104) Weight reduction hole
(symmetrical) (symmetrical) (symmetrical)
(88) Under cover mounting hole
(symmetrical)
BS - 48
Body Reference Points
Measurement point Datum dimension mm (in) Measurement point Datum dimension mm (in)
Datum line — (80) 198 (7.80) (94) RH — (94) LH 343 (13.50)
Datum line — (81) 212 (8.35) (95) RH — (95) LH 796 (31.34)
Datum line — (82) 77 (3.03) (96) RH — (96) LH 1,382 (54.51)
Datum line — (84) 17(0.07) (97) RH — (97) LH 1,200 (47.24)
(4AT, MT) 35 (1.38) (98) RH — (98) LH 1,163 (45.49)
Datum line — (89)
(5AT) 56 (2.20) (99) RH — (99) LH 1,115 (43.90)
Datum line — (90) 18 (0.71) (100) RH — (100) LH 930 (36.61)
Datum line — (94) 9 (0.35) (101) RH — (101) LH 856 (33.70)
Datum line — (98) 75 (2.95) (102) RH — (102) LH 970 (38.19)
Datum line — (100) 164 (6.46) (103) RH — (103) LH 836 (32.91)
Datum line — (102) 243 (9.57) (104) RH — (104) LH 814 (32.05)
Datum line — (103) 255 (10.04) Height 86 (3.39),
(85)
Datum line — (104) 241 (9.49) Width 620 (24.41)
(17) — (80) 439 (17.28) Height 117 (4.61),
(86)
(17) — (84) 423 (16.65) Width 600 (23.62)
(80) — (81) 408 (16.06)
(80) — (84) 862 (33.94) Datum dimension/pro-
(81) — (84) 454 (17.87) Measurement point jected reference dimen-
sions mm (in)
(82) — (84) 104 (4.09)
(80) RH — (82) LH 1,135 (44.68)/1,128 (44.41)
(84) — (88) 335 (13.19)
(80) LH — (81) RH 973 (38.31)/973 (38.31)
(4AT, MT) 257 (10.12)
(84) — (89) (81) RH — (82) LH 877 (34.53)/867 (34.13)
(5AT) 357 (14.06)
(88) — (92) 503 (19.80) (82) LH — (88) LH 894 (35.20)/889 (35.00)
(89) — (90) 302 (11.89) (88) RH — (92) LH 943 (37.13)/943 (37.13)
(90) — (94) 363 (14.29) (88) RH — (95) LH 1,251 (49.25)/1,251 (49.25)
(92) — (98) 887 (34.92) (92) LH — (98) RH 1,325 (52.17)/1,321 (52.01)
(93) — (94) 68 (2.68) (95) LH — (98) RH 1,072 (42.20)/1,069 (42.09)
(97) — (98) 215 (8.46) (98) RH — (100) LH 1,101 (43.35)/1,097 (43.19)
(98) — (99) 152 (5.98) (98) RH — (102) LH 1,335 (52.56)/1,325 (52.17)
(98) — (100) 329 (12.95) (100) LH — (104) RH 1,305 (51.38)/1,303 (51.30)
(99) — (100) 177 (6.97) (102) LH — (104) RH 1,028 (40.47)/1,028 (40.47)
(100) — (55) 149 (5.87)
(100) — (102) 457 (17.99)
(101) — (102) 123 (4.84)
(102) — (103) 157 (6.18)
(102) — (104) 511 (20.12)
(103) — (104) 354 (13.94)
(80) RH — (80) LH 926 (36.46)
(81) RH — (81) LH 840 (33.07)
(82) RH — (82) LH 746 (29.37)
(83) RH — (83) LH 968 (38.11)
(84) RH — (84) LH 756 (29.76)
(87) RH — (87) LH 1,382 (54.41)
(87) — (91) 510 (20.08)
(88) RH — (88) LH 800 (31.50)
(4AT, MT) 529 (20.83)
(89) RH — (89) LH
(5AT) 433 (17.05)
(90) RH — (90) LH 396 (15.59)
(91) RH — (91) LH 1,382 (54.41)
(91) — (96) 510 (20.08)
(92) RH — (92) LH 796 (31.34)
(93) RH — (93) LH 200 (7.87)
BS - 49
Body Reference Points
(82)
(83)
Ft
(80)
(86)
(85)
(81) (105)
Ft
(85)
(84)
BS-02526 BS-02527
Ft
Ft
(87) (89)
(88)
(90)
(91)
(92)
BS-02528 BS-02529
Ft
Ft
(93)
(96)
(95)
(94)
(97)
BS-02530 BS-02531
(99)
(102) Ft
(98) (103)
Ft (104)
(101)
(100)
BS-02532 BS-02533
CAUTION:
For reference point (17) strut mount mounting hole (symmetrical), refer to the "Body Reference
Points". (Refer to the figure "FRONT STRUCTURE, DIMENSIONS, Body Reference Points" on page
51.)
For reference point (55) rear suspension mounting hole (symmetrical), refer to the "Body Reference
Points". (Refer to the figure "INSIDE, DIMENSIONS, Body Reference Points" on page 54.)
BS - 50
Body Reference Points
2. FRONT STRUCTURE
• Common for wagon, sedan
(12)
(13)
(14)
(11)
(4)
(15)
(12)
(18) (13)
(14)
(15)
(10)
(16)
(17)
(20)
(3)
(2) (4) (18)
(1)
(5)
(6) (23)
(8) (7)
(19)
(5)
(9)
(6)
(7)
(8)
(9)
BS-01531
(1) Repair locator hole (body center) (9) Bumper beam mounting hole (16) Strut mount mounting hole
(2) Radiator mounting hole (symmetrical), lower (symmetrical), rear inside
(3) Headlight mounting hole (10) Cowl panel mounting hole (body (17) Strut mount mounting hole
(symmetrical) center) (symmetrical), front
(4) Reinforcement fender mounting (11) Fender mounting hole (18) Fender mounting hole
hole (symmetrical) (symmetrical) (symmetrical)
(5) A/C condenser mounting hole (12) Locator hole (symmetrical) (19) Fender mounting hole
(symmetrical) (13) Hood hinge mounting hole (symmetrical)
(6) Beam corner side mounting hole (symmetrical), front (20) Fender mounting hole
(symmetrical) (14) Fender extension mounting hole (symmetrical)
(7) Heat insulation cover mounting (symmetrical) (23) Fender mounting hole
hole (symmetrical) (15) Strut mount mounting hole (symmetrical)
(8) Bumper beam mounting hole (symmetrical), rear outside
(symmetrical), upper
BS - 51
Body Reference Points
BS - 52
Body Reference Points
Ft
(19)
BS-02534 BS-02535
(5)
(6) (8)
(10)
Ft
Ft
(7)
(9)
BS-02536 BS-02537
(11)
(15) (16)
(12) (14)
Ft
(17)
Ft
(13)
(18)
BS-02538 BS-02539
(20)
Ft
Ft
(23)
BS-02540 BS-02541
BS - 53
Body Reference Points
3. INSIDE
• Common for wagon and sedan, 1
(36)
(26)
(35)
(27)
(36)
(28)
(29)
(27) (37)
(20)
(28) (30)
(21) (31)
(22)
(23)
BS-01413
(20) Fender mounting hole (27) Weatherstrip mounting hole (31) Gauge hole (symmetrical)
(symmetrical) (symmetrical) (35) Weatherstrip mounting hole
(21) Front door hinge upper mounting (28) Front door striker mounting hole (symmetrical)
hole (symmetrical), upper side (symmetrical) (36) Rear door striker mounting hole
(22) Front door hinge lower mounting (29) Rear door hinge upper mounting (symmetrical)
hole (symmetrical), upper side hole (symmetrical) (37) Protector mounting hole
(23) Fender mounting hole (30) Rear door hinge lower mounting hole (symmetrical)
(symmetrical) (symmetrical)
(26) Gauge hole (symmetrical)
BS - 54
Body Reference Points
20
21 22
Ft
Ft
23
BS-00808 BS-00809
27 26
29
Ft
28
31 30 Ft
BS-00810 BS-00811
35
37
Ft
36
Ft
BS-00812 BS-00813
BS - 55
Body Reference Points
(24)
(25)
(33)
BS-01414
(24) Weatherstrip mounting hole (43) Harness clip mounting hole (50) Side sill cover mounting hole
(symmetrical) (symmetrical) (symmetrical)
(25) Front door checker mounting hole (45) Trim clip mounting hole (51) Gauge hole (symmetrical)
(symmetrical) (symmetrical) Trim clip mounting hole
(32) Weatherstrip mounting hole (46) Trim clip mounting hole (52) (symmetrical)
(symmetrical) (symmetrical) (65) Airbag unit mounting hole
(33) Rear door checker mounting hole (47) Harness clip mounting hole (body center)
(symmetrical) (symmetrical) (66) Hand brake mounting hole (body
(41) Side sill cover mounting hole (48) Harness clip mounting hole center)
(symmetrical) (symmetrical) (67) Floor mat mounting hole (body
(42) Harness clip mounting hole center)
(symmetrical)
BS - 56
Body Reference Points
Unit: mm
Measurement point Datum dimension Measurement point Datum dimension
24 — 24 1482 43 — 43 1373
25 — 25 1476 43 — 66 693
32 — 32 1448 45 — 52 838
33 — 33 1464 47 — 51 740
41 — 46 863 48 — 67 711
42 — 42 1373 49 — 67 649
42 — 65 706 50 — 67 704
NOTE:
• The reference points 65, 66 and 67 are at the body center, while the other points are left-right symmetrical.
• The dimensions are the actual dimensions between the reference points.
24
41
Ft
42
Ft
25
BS-00815 BS-00816
45
Ft
Ft
32
33 46
47
48
43
BS-00817 BS-00818
65
66
Ft
67
Ft
BS-00819 BS-00820
BS - 57
Body Reference Points
51
50
Ft
49
Ft
BS-00821 BS-00822
52
Ft
BS-00823
BS - 58
Body Reference Points
(38)
(39)
(40) (44)
(48)
(45) (49)
(50)
(57)
(56)
(55)
(48)
(49)
(50) (57) (60)
(56) (58)
(61)
(60)
(55) (58)
(61)
BS-01532
(38) Trim clip mounting hole (48) Harness clip mounting hole (56) Rear suspension mounting hole
(symmetrical) (symmetrical) (symmetrical), front
(39) ED hole (symmetrical) (49) Harness clip mounting hole (57) Rear seat hinge mounting hole
(40) Hood lock lever area stop hole (symmetrical) (symmetrical)
(symmetrical) (50) Side sill cover mounting hole (58) Gauge hole (symmetrical)
(44) Trim clip mounting hole (symmetrical) (60) Gauge hole (symmetrical)
(symmetrical) (55) Rear suspension mounting hole (61) Gauge hole (symmetrical)
(45) Trim clip mounting hole (symmetrical), rear
(symmetrical)
Measurement point Datum dimension mm (in) Measurement point Datum dimension mm (in)
(38) — (44) 586 (23.07) (55) — (55) 1,084 (42.68)
(39) — (45) 993 (39.09) (56) — (56) 1,090 (42.91)
(40) — (45) 1,043 (41.06) (57) — (57) 886 (34.88)
(48) — (48) 1,380 (54.33) (58) — (58) 820 (32.28)
(49) — (49) 1,280 (50.39) (60) — (60) 820 (32.28)
(50) — (50) 1,294 (50.94) (61) — (61) 840 (33.07)
BS - 59
Body Reference Points
NOTE:
• All reference points are left-right symmetrical.
• The dimensions are the actual dimensions between the reference points.
38 40
Ft
Ft
39
BS-00825 BS-00826
45
Ft
44 48
Ft
BS-00827 BS-00828
Ft
50
55
56
57
49 58
Ft
BS-00829 BS-01521
61
60
Ft
BS-00831
BS - 60
Body Reference Points
4. REAR S906337a1404
• Wagon only
(64)
(63) (44)
(64)
(62) (53)
(54)
(34)
(26)
(58)
(71)
(72)
(68)
(69) (74)
(70) (73)
(71)
(75)
(72)
(74)
(73)
(75)
BS-01534
(26) Gauge hole (symmetrical) (63) Trim clip mounting hole (71) Combination light mounting hole
(34) Rear quarter glass mounting hole (symmetrical) (symmetrical)
(symmetrical) (64) Harness clip mounting hole (72) Buffer mounting hole
(44) Trim clip mounting hole (symmetrical) (symmetrical)
(symmetrical) (68) Trim clip mounting hole (73) Bumper mounting hole
(53) Trim clip mounting hole (symmetrical) (symmetrical)
(symmetrical) (69) Trim clip mounting hole (74) Bracket corner mounting hole
(54) Rear seat striker mounting hole (symmetrical) (symmetrical)
(symmetrical) (70) Repair locator hole (body center) (75) Gauge hole (symmetrical)
(58) Gauge hole (symmetrical)
(62) Trim clip mounting hole
(symmetrical)
BS - 61
Body Reference Points
34
26
Ft
44
53 Ft
BS-00833 BS-00834
54 64
Ft
Ft
BS-00835 BS-00836
BS - 62
Body Reference Points
63
Ft
62
Ft
58
BS-00837 BS-01522
71
Ft
72
70 74 73
69
Ft
68
75
BS-00839 BS-00840
BS - 63
Body Reference Points
• Sedan only
(44)
(45) (121)
(26) (122)
(125)
(126)
(123) (124)
(120)
(124) (125)
(58)
(123)
(126)
(129)
(128)
(127) (130)
(131)
(129)
(130)
(131)
BS-01536
(26) Gauge hole (symmetrical) (122) Trim clip mounting hole (127) Trim clip mounting hole
(44) Trim clip mounting hole (symmetrical) (symmetrical)
(symmetrical) (123) Sunroof drain hose (128) ED hole (symmetrical)
(45) Trim clip mounting hole clip mounting hole (symmetrical) (129) Combination light mounting hole
(symmetrical) (124) Trim clip mounting hole (symmetrical)
(58) Gauge hole (symmetrical) (symmetrical) (130) Bumper bracket mounting hole
(120) Six light glass mounting hole (125) Harness clip mounting hole (symmetrical)
(symmetrical) (symmetrical) (131) ED hole (symmetrical)
(121) Trim clip mounting hole (126) Gauge hole (symmetrical)
(symmetrical)
BS - 64
Body Reference Points
26
120
44
Ft
Ft
45
BS-00842 BS-00843
124
Ft
123
121
Ft
125
122 126
BS-00844 BS-00845
129
Ft
Ft
58
130
127
128 131
BS-01523 BS-00847
BS - 65
Body Reference Points
5. SUSPENSION MOUNT
(B)
(A)
(C)
(C)
(102)
(100)
(105) (81)
(105)(81)
(100) (102)
BS-01418
(81) Front crossmember mounting hole (102) Rear suspension crossmember (105) Front crossmember mounting hole
(symmetrical), rear mounting hole (symmetrical) (symmetrical), front
(100) Rear suspension crossmember
mounting hole (symmetrical)
BS - 66
Body Reference Points
BS - 67
Radiator Panel (total replacement)
(1) ★ (3)
(1)
(1)
(2)
A (2)
E
(3)
D
(7)
(6)
(7)
(6) (4)
C ★ (5)
BS-00850
(1) 2 points (outside 1) (4) Rough cutting (140 mm) to make (6) Rough cutting (190 mm) to make
(2) Rough cutting (80 mm) to make removal easier removal easier
removal easier (5) 2 points (top 1, bottom 1) (7) 1 point (outside 1)
(3) 1 point (top 1)
NOTE:
For locations marked by ★, the welding method, the number of welding points, and the rough cutting dimen-
sions are the same on the left and the right.
BS - 68
Radiator Panel (total replacement)
• Views
(1)
(2)
(2)
(1)
(3)
A
(4)
★ (5) B
★ (6)
★ (7)
★ (6) D
★ (5) C
(1)
(3)
(4)
E BS-00851
(1) 1 point (top 1) (4) 2 points (top 1, bottom 1) (6) 1 point (bottom 1)
(2) 1 point (inside 1) (5) 2 points (bottom 1) (7) 2 points (outside 1)
(3) 3 points (top 1, bottom 1)
BS - 69
Radiator Panel (total replacement)
B: INSTALLATION
• Overall view
(1)
★ (1)
A ★ (2)
(1)
(3)
★ (7)
(4)
E
D
(5)
(4)
(3)
★ (8) (5)
C ★ (6)
BS-00852
For locations marked by ★, the welding method, the number of welding points, and the dimensions are the
same on the left and the right.
BS - 70
Radiator Panel (total replacement)
• Views
★ (1)
★ (1)
★ (2)
(1)
(3)
A (2)
B
★ (3)
★ (4)
★ (2)
★ (4)
★ (3) D
C
(5)
(6)
(2)
E BS-00853
BS - 71
Radiator Panel (partial replacement)
30 mm
C
(1)
A (2)
BS-00854
BS - 72
Radiator Panel (partial replacement)
• Views
(1)
10 mm
(2)
(3)
A B
20 mm
C (4)
BS-00855
(1) Rough cutting (80 mm) to make (2) Rough cutting (4) Rough cutting (110 mm) to make
removal easier (3) 2 points removal easier
BS - 73
Radiator Panel (partial replacement)
B: INSTALLATION
• Overall view
A (1)
BS-00856
(1) 4 points
BS - 74
Radiator Panel (partial replacement)
• Views
∗ (1)
45 mm
15 mm
(2)
∗ (3)
A B
10 mm
C ∗ (4)
BS-00857
(1) 1 point (both face plug) (80 mm) (3) 1 point (180 mm) (4) 1 point (110 mm)
(2) 3 points
For continuous welds marked by *, apply anticorrosion wax thoroughly on the reverse side.
BS - 75
Front Wheel Apron (total replacement)
(5)
(3)
F E
(2)
(4)
(1)
(6)
(5)
(7)
(2)
B C D
(5)
(1)
(1)
(8) (2)
(2) (8)
BS-00858
BS - 76
Front Wheel Apron (total replacement)
• Views 1
(2)
(2) (2)
A (1) B
(3)
(2)
(2)
BS-00859
(1) 4 points (outside 1, belt sander) (2) 2 points (outside 1) (3) 1 point (outside 1)
BS - 77
Front Wheel Apron (total replacement)
• Views 2
(1)
(2)
(3) (4)
D E
(12)
(7)
(7)
(8)
(11)
(9)
(13)
(7) (10)
(6)
BS-00860
(1) 2 points (inside 2, belt sander) (6) 3 points (top 1) (10) 2 points (top 1)
(2) 3 points (outside 2) (7) 1 point (top 1) (11) 3 points (top 2)
(3) 1 point (outside 1) (8) 2 point plug weld (12) 2 points (top 2)
(4) 4 points (bottom 1) (9) 1 point (top 2) (13) Rough cutting
(5) 1 point (inside 1, belt sander)
★ hidden hit point
CAUTION:
When rough cutting, be careful not to damage the duct in the front panel and the closing plate.
BS - 78
Front Wheel Apron (total replacement)
B: INSTALLATION
• Overall view
(4)
(2) G
F
(2)
H (3)
(1) J
(5)
(4)
D (6)
(2)
B C E
(4)
(1)
(1)
(7) (2)
(2) (7)
BS-00861
BS - 79
Front Wheel Apron (total replacement)
• Views 1
(10) (1)
(1)
(3)
(2)
(1)
(4)
(1)
(5) (1)
B
(6)
(4) (1)
(7)
A
(6)
(1)
(1)
(1) (1)
D
C
(8) (9) (1)
E BS-00862
BS - 80
Front Wheel Apron (total replacement)
• Views 2
(5) (3)
(4)
(3)
(1) (3)
(3)
(2)
(3) (4)
(2)
(4)
(3) (2)
F G
(6) (8)
(7)
(3)
(4)
(7)
(5)
H J
BS-00863
BS - 81
Closing Plate (partial replacement)
(3)
(6)
(3) (4)
40 mm
(5)
(1)
∗a (3)
∗a (7)
(2)
(1)
(4)
(3)
(6)
(3)
(1)
(3) 40 mm
(5)
(RH)
BS-00864
(1) 1 point (outside 2) (4) Closing plate cut position (160 (6) 3 points (outside 1)
(2) 4 points (outside 1) mm) for butt welding (7) 2 points (outside 1)
(3) 1 point (outside 1) (5) 5 points (outside 1)
For locations marked by a, lift a part of the front wheel apron to make it easier to cut the closing plate.
BS - 82
Closing Plate (partial replacement)
B: INSTALLATION
(1)
(2) (3)
(3)
(6)
(3)
∗ (4)
40 mm
(5)
(1)
∗ a (7)
∗ a (8)
(2)
(1)
∗ (4)
(3)
(6)
(3)
(1)
(3)
40 mm
(5)
(RH)
BS-00865
(1) 1 point (service matching) (4) 1 point (160 mm) (7) 1 point
(2) 4 points (5) 5 points (8) 2 points
(3) 1 point (service) (6) 3 points (service)
For continuous welds marked by *, apply anticorrosion wax thoroughly on the reverse side.
BS - 83
Frame Side Front (partial replacement)
(1)
BS-00866
BS - 84
Frame Side Front (partial replacement)
• Views
(5)
(1)
(2)
(4)
(2)
(2)
(6)
(3) (6)
(3)
A (7)
(5)
(6)
B
BS-00867
BS - 85
Frame Side Front (partial replacement)
B: INSTALLATION
• Overall view
(3)
(2) D
(1)
B (5)
(2)
(1)
C
(1) (6) (4)
A
BS-00868
BS - 86
Frame Side Front (partial replacement)
• Views
(5)
(5) (5)
(3) (6)
(2)
(1)
(2)
(5)
(5)
(4)
(2)
A
(5)
(7)
(6)
(7)
(2)
C
(7) D
BS-00869
BS - 87
Front Side Frame (partial replacement)
(1)
215 mm
130 mm
(2)
(5)
(4)
(3)
(6)
BS-00870
(1) 2 points (inside 1) (During H4 (4) H4 cutting position (230 mm) (6) 1 point (inside 1) (During H4
cutting) for butt welding cutting)
(2) Separator bracket (5) Tailored line
(3) H6 cutting position (230 mm)
for butt welding
During H6 cutting work, replace the separator bracket (single part) in the front side frame.
BS - 88
Front Side Frame (partial replacement)
B: INSTALLATION
(1)
215 mm
130 mm
(2)
(5)
H4
∗ (3) H6
∗ (3)
(4)
BS-00871
(1) 3 points (During H4 cutting) (3) 1 point (230 mm) (5) Tailored line
(2) Separator bracket (4) 2 points (During H4 cutting)
• During H6 cutting work, replace the separator bracket (single part) in the front side frame.
• For continuous welds marked by *, apply anticorrosion wax thoroughly on the reverse side.
BS - 89
Front Fender Reinforcement (total replacement)
(1)
(1)
(1)
(1)
BS-00872
BS - 90
Front Fender Reinforcement (total replacement)
B: INSTALLATION
(1)
(1)
(1)
(1)
BS-00873
(1) 1 point
BS - 91
Reinforcement Toe Board (total replacement)
(1)
(4)
(6)
(5)
B
BS-00874
(1) 1 point (outside 1) (3) 1 point (inside 1, belt sander) (5) 3 points (outside 1)
(2) 4 points (outside 1) (4) 2 points (inside 1, belt sander) (6) 2 points (outside 1)
BS - 92
Reinforcement Toe Board (total replacement)
• Views
(1)
(2)
(3)
(4)
(6)
(3)
(3)
(5)
(5)
(5)
B
(5)
BS-00875
BS - 93
Reinforcement Toe Board (total replacement)
B: INSTALLATION
• Overall view
(1) (3)
(3)
(4)
BS-00876
BS - 94
Reinforcement Toe Board (total replacement)
• Views
(1)
(2)
(3)
(3)
(2)
(4)
(4)
(4)
B
(4)
BS-00877
BS - 95
Front Pillar (partial replacement)
m
m
0
(1) 25
(1)
(2)
A
(6)
B
(1)
(1)
(5) C
F 180 mm
(3)
D
E, G (4)
(4) (1)
BS-00878
(1) 2 points (outside 1) (3) Cut (270 mm) (4) 3 points (outside 1)
(2) Rough cutting (250 mm) to make removal easier (5) 8 points (outside 1)
Inner lower piller (6) 4 points (outside 1)
BS - 96
Front Pillar (partial replacement)
• Views 1
(3)
(1)
(1)
(2)
(4)
A B
(10)
(10)
(5)
(6) (7)
(9)
(7) (5) (12)
(8) (11)
(13)
C D
BS-00879
(1) 2 points (top 1, belt sander) (6) 4 points (outside 1) (10) 3 points (bottom 1)
(2) 1 point (top 1) (7) Cut (11) 5 points (outside 1)
(3) 2 points (inside 2, belt sander) (8) 3 points (top 1) (12) 7 points (outside 1)
(4) 1 point (inside 1, belt sander) (9) 2 points (top 1) (13) 1 point (outside 1)
(5) 3 points (outside 1)
BS - 97
Front Pillar (partial replacement)
• Views 2
b (1)
b (2)
(10)
E b (3)
(5)
c (1) (7)
(4)
(6)
c (1) c (8)
F
c (8)
c (1) c (8)
c (1)
G
b c 20 mm
c
b c c
c (9)
BS-00880
POINT: • To make removal easier, remove the front pillar and remove the welding location b.
• Remove the front pillar, cut the side sill inner (reuse), and remove section c.
View E shows the front pillar removed condition.
BS - 98
Front Pillar (partial replacement)
B: INSTALLATION
• Overall view
m
m
0
15
H
(12)
(11) ∗ (1)
(2)
(4) (3)
(10) A
(3)
(6)
B
(2)
G
(5)
(6) ∗ (7)
(9) C
F 180 mm
D
E (8)
(8) (6)
BS-00881
CAUTION:
When servicing (7), after welding the section b in the View E, perform butt welding of the side sill out-
er.
For continuous welds marked by *, apply anticorrosion wax thoroughly on the reverse side.
BS - 99
Front Pillar (partial replacement)
• Views 1
(1) (2)
(2)
(3)
(4)
(4)
(5)
A B
(6)
(7)
(9)
(9)
(8)
C (9)
b (4)
E b (12)
BS-01518
(1) 1 point (30 mm) (5) 1 point (10 mm) (9) 3 points (service)
(2) 2 points (15 mm u 2) (6) 3 points (10) 10 points
(3) 2 points (20 mm) (7) 4 points (11) 5 points
(4) 1 point (8) 2 points (service) (12) 7 points
BS - 100
Front Pillar (partial replacement)
• Views 2
(4)
(5)
(7)
(2)
(3)
(6)
(1)
(2) (3)
(1)
F G
∗ (8)
10
m
m
b
c
b c 20 mm
c c c
b ∗ (9)
BS-00883
POINT: • After welding section b, perform butt welding of the side sill outer.
• After welding section c, perform butt welding of the side sill inner.
For continuous welds marked by *, apply anticorrosion wax thoroughly on the reverse side.
BS - 101
Center Pillar (partial replacement)
150 mm
(1)
(1)
(2)
(3)
(3)
(8)
(4)
(5)
(5) B
(1)
(1)
(6)
(6)
(7)
C
BS-00884
BS - 102
Center Pillar (partial replacement)
• Views
(1)
(2)
(2)
(2)
(2)
(3) (3)
(4)
(4)
A
(5)
(6)
(6)
(7)
C
BS-00885
(1) 5 points (inside 1) (4) 1 point (inside 1, belt sander) (6) 2 points (outside 1, belt sander)
(2) 1 point (inside 1) (5) 5 points (inside 1) (7) 5 points (outside 1)
(3) 2 points (inside 1)
BS - 103
Center Pillar (partial replacement)
B: INSTALLATION
• Overall view
100 mm
D
A
∗ (1)
(2)
(2)
(8)
(3)
(4)
(4) B
(5)
(5)
(6)
(6)
(7)
C
BS-00886
For continuous welds marked by *, apply anticorrosion wax thoroughly on the reverse side.
BS - 104
Center Pillar (partial replacement)
• Views
(1)
(2)
(2)
(2)
(2)
(3) (3)
(4)
A (4)
(1)
(5)
(5)
(6)
C BS-00887
BS 0089
(1) 5 points (service) (3) 3 points (5) 2 points
(2) 1 point (4) 1 point (15 mm) (6) 5 points
BS - 105
Rear Quarter / Wagon (partial replacement)
(1)
(2)
(3)
(3)
(6)
(3)
G (5)
20
(4)
0m
m
(5)
F
E
(3)
(3)
(7)
(8)
(9) (7)
(3)
D
(8)
(5)
C
A
(7)
B
BS-00888
(1) Rough cutting (130 mm) (4) 3 points (outside 1) (7) 5 points (outside 1)
(2) 2 points (outside 1) (5) 4 points (outside 1) (8) 8 points (outside 1)
(3) 1 point (outside 1) (6) Rough cutting (170 mm) (9) 12 points (outside 1)
BS - 106
Rear Quarter / Wagon (partial replacement)
• Views 1
(1)
(7)
(2)
(3) (7)
(8)
(4)
(5)
(1)
(2)
A B
(6)
(1)
(1)
(4)
(5)
(6) (9)
(1)
(5) (1)
(6) (5)
(6)
C D
BS-00889
(1) 1 point (outside 1) (5) 3 points (outside 1) (8) 1 point (outside 1), hidden hit
(2) 2 points (top 1) (6) 2 points (outside 1) point
(3) 4 points (top 1) (7) 4 points (outside 1) (9) 1 point (bottom 1)
(4) 5 points (outside 1)
BS - 107
Rear Quarter / Wagon (partial replacement)
• Views 2
(1) (1)
a (2)
(1)
(1)
(3)
(1)
(4)
b (2)
(1)
(4)
(6)
(5)
F
(5)
E
(7)
(7)
200 mm (8)
(10)
(9)
(1)
(1) (1) (11)
b (2)
(10)
(1) (1)
Approx. 18 mm
c (2)
(1)
(4)
BS-00890
(1) 1 point (outside 2) (4) 2 points (outside 2) (8) Rough cutting (170 mm)
(2) 1 point (outside 1), hidden hit (5) 1 point (outside 1) (9) 6 points (outside 1)
point (6) 3 points (inside 1, belt sander) (10) 4 points (outside 1)
(3) 9 points (outside 1) (7) 3 points (outside 1) (11) 2 points (outside 1)
POINT: When replacing the D-pillar by itself, there are two weld locations a and b (hidden hit point).
BS - 108
Rear Quarter / Wagon (partial replacement)
B: INSTALLATION
• Overall view
∗ (1)
(2)
(3)
a∗
a∗
(3)
(3)
16
G, H
0m
(4) (5)
m
(5)
F
E
(11)
(3)
(6)
(10)
(9) (6)
(3)
D
(7)
(5) C
A
(8)
B
BS-00891
For continuous welds marked by *, apply anticorrosion wax thoroughly on the reverse side.
BS - 109
Rear Quarter / Wagon (partial replacement)
• Views 1
(3)
(6)
(1)
(3) (2)
(7)
(3)
(6) (4)
(5)
(5) A B
(6)
(7)
(9)
(8) (6)
(4)
(5)
C D
BS-00892
BS - 110
Rear Quarter / Wagon (partial replacement)
• Views 2
(1) (1)
(1)
(1)
(2)
(3)
(1)
(4)
(1)
(1)
(5)
(1)
(4)
F
(1)
E
a ∗ (6)
50 mm 110
(7)
a ∗ (6) ∗ (9)
80 mm
mm
(12) (8)
(7)
(4)
(12) H
(1)
(10)
G
b (11)
(1)
(2)
(1)
c (11)
(1)
(5)
BS-00893
(1) 1 point (service) (6) 2 points (170 mm) (10) 1 point (outside 2)
(2) 1 point (7) 4 points (11) 1 point (service matching),
(3) 10 points (8) 7 points hidden hit point
(4) 3 points (9) 1 point (170 mm) (12) 5 points
(5) 2 points (service)
POINT: When replacing the D-pillar by itself, there are two weld locations b and c (hidden hit point).
BS - 111
Rear Quarter / Wagon (partial replacement)
CAUTION:
Repair weld location a (2 locations on the D-pillar) after butt welding the inner H.
For continuous welds marked by *, apply anticorrosion wax thoroughly on the reverse side.
BS - 112
Rear Quarter / Sedan (partial replacement)
(1) (1)
C (2)
(1)
(3)
F G
D
10
0m
m
(1)
(6)
(4)
(5)
E
(9)
(5)
(6)
A (7)
(8)
(5)
BS-00894
BS - 113
Rear Quarter / Sedan (partial replacement)
• Views 1
(2) (1)
(1)
(3)
(2)
(3) (4)
(7)
(8)
(6) (5)
A B
(1)
(9)
(2)
(7)
(13)
(10)
100
(7)
mm
(6)
(12)
(2)
(14)
(11)
C D
BS-00895
BS - 114
Rear Quarter / Sedan (partial replacement)
• Views 2
(1)
(2) (5)
(3)
(4)
E (4)
(5)
(5)
(5)
(5)
(5)
(4)
(2)
(6)
(2)
G
BS-00896
BS - 115
Rear Quarter / Sedan (partial replacement)
B: INSTALLATION
• Overall view
∗ (1)
(2)
C ∗ (3)
(2)
F G
D
30
mm
(2) (4)
(7)
(5)
(6)
E
(10)
(6)
(7)
B
A (8)
(9)
(6)
BS-00897
For continuous welds marked by *, apply anticorrosion wax thoroughly on the reverse side.
BS - 116
Rear Quarter / Sedan (partial replacement)
• Views 1
(1)
(2)
(1)
(3)
(2)
(6) (4)
(6) (7)
(5) (1)
A B
(8)
30
mm
(2)
(8)
(5)
(9) (11)
(5)
(5)
(2)
(12)
∗ (10)
C D
BS-00898
For continuous welds marked by *, apply anticorrosion wax thoroughly on the reverse side.
BS - 117
Rear Quarter / Sedan (partial replacement)
• Views 2
(1)
(2)
(5)
(3)
(4)
E (2)
(2)
(2)
(5)
(2)
(2)
(6)
(2)
(2)
(2)
G
BS-00899
For continuous welds marked by *, apply anticorrosion wax thoroughly on the reverse side.
BS - 118
Side Sill Outer (partial replacement)
(2)
E
A F
(1)
BS-00900
BS - 119
Side Sill Outer (partial replacement)
• Views 1
(1)
(2)
(3)
m
70 m
(4)
B
(5)
C
BS-00901
(1) Cut (270 mm) (3) 2 points (outside 1) (5) 24 points (outside 1)
(2) 6 points (outside 1) (4) 9 points (outside 1)
BS - 120
Side Sill Outer (partial replacement)
(1)
(2)
(3)
(4)
D
(3)
(5)
(1)
(6)
(7)
(3)
(3)
(1) (1)
(8)
F
BS-00902
BS - 121
Side Sill Outer (partial replacement)
B: INSTALLATION
• Overall view
E
A F (2)
(1)
BS-00903
For continuous welds marked by *, apply anticorrosion wax thoroughly on the reverse side.
BS - 122
Side Sill Outer (partial replacement)
• Views 1
(1)
(2)
∗ (3)
m
70 m
(4)
B
(5)
C
BS-00904
BS - 123
Side Sill Outer (partial replacement)
• Views 2
(1)
(2)
(2)
(3)
D
(2)
(4)
(4)
(5)
(6)
(2)
(2)
(4) (4)
(7)
F
BS-00905
BS - 124
Side Sill Outer (partial replacement)
C: REMOVAL
• Overall view
(2)
(1)
(1)
B
A
(2)
BS-00906
(1) Front cutting position (270 mm) (2) Rear cutting position (270 mm)
(for butt welding) (for butt welding)
BS - 125
Side Sill Outer (partial replacement)
• Views
(5)
(1) 10 mm
70 mm
A B
70 mm (7)
C D
BS-00907
BS - 126
Side Sill Outer (partial replacement)
D: INSTALLATION
• Overall view
∗ (1) ∗ (1)
∗ (1)
B
A
∗ (2)
BS-00908
(1) 1 point (270 mm) (butt welding) (2) 1 point (300 mm) (butt welding)
For continuous welds marked by *, apply anticorrosion wax thoroughly on the reverse side.
BS - 127
Side Sill Outer (partial replacement)
• Views
(5)
(1) 10 mm
70 mm
(4) 115 mm
(2) (3)
(6)
A B
70 mm (7)
C D
BS-00909
BS - 128
Rear Quarter Upper / Wagon (total replacement)
(1)
(1)
(2)
(1)
(1)
(3)
(2)
(3)
(2)
(3)
BS-00910
BS - 129
Rear Quarter Upper / Wagon (total replacement)
B: INSTALLATION
(1)
(1)
(2)
(1)
(1)
(2)
(3)
(4)
(3)
(4)
BS-00911
BS - 130
Rear Quarter Inner Upper / Sedan (total replacement)
(2)
(3)
(9) (4)
(5)
(6)
(3)
(7)
(8)
(3)
(14)
(10)
(12)
(11)
(10) (12)
(13) BS-00912
(1) Make removal easier (5) 3 points (outside 1) (10) 2 points (top 1)
Rough cutting (170 mm) (6) 1 point (outside 1) (11) 4 points (top 1)
(2) Make removal easier (7) 9 points (outside 1) (12) 1 point (top 1)
Rough cutting (320 mm) (8) 5 points (outside 1) (13) 2 points (top 2)
(3) 2 points (outside 1) (9) 4 points (outside 1) (14) 3 points (top 1)
(4) 6 points (outside 1)
BS - 131
Rear Quarter Inner Upper / Sedan (total replacement)
• Views
(2)
(1) (3)
(4) (4)
(7)
(3)
(5)
(5)
(6) (5)
BS-01519
BS - 132
Rear Quarter Inner Upper / Sedan (total replacement)
B: INSTALLATION
• Overall view
(7) (1)
(2)
(3)
(4)
(1)
(5)
(6)
(1)
(3) (8)
(4)
(9)
(4)
(10) (8) BS-00914
BS - 133
Rear Quarter Inner Upper / Sedan (total replacement)
• Views
(2)
(1) (3)
(4)
(4)
(4)
(6)
(5)
(5)
(3) (5)
BS-00915
BS - 134
Rear Quarter Inner Reinforcement / Sedan (total replacement)
(1)
(2)
(1)
(3)
(3)
(4)
(1)
(1)
(5)
(2) (6)
BS-00916
BS - 135
Rear Quarter Inner Reinforcement / Sedan (total replacement)
B: INSTALLATION
(1)
(2)
(1)
(3)
(8)
(4)
(5)
(5)
(6)
(2) (7)
BS-00917
BS - 136
Rear Bulkhead / Sedan (total replacement)
A
(2)
(1)
(3)
(4)
(5)
(1)
(1)
(1) (2)
(7)
(6)
BS-00918
BS - 137
Rear Bulkhead / Sedan (total replacement)
• Views
(1)
(2)
(3)
(1) (4)
(5)
(5)
BS-00919
BS - 138
Rear Bulkhead / Sedan (total replacement)
B: INSTALLATION
• Overall view
A
(2)
(1)
(5)
(4)
(2)
(3)
(3)
(3) (2)
(2)
(1)
BS-00920
BS - 139
Rear Bulkhead / Sedan (total replacement)
• Views
(1)
(2)
(2)
(1) (3)
(2)
(2)
BS-00921
BS - 140
Rear Floor Side / Wagon (total replacement)
(1)
(3)
(2)
A
B
(4) (4)
BS-00922
BS - 141
Rear Floor Side / Wagon (total replacement)
• Views
(5)
(1) (1)
(1)
(2)
(5)
(1)
(2)
(3)
(3)
(4) (4)
A A (RH)
(3)
(6) (6)
B B (RH)
BS-00923
BS - 142
Rear Floor Side / Wagon (total replacement)
B: INSTALLATION
• Overall view
(4)
B
(4)
BS-00924
BS - 143
Rear Floor Side / Wagon (total replacement)
• Views
(5)
(1) (1)
(1)
(2)
(5)
(1)
(3) (2)
(4) (3)
(4)
A A (RH)
(6)
(6)
(7)
(6) (7)
(6)
B B (RH)
BS-00925
BS - 144
Rear Floor Side / Sedan (total replacement)
(2)
(1)
B
(1)
BS-00926
BS - 145
Rear Floor Side / Sedan (total replacement)
• Views
(1)
(1)
(2)
(4)
(4)
(2)
(3)
(3)
A A (RH)
(5)
(5)
(5)
(6)
(5)
(7)
B B (RH)
BS-00927
BS - 146
Rear Floor Side / Sedan (total replacement)
B: INSTALLATION
• Overall view
(1)
(1)
B
(1)
BS-00928
(1) 1 point
BS - 147
Rear Floor Side / Sedan (total replacement)
• Views
(1)
(1)
(2)
(4)
(4)
(2)
(3)
(3)
A A (RH)
(5) (5)
(5)
(6)
(5)
(6)
B B (RH)
BS-00929
BS - 148
Rear Skirt / Wagon (partial replacement)
(1)
(1)
(2)
(3)
C D
(4)
(6)
(5)
A
20 mm 50 mm
B
BS-00930
BS - 149
Rear Skirt / Wagon (partial replacement)
• Views
(1)
(1)
(2)
(2)
(2)
(1)
A B
(3)
(5)
(3)
(5)
(4)
D
C
BS-00931
(1) 1 point (bottom 1) (3) 2 points (inside 1, belt sander) (5) 3 points (inside 1, belt sander)
(2) 1 point (outside 1) (4) 2 points (top 1, belt sander)
BS - 150
Rear Skirt / Wagon (partial replacement)
B: INSTALLATION
• Overall view
(1)
(1)
(2)
(3)
C D
(4)
(6)
(5)
A
20 mm 50 mm
B
BS-00932
(1) 1 point (3) 1 point (320 mm) (5) 1 point (300 mm)
(2) 3 points (4) 5 points (6) D-pillar outer
BS - 151
Rear Skirt / Wagon (partial replacement)
• Views
(1) (1)
(1)
(1)
(1)
(1)
A B
(3)
(2)
(3)
(2)
(2)
C D
BS-00933
BS - 152
Rear Skirt / Sedan (total replacement)
A (1)
(2) (1)
(2)
(3)
(1)
(1)
(4) (4)
B
(3) (5) (5)
(6) (6)
(1) (1)
(3)
BS-00934
BS - 153
Rear Skirt / Sedan (total replacement)
• Views
(1)
(5)
(2)
(5)
(4) (3)
(5)
A B
BS-00935
BS - 154
Rear Skirt / Sedan (total replacement)
B: INSTALLATION
• Overall view
A (1)
(2) (1)
(2)
(3)
(1)
(1)
(4) (4)
B
(3) (5) (5)
(6) (6)
(1) (1)
(3)
BS-00936
BS - 155
Rear Skirt / Sedan (total replacement)
• Views
(1)
(2)
(2)
(2)
(4) (3)
(2)
A B
BS-00937
BS - 156
Rear Skirt Outer / Wagon (total replacement)
(1)
(5)
(5)
(6) (1)
(1)
BS-00938
BS - 157
Rear Skirt Outer / Wagon (total replacement)
B: INSTALLATION
(3)
(8)
(6)
(6)
(7) (8)
(8)
BS-00939
BS - 158
Rear Skirt Inner / Wagon (partial replacement)
(1) (2)
A
(3)
(4)
B
(5)
mm
100
BS-00940
(1) 4 points (outside 1) (4) Rough cutting (350 mm) (6) 3 points (outside 1)
(2) 2 points (outside 1) (5) 5 points (outside 1) (7) 7 points (outside 1)
(3) 1 point (outside 1)
BS - 159
Rear Skirt Inner / Wagon (partial replacement)
• Views
(1)
(1)
(2)
(3)
(3)
B BS-00941
(1) 2 points (inside 1, belt sander) (2) 2 points (top 1, belt sander) (3) 3 points (inside 1, belt sander)
BS - 160
Rear Skirt Inner / Wagon (partial replacement)
B: INSTALLATION
• Overall view
∗ (4)
B
(5)
mm
50
BS-00942
For continuous welds marked by *, apply anticorrosion wax thoroughly on the reverse side.
BS - 161
Rear Skirt Inner / Wagon (partial replacement)
• Views
(1)
(1)
(1)
(2)
(2)
B
BS-00943
BS - 162
Rear Floor Pan (total replacement)
(1) (2)
B
A
(1)
BS-00944
(1) 5 points (inside 1) (3) Rough cutting (2300 mm) (4) 4 points (top 1)
(2) 9 points (top 1)
BS - 163
Rear Floor Pan (total replacement)
• Views
(1) (3)
(2)
(4)
(5)
A
(1)
(3)
(2)
(4)
(5)
BS-00945
POINT: To make removal easier, remove the rear floor side when working.
BS - 164
Rear Floor Pan (total replacement)
B: INSTALLATION
• Overall view
(1) (2)
B
A
(1)
(3) (3)
BS-00946
BS - 165
Rear Floor Pan (total replacement)
• Views
(1)
(3)
(2)
(4)
(5)
A
(1)
(3)
(2)
(4)
(5)
BS-00947
POINT: To make removal easier, remove the rear floor side when working.
BS - 166
Closing Plate (total replacement)
(2)
(1)
(3) (3)
(1)
(4) (1)
(5)
(4) (3)
(3)
(5)
(6)
(8)
(1)
(9)
(7) (4)
(7)
(10)
(7) (1)
(4)
(3)
(9)
(1)
(9)
F BS-00950
CAUTION:
Remove the closing plate front CP to make rear frame removal easier.
BS - 167
Closing Plate (total replacement)
B: INSTALLATION
• Views
(2)
(1)
(3)
(2) (2)
(3)
(1) (3)
(2)
(1) (2)
(2)
(2)
(1)
(4)
(3)
(2)
(1)
(5)
(6)
(5) (3)
(1)
(7)
(7)
(6)
(7)
BS-00953
BS - 168
Rear Frame / Wagon (total replacement)
F
A
BS-00948
BS - 169
Rear Frame / Wagon (total replacement)
• Views
(3)
(1)
(2)
(7)
(6)
(8)
(4)
(4) (6) (3)
(5) (5) B (2 )
(2)
(3)
(9)
(3)
(10)
C
(11)
(12)
(14)
(13) (15)
D E
BS-00949
(1) 5 points (bottom 1) (6) 1 point (bottom penetration) (11) 4 points (outside 1)
(2) 1 point (bottom 1) (7) 3 points (inside penetration) (12) 2 points (outside 1)
(3) 3 points (inside 1) (8) 1 point (inside penetration) (13) 3 points (outside 1)
(4) 2 points (bottom penetration) (9) 4 points (inside 2) (14) 1 point (inside 1)
(5) 2 points (inside penetration) (10) 6 points (inside 1) (15) 5 points (inside 1, belt sander)
BS - 170
Rear Frame / Wagon (total replacement)
B: INSTALLATION
• Overall view
F
A
BS-00951
BS - 171
Rear Frame / Wagon (total replacement)
• Views
(2)
(1)
(3)
(2)
(3)
(3)
(4)
(3) (2)
(4)
(4) B (3)
(4)
A
(3)
(2)
(5)
(2)
(6)
C
(5)
(4)
(3)
(2)
(1)
D E
BS-00952
BS - 172
Rear Side Frame Rear (partial replacement)
(1)
(1)
BS-00954
BS - 173
Rear Side Frame Rear (partial replacement)
• Views
(4)
(1)
(2)
(2)
(1)
(4) (3)
(3)
B
BS-00955
BS - 174
Rear Side Frame Rear (partial replacement)
B: INSTALLATION
• Overall view
(1)
(1)
BS-00956
(1) 2 points
BS - 175
Rear Side Frame Rear (partial replacement)
• Views
(1)
(2)
(2)
(2) (1)
(2) (2)
(2)
B
BS-00957
BS - 176
Plate Tractive (total replacement)
(1) (1)
(2)
(3) (4)
(3)
(5) (5)
BS-00958
BS - 177
Plate Tractive (total replacement)
B: INSTALLATION
(1)
(2)
(1)
265 265
(3)
(4)
(4)
(5) (5)
BS-00959
BS - 178
Rear Panel / Sedan (total replacement)
(1) (1)
(2)
(1)
(1) (1)
(3)
(4)
(4)
(1)
(5)
(1)
(6)
(1)
(7)
(5)
(6)
(4)
(4)
(8)
(1)
A
(4) (4)
BS-00960
BS - 179
Rear Panel / Sedan (total replacement)
• Views
(1) (1)
(1)
(2)
BS-00961
BS - 180
Rear Panel / Sedan (total replacement)
B: INSTALLATION
• Overall view
(1) (1)
(1)
(1)
(1) (1)
(2)
(3)
(3)
(1)
(4)
(1)
(5)
(1)
(4)
(4)
(5)
(3)
(3)
(5)
(1)
A
(3) (3)
BS-00962
BS - 181
Rear Panel / Sedan (total replacement)
• Views
(1) (1)
(1)
(2)
BS-00963
BS - 182
Roof Panel / Wagon (total replacement)
(2)
(1) B
★ (3)
★ (4)
★ (4)
★ (6) ★ (5)
A
★ (7)
(2)
B
(1)
★ (4) ★ (3)
★ (4)
★ (8)
★ (9)
★ (6)
A ★ (9)
★ (5)
★ (9)
★ (8)
BS-00964
For locations marked by ★, the welding method, the number of welding points, and the rough cutting dimen-
sions are the same on the left and the right.
BS - 183
Roof Panel / Wagon (total replacement)
• Views
★ (1)
★ (2) ★ (3)
★ (2)
★ (2)
★ (2)
★ (2)
★ (2)
★ (2)
★ (4)
★ (2)
B
BS-00965
For locations marked by ★, the welding method, the number of welding points, and the rough cutting dimen-
sions are the same on the left and the right.
BS - 184
Roof Panel / Wagon (total replacement)
B: INSTALLATION
At the time of roof panel installation, apply adhesive at the locations shown in the following figure.
• Overall view
(2)
B
(1)
★ (2)
★ (3)
★ (4)
★ (5)
★ (6)
A ★ (7)
(2)
(1)
★ (2)
★ (3)
★ (4)
★ (8)
★ (3)
★ (6)
A ★ (3)
★ (5)
★ (3)
★ (8)
BS-00966
BS - 185
Roof Panel / Wagon (total replacement)
• Views
★ (2)
★ (2)
★ (2)
★ (2)
★ (1)
★ (4)
★ (2) ★ (2)
★ (5)
★ (6)
★ (3)
A
B
BS-00967
BS - 186
Roof Panel / Wagon (total replacement)
At the time of roof panel installation, apply adhesive at the locations shown in the following figure.
(2)
(1)
(5)
★ (3)
★ (3)
★ (3)
(4)
(2)
(5)
★ (3)
★ (3)
★ (6)
★ (6)
★ (6)
BS-00968
BS - 187
Roof Panel / Sedan (total replacement)
(1)
★ (3) B
★ (4)
★ (5)
★ (6)
★ (5)
★ (5)
★ (9)
A
(1)
★ (4) B
★ (3)
★ (5)
★ (10)
★ (5)
(2) ★ (7)
★ (10)
★ (7)
A
★ (5)
★ (9)
BS-00969
BS - 188
Roof Panel / Sedan (total replacement)
For locations marked by ★, the welding method, the number of welding points, and the rough cutting dimen-
sions are the same on the left and the right.
• Views
★ (1)
★ (2)
★ (2)
A ★ (2)
★ (2)
★ (1)
★ (2)
B
BS-00970
For locations marked by ★, the welding method, the number of welding points, and the rough cutting dimen-
sions are the same on the left and the right.
BS - 189
Roof Panel / Sedan (total replacement)
B: INSTALLATION
At the time of roof panel installation, apply adhesive at the locations shown in the following figure.
• Overall view
(1)
★ (2) B
★ (3)
★ (5)
★ (4)
★ (5)
(1) ★ (6)
★ (2)
★ (5)
★ (7)
A
(1)
★ (2) B
★ (3)
★ (5)
★ (4)
★ (5)
(1) ★ (2)
★ (8)
★ (2)
A
★ (5)
★ (7)
BS-00971
For locations marked by ★, the welding method, the number of welding points, and the rough cutting dimen-
sions are the same on the left and the right.
BS - 190
Roof Panel / Sedan (total replacement)
• Views
★ (1)
★ (2)
★ (2)
★ (4)
★ (1)
★ (5)
(3)
A B
BS-00972
For locations marked by ★, the welding method, the number of welding points, and the rough cutting dimen-
sions are the same on the left and the right.
BS - 191
Roof Panel / Sedan (total replacement)
At the time of roof panel installation, apply adhesive at the locations shown in the following figure.
(4)
★ (3)
★ (3)
(1)
★ (3)
(2)
(4)
★ (3)
★ (3)
★ (3)
(1)
★ (3)
BS-00973
BS - 192