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Foreword

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

(1) Overall view (A) Welding method


(2) Views (B) View direction
(3) Number of welding points etc. (C) Towards front of vehicle
(4) Removal direction
(5) Number of panels to be drilled
(6) Cautions when working, etc.

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

3. NUMBER OF PANELS TO BE DRILLED 4. HOLE DRILLING FOR PLUG WELDING


Depending on the number of panels, drilling is per- (1) Drilling of holes for plug welding in service parts
formed through one or two panels, and this is listed
together with the removal direction.
(1) Drilling through one plate
(Service part)

Inside Outside

(A) (B) (1)

BS-00653

(A) Service part


BS-00651
(2) Drilling of holes on service parts for plug weld-
(A) (Inside ˜ 1) ing, to match the holes on the vehicle side
(B) (Outside ˜ 1)
(2)
(2) Drilling through two plate
(Service part, matching)

Inside Outside
(1)
(C) (D)

BS-00654

(1) Service part


BS-00652 (2) Vehicle side

(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-00659 BS-00660 BS-00657 BS-00658

• Carbon dioxide gas arc welding (MIG welding)


Plug welding

BS-00661 BS-00662 BS-00663


Continuous welding

BS-00664 BS-00665 BS-00666

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

(1) Front panel (3) Toe board (5) Stud bolt


(2) Duct (4) Stud bolt

BS - 7
Panel Components

2. RADIATOR PANEL & FRONT WHEEL APRON

(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

3. FRONT SIDE FRAME

(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

4. FRONT FLOOR PANEL

(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

5. REAR FLOOR PANEL & REAR SKIRT

(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

(A) Sedan (B) Wagon

(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

6. REAR FLOOR SIDE FRAME

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

3. Galvanized Sheet Metal


A: SPECIFICATION

(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

4. Aluminium Sheet Metal


A: SPECIFICATION

(1)

BS-02640

(1) Hoods for vehicles other than the OUTBACK


are aluminum sheet metal

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

Cross section A — A Cross section B — B


(1) (1)

(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

Cross section F — F Cross section G — G


(1) (1)
(2) (2)

(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

Cross section L — L Cross section M — M


(1)
(2)
(3)
(1)

(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

(1) (1) (2)

(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

Cross section Q — Q Cross section R — R


(1) (1)

(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

6. Gauge Values for Fitting


1. SIDE

(A)

(D)
(B) (C)

(E) (F) (G)

(1)

(2)

(2) (3) (3) (4)

(A) (B) (C)

(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

Section Part Specification


Except for OUTBACK: 3.5r1.0 mm (0.14r0.04 in)
(A) Between front hood panel to front fender panel
OUTBACK: 3.8r1.0 mm (0.15r0.04 in)
(B) Between front fender panel to front door panel 4.65r1.0 mm (0.18r0.04 in)
(C) Between front door panel to rear door panel 5.1r1.0 mm (0.20r0.04 in)
(D) Between rear door panel to rear quarter panel 4.6r1.0 mm (0.18r0.04 in)
(E), (F) Between door panel to side sill 6.0r1.0 mm (0.24r0.04 in)
(G) Between side sill to rear quarter lower protector 5.0r1.0 mm (0.20r0.04 in)

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)

(D) (5) (E)


EB-00177

(1) Front bumper (3) Front hood panel (5) Front fender panel
(2) Front grille (4) Headlight

Section Part Specification


(A) Between front bumper to front grille 1.0r0.7 mm (0.04r0.03 in)
(B) Between front hood panel to front bumper 4.0 — 6.0 mm (0.16r0.24 in)
C1: 5.0r1.0 mm (0.20r0.04 in)
(C) Between front hood panel to headlight
C2: 6.0r1.0 mm (0.24r0.04 in)
(D) Between front fender panel to headlight 2.0r1.0 mm (0.08r0.04 in)
(E) Between front fender panel to front bumper 1.0r0.7 mm (0.04r0.03 in)

BS - 26
Gauge Values for Fitting

3. REAR (SEDAN MODEL)

(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

Section Part Specification


(A) Between trunk lid garnish to rear bumper 7.0r1.0 mm (0.28r0.04 in)
(B) Between trunk lid garnish to rear combination light 4.0r1.0 mm (0.16r0.04 in)
(C) Between trunk lid panel to rear combination light 3.5r1.0 mm (0.14r0.04 in)
(D) Between trunk lid panel to rear fender panel 3.5r1.0 mm (0.14r0.04 in)
(E) Between rear fender panel to rear bumper 1.0r0.7 mm (0.04r0.03 in)
F1: 3.7r0.5 mm (0.15r0.02 in)
(F) Between rear fender panel to fuel filler flap lid (vertical direction)
F2: 3.4r0.5 mm (0.13r0.02 in)
(G) Between rear fender panel to fuel filler flap lid (horizontal direction) G1, G2: 3.5r0.5 mm (0.14r0.02 in)

BS - 27
Gauge Values for Fitting

4. REAR (WAGON MODEL)

(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)

(7) (8) (7)


(2)

(4)

H1 H2

(E) (F) (H)

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

Section Part Specification


(A) Between rear gate panel to rear bumper 8.0r1.5 mm (0.31r0.06 in)
(B) Between rear gate panel to rear combination light 5.1r1.0 mm (0.20r0.04 in)
(C) Between rear gate glass to rear combination light 5.5r1.0 mm (0.22r0.04 in)
(D) Between rear gate glass to rear quarter glass 4.0r1.5 mm (0.16r0.06 in)
(E) Between roof panel to roof spoiler 5.5r1.0 mm (0.22r0.04 in)
(F) Between rear fender panel to rear bumper 1.0r0.7 mm (0.04r0.03 in)
G1: 3.7r0.5 mm (0.15r0.02 in)
(G) Between rear fender panel to fuel filler flap lid (vertical direction)
G2: 3.4r0.5 mm (0.13r0.02 in)
(H) Between rear fender panel to fuel filler flap lid (horizontal direction) H1, H2: 3.5r0.5 mm (0.14r0.02 in)

BS - 28
Plastic Parts and Materials

7. Plastic Parts and Materials


A: SPECIFICATION
(10)
(9)

(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

(1) Headlight (11) Side garnish (21) Center pillar cover


(2) Front fog light (12) Side turn light (22) Door handle
(3) Front bumper (13) Side spoiler (23) Roof rail
(4) Air intake cover (14) Rear spoiler (24) Rear quarter protector
(5) Front grille (15) Rear garnish (25) Trunk garnish
(6) Turbo grille (16) License light (26) License light
(7) Hood duct inner (17) Rear bumper (27) Rear bumper
(8) Front window moulding (18) Rear gate handle (28) Rear combination light
(9) Door mirror (19) Backup light (29) Rear window molding
(10) Side protector (20) Rear combination light (30) Six light molding

BS - 29
Plastic Parts and Materials

• Wagon-only parts and common parts for wagon and sedan


No. Part name Material
Lens PC
(1) Headlight Housing PP
Extension PBT + PET
Front fog light (standard) Housing PET
Lens PC
(2)
Front fog light (OUTBACK) Reflector UP - GF10
Bracket PP - GF30
Face PP
EA form Foamed PP
(3) Front bumper Fog light cover PP
Hook cover PP
Bumper cover (OUTBACK) PP
(4) Air intake cover PP
(5) Front grille ABS
(6) Turbo grille PA + PPE
(7) Hood duct inner PP + EPDM
(8) Front window moulding PVC
Body ASA
Inner cover AES
(9) Door mirror
Outer cover ABS
Mirror holder PP
(10) Side protector PP
Door body PC + PET
(11) Side garnish Other than door body PP
Side sill end cover PP + EPDM
Lens PMMA + PC
(12) Side turn light
Housing PC
(13) Side spoiler Body PP
Body PC + PET
(14) Rear spoiler High mount lens PMMA
High mount housing ABS
Body PC + PET
(15) Rear garnish
Molding ABS
Lens PC
(16) License light
Housing PBT + PET
Face PP
(17) Rear bumper
EA form Foamed PP
(18) Rear gate handle PP - GF 20
Lens PMMA
(19) Backup light
Housing ASA
Lens PMMA
Inner lens PC
(20) Rear combination light Housing ASA
Reflex reflector PMMA
Cover ASA
(21) Center pillar cover ABS
Handle PPE + PA
(22) Door handle
End cover PP

BS - 30
Plastic Parts and Materials

No. Part name Material


Front cover PC + PET
(23) Roof rail Center cover (OUTBACK) PC + PET
Rear cover PC + PET
(24) Rear quarter protector PP
Body PE
Front mudguard
Air flap TPO
Rear mudguard PE
Body PP
Under cover
Flap TPO
Splashboard PP
Body, side PP
Cowl panel
Cover PP
Blade PBT
Rear wiper Arm PET
Arm cover PBT

• 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

8. List of Plastic Material Notations


A: SPECIFICATION
Notation Notation
Material name Material name
symbol symbol
ABS resin
ABS PMMA Polymethyl methacrylate
(acrylonitrile/butadiene/styrene/resin)
AES Acrylonitrile/ethylene/styrene PP Polypropylene
ASA Acrylonitrile/styrene/acrylic resin PPE Polyphenylene ether
EPDM Ethylene/propylene/dien rubber PP - GF20 Polypropylene (20% glass fiber content)
GF Glass fiber PP - GF30 Polypropylene (30% glass fiber content)
PA Polyamide PVC Polyvinyl chloride
PBT Poly (butylene terephthalate) SEPM Styrene/ethylene/propylene rubber
PC Polycarbonate TPO Thermoplastic olefine
PE Polyethylene UP Unsaturated polyester resin
Unsaturated polyester resin (10% glass fiber
PET Polyethylene terephthalate UP - GF10
content)

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

(1) Front hood (3) Rear door (4) Front door


(2) Rear gate

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) Application thickness: 50 Pm or more (b) Application area

(1) Wax application work openings (2) 10 mm (0.39 in)

• Door (Front, rear)

:(a)
:(b)

(1) (1)

B B
(2) (4)
B B (3) (2)

B-B

BS-02515

(a) Application thickness: 50 Pm or more (b) Application area

(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

(a) Application thickness: 50 Pm or more (b) Application area

(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

(a) Application thickness: 50 Pm or more (b) Application area

(1) Wax application work openings (2) 10 mm (0.39 in) (3) 40 mm (1.57 in)

BS - 41
Anticorrosion Wax

• Front hood hinge


Apply around the installation outer circumference
(indicated range) at two locations on the left and
right.

:(a)

BS-02518

(a) Application thickness: 15 Pm or more

• Door hinge
Apply to the installation outer circumference at two
locations at the top and bottom (eight locations in
all).

:(a)

BS-02519

(a) Application thickness: 15 Pm or more

• Rear gate hinge


Apply around the installation outer circumference
(plate edges) at two locations on the left and right.

:(a)

BS-02520

(a) Application thickness: 15 Pm or more

BS - 42
Anticorrosion Wax

• Overall view

B A

(A) (B)
F

(1)

(C)

(2) (3)

(4)

(5) (5)

BS-02521

(A) View A (B) View B (C) Cross section C — C

(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

(a) Undercoat application location

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.

Cross section A — A Cross section B — B

:(a) :(a)

BS-01429 BS-01430
View C View D

:(a)

Ft

BS-01431 BS-02523

BS - 45
Undercoat

View E Cross section F — F

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

(a) Undercoat application location

BS - 46
Body Reference Points

12.Body Reference Points


A: DIMENSIONS
1. BOTTOM
Unit: mm

(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)

(87) (91) (96)


(97) (98)
(99) (102)
(80) (83) (100)
(81) (95) (101) (103) (104)
(88) (92)
(89)
(82) (84) (90)
(94)
(93)

(93)
(90) (94)
(82) (84)
(89)

(81) (88) (92) (95) (101) (103) (104)


(80) (83) (100) (102)
(97) (98) (99)
(87) (91) (96)
(85) (86)

(98)
(80) (81)
(88) (104)

(82) (92) (95)


(80) (100)
(102)

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)

(17) (16) (11)

(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

Measurement point Datum dimension mm (in)


(1) — (10) 893 (35.16)
(2) — (10) 948 (37.32)
(3) — (10) 934 (36.77)
(4) — (10) 918 (36.14)
(4) — (4) 1,314 (51.73)
(4) — (12) 882 (34.72)
(4) — (14) 557 (21.93)
(4) RH — (14) LH 1,498 (58.98)
(4) LH — (14) RH 1,498 (58.98)
(5) — (5) 658 (25.91)
(6) — (6) 740 (29.13)
(7) — (7) 700 (27.56)
(8) — (8) 900 (35.43)
(9) — (9) 900 (35.43)
(10) — (11) 755 (29.72)
(10) — (12) 794 (31.26)
(10) — (13) 707 (27.83)
(10) — (14) 745 (29.33)
(10) — (15) 639 (25.16)
(10) — (16) 512 (20.16)
(10) — (17) 585 (23.03)
(10) — (18) 804 (31.65)
(11) — (11) 1,422 (55.98)
(12) — (12) 1,508 (59.37)
(12) — (14) 326 (12.83)
(13) — (13) 1,402 (55.20)
(14) — (14) 1,472 (57.95)
(15) — (15) 1,258 (49.53)
(16) — (16) 995 (39.17)
(17) — (17) 1,104 (43.46)
(18) — (18) 1,456 (57.32)
(19) — (20) 1,064 (41.89)
(19) — (23) 1,035 (40.75)
NOTE:
• The reference points (1) and (10) are at the body center, while the other points are left-right symmetrical.
• The dimensions are the actual dimensions between the reference points.

BS - 52
Body Reference Points

(2) (1) (2) (3)


(4)
Ft

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

Measurement point Datum dimension mm (in)


(20) — (26) 1,232 (48.50)
(20) — (29) 1,034 (40.71)
(20) — (30) 1,066 (41.97)
(21) — (29) 1,080 (42.52)
(22) — (30) 1,055 (41.54)
(23) — (31) 1,070 (42.13)
(27) — (27) 1,448 (57.01)
(28) — (28) 1,523 (59.96)
(29) — (35) 863 (33.98)
(30) — (35) 1,002 (39.45)
(30) — (37) 753 (29.65)
(31) — (37) 679 (26.73)
(36) — (36) 1,506 (59.29)
NOTE:
• All reference points are left-right symmetrical.
• The dimensions between the reference points are the actual dimensions.

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

• Common for wagon and sedan, 2

(24)

(25)

(41) (42) (43) (45)


(32)

(24) (46) (33)


(65) (52)
(48)
(49) (50)
(25) (47) (51)
(42) (43)
(66)
(32)
(67)

(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

• Common for wagon and sedan, 3

(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

Measurement point Datum dimension mm (in)


(26) — (34) 613 (24.13)
(44) — (53) 591 (23.27)
(54) — (62) 969 (38.15)
(54) — (63) 884 (34.80)
(58) — (68) 900 (35.43)
(58) — (69) 958 (37.72)
(58) — (70) 990 (38.98)
(64) — (64) 944 (37.17)
(71) — (71) 1,224 (48.19)
(72) — (72) 1,173 (46.18)
(73) — (73) 1,438 (56.61)
(74) — (74) 1,250 (49.21)
(75) — (75) 1,320 (59.97)
NOTE:
• The reference point (70) is at the body center, while the other points are left-right symmetrical.
• The dimensions are the actual dimensions between the 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

Measurement point Datum dimension mm (in)


(26) — (120) 598 (23.54)
(44) — (121) 570 (22.44)
(45) — (122) 835 (32.87)
(58) — (127) 904 (35.59)
(58) — (128) 916 (36.06)
(123) — (123) 1,024 (40.31)
(124) — (124) 940 (37.01)
(125) — (125) 1,024 (40.31)
(126) — (126) 1,040 (40.94)
(129) — (129) 1,191 (46.89)
(130) — (130) 1,442 (56.77)
(131) — (131) 1,322 (52.05)
NOTE:
• All reference points are left-right symmetrical.
• The dimensions are the actual dimensions between the 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)

(105) (81) (102)


(100)

(A)

(C)
(C)
(102)
(100)
(105) (81)

(105)(81)
(100) (102)

BS-01418

(A) Standard line (B) Side sill (C) Crossmember

(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

Measurement point Datum dimension mm (in)


(105) — (81) 144 (5.67)
(81) — (100) 2508 (98.74)
(100) — (102) 457 (17.99)
(A) — (105) 212 (8.35)
(A) — (81) 212 (8.35)
(A) — (100) 164 (6.46)
(A) — (102) 243 (9.57)
(105) — (105) 862 (33.94)
(81) — (81) 840 (33.07)
(100) — (100) 930 (33.61)
(102) — (102) 970 (38.19)
NOTE:
• Longitudinal dimensions are projected dimensions.
• Height dimensions are the vertical distances from the gauge point on the assumed horizontal line through
the side sill flange joint (bending angle point).
CAUTION:
Refer to "Datum dimension" for the reference point position. (Refer to the figure "INSIDE, DIMEN-
SIONS, Body Reference Points" on page 54.)

BS - 67
Radiator Panel (total replacement)

13.Radiator Panel (total replacement)


A: REMOVAL
• Overall view

(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

(1) 2 points (5) 1 point (service ˜ matching) (7) 5 points


(2) 3 points (6) 2 points (service ˜ both surface (8) 10 points
(3) 4 points plug)
(4) 1 point

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

(1) 1 point (3) 3 points (5) 1 point (service ˜ matching)


(2) 2 points (4) 1 point (service) (6) 4 points

BS - 71
Radiator Panel (partial replacement)

14.Radiator Panel (partial replacement)


A: REMOVAL
• Overall view

30 mm
C

(1)
A (2)

BS-00854

(1) Rough cutting (280 mm) to make (2) 3 points (top ˜ 1)


removal easier

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)

15.Front Wheel Apron (total replacement)


A: REMOVAL
1) Radiator panel removal condition
• Overall view

(5)
(3)
F E
(2)
(4)
(1)

(6)

(5)
(7)

(2)
B C D
(5)
(1)
(1)
(8) (2)
(2) (8)

BS-00858

(1) 3 points (outside ˜ 1) (4) 6 points (outside ˜ 1) (7) 7 points (outside ˜ 1)


(2) 1 point (outside ˜ 1) (5) 2 points (outside ˜ 1) (8) 2 points (outside ˜ 1, belt sander)
(3) 1 point (outside ˜ 2) (6) 5 points (outside ˜ 1, belt sander)

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

(5) (6) (7)

(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

(1) 3 points (service) (4) 2 points (service) (6) 9 points


(2) 1 point (service) (5) 5 points (20 mm u 5) (7) 2 points (20 mm u 5)
(3) 6 points (service)

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

(1) 1 point (service) (5) 4 points (15 mm u 4) (8) 3 points


(2) 5 points (6) 1 point (service) (9) 2 points
(3) 1 point (7) 1 point (service ˜ matching) (10) 5 points
(4) 3 points (service)

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)

(9) (3) (3)

H J

BS-00863

(1) 3 points (service ˜ matching) (4) 2 points (7) 2 points (service)


(2) 3 points (5) 4 points (8) 10 points
(3) 1 point (6) 1 point (service) (9) 7 points

BS - 81
Closing Plate (partial replacement)

16.Closing Plate (partial replacement)


A: REMOVAL
(1)
∗a(2)
(3)

(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)

17.Frame Side Front (partial replacement)


A: REMOVAL
1) Radiator panel and front wheel apron removal condition
• Overall view

(1)

BS-00866

(1) Rough cutting (480 mm) to make


removal easier

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

(1) 1 point (inside ˜ 1) (4) 2 points (outside ˜ 1) (6) 3 points (outside ˜ 1)


(2) 2 points (bottom ˜ 1) (5) 4 points (outside ˜ 1) (7) 1 point (outside ˜ 1)
(3) 2 points (inside ˜ 1)

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

(1) 5 points (3) 10 points (5) 8 points


(2) 3 points (4) 1 point (6) 1 point (40 mm u 1)

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

(1) 5 points (service) (4) 14 points (6) 4 points (service)


(2) 1 point (service) (5) 2 points (service) (7) 3 points (service)
(3) 10 points

BS - 87
Front Side Frame (partial replacement)

18.Front Side Frame (partial replacement)


A: REMOVAL

(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)

19.Front Fender Reinforcement (total replacement)


A: REMOVAL
1) Frame fender removal condition

(1)

(1)

(1)

(1)

BS-00872

(1) 1 point (inside ˜ 1)

Makes front fender tip repair easier.

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)

20.Reinforcement Toe Board (total replacement)


A: REMOVAL
• Overall view

(1) (2) (1) (3)

(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

(1) 3 points (bottom ˜ 1) (3) 2 points (bottom ˜ 1) (5) 1 point (inside ˜ 1)


(2) 5 points (bottom ˜ 1) (4) 2 points (inside ˜ 1) (6) 1 point (bottom ˜ 0)

BS - 93
Reinforcement Toe Board (total replacement)

B: INSTALLATION
• Overall view

(1) (2) (1) (1)

(1) (3)

(3)

(4)

BS-00876

(1) 1 point (service) (3) 2 points (service) (4) 3 points (service)


(2) 4 points (service)

BS - 94
Reinforcement Toe Board (total replacement)

• Views

(1)
(2)

(3)

(3)

(2)

(4)

(4)

(4)
B
(4)

BS-00877

(1) 3 points (service) (3) 2 points (service) (4) 1 point (service)


(2) 5 points (service)

BS - 95
Front Pillar (partial replacement)

21.Front Pillar (partial replacement)


A: REMOVAL
1) Frame side upper removal condition
• Overall view

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

(1) 1 point (outside ˜ 1) (5) 1 point (inside ˜ 1) (8) 2 points (outside ˜ 1)


(2) 3 points (outside ˜ 1) (6) 3 points (inside ˜ 1) (9) Cut (240 mm) to make work easier
(3) 7 points (outside ˜ 1) (7) 2 points (inside ˜ 1) (10) Cut
(4) 1 point (top ˜ 1)

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

(1) 1 point (150 mm) (5) 10 points (9) 10 points (service)


(2) 5 points (6) 2 points (service) (10) 4 points (service)
(3) 2 points (7) 1 point (270 mm) (11) 7 points
(4) 3 points (8) 3 points (service) (12) 13 points

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)

(4) (7) (10) (11)


b (6)
D

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

(1) 1 point (4) 5 points (15 mm u 5) (7) 2 points (service)


(2) 3 points (5) 1 point (service ˜ matching) (8) 1 point (100 mm)
(3) 2 points (6) 1 point (service) (9) 1 point (240 mm)

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)

22.Center Pillar (partial replacement)


A: REMOVAL
• Overall view

150 mm
(1)
(1)

(2)

(3)
(3)

(8)

(4)

(5)
(5) B
(1)
(1)
(6)
(6)

(7)
C
BS-00884

(1) 2 points (outside ˜ 1) (3) 16 points (outside ˜ 1) (6) 2 points (top ˜ 1)


(2) Rough cutting (240 mm) outer, (4) 5 points (outside ˜ 1) (7) 9 points (outside ˜ 1)
Reinforcement (5) 1 point (outside ˜ 1) (8) 4 points (outside ˜ 1)

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

(1) 1 point (240 mm) (4) 1 point (7) 9 points (service)


(2) 19 points (5) 3 points (8) 5 points
(3) 6 points (6) 2 points (service)

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)

23.Rear Quarter / Wagon (partial replacement)


A: REMOVAL
• Overall view

(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)

• Rear quarter removal condition


• Detach the hidden hit point between the rear door catcher BKT and side sill reinforcement.

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

(1) 1 point (130 mm) (5) 5 points (9) 14 points


(2) 3 points (6) 6 points (10) 10 points
(3) 1 point (7) 9 points (11) 2 points
(4) 4 points (8) 7 points

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)

(4) (4) (6) (6) (10) (6)

C D

BS-00892

(1) 2 points (service) (5) 2 points (8) 3 points (service)


(2) 4 points (service) (6) 1 point (9) 6 points
(3) 5 points (7) 1 point (service) (10) 4 points
(4) 3 points

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)

24.Rear Quarter / Sedan (partial replacement)


A: REMOVAL
• Overall view

(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

(1) 2 points (outside ˜ 1) (4) 3 points (outside ˜ 1) (7) 8 points (bottom ˜ 1)


(2) Rough cutting (80 mm) (5) 1 point (outside ˜ 1) (8) 5 points (outside ˜ 1)
(3) Rough cutting (230 mm) (6) 4 points (outside ˜ 1) (9) 12 points (outside ˜ 1)

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

(1) 4 points (outside ˜ 1) (6) 3 points (outside ˜ 1) (10) 8 points (top ˜ 1)


(2) 1 point (outside ˜ 1) (7) 2 points (outside ˜ 1) (11) Rough cutting (230 mm)
(3) 2 points (top ˜ 1) (8) 1 point (outside ˜ 1), hidden hit (12) Rough cutting
(4) 4 points (top ˜ 1) point (13) 6 points (outside ˜ 1)
(5) 5 points (outside ˜ 1) (9) 3 points (top ˜ 1) (14) 4 points (outside ˜ 2)
• Rear quarter removal condition
• Detach the hidden hit point between the rear door catcher bracket and side sill reinforcement.

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

(1) 2 points (outside ˜ 1) (3) 7 points (outside ˜ 1) (5) 1 point (top ˜ 1)


(2) 1 point (outside ˜ 1) (4) 1 point (top ˜ 2) (6) 1 point (inside ˜ 1)

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

(1) 1 point (80 mm) (5) 4 points (8) 11 points


(2) 3 points (6) 1 point (9) 6 points
(3) 1 point (210 mm) (7) 5 points (10) 15 points
(4) 2 points

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

(1) 5 points (5) 3 points (9) 10 points


(2) 1 point (6) 2 points (10) 1 point (230 mm)
(3) 2 points (service) (7) 1 point (service), hidden hit point (11) 6 points
(4) 4 points (service) (8) 4 points (12) 4 points (matching)

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

(1) 3 points (3) 9 points (5) 1 point (service)


(2) 1 point (4) 1 point (service ˜ matching) (6) 1 point (matching)

For continuous welds marked by *, apply anticorrosion wax thoroughly on the reverse side.

BS - 118
Side Sill Outer (partial replacement)

25.Side Sill Outer (partial replacement)


A: REMOVAL
• Overall view

(2)
E
A F
(1)

BS-00900

(1) 7 points (outside ˜ 1) (2) 13 points (outside ˜ 1)

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)

• The side sill outer is inside the front pillar


• (1) is to make work easier.

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

(1) 2 points (outside ˜ 1) (4) 10 points (outside ˜ 1) (7) 3 points (outside ˜ 1)


(2) 1 point (bottom ˜ 1) (5) 2 points (top ˜ 1) (8) 9 points (outside ˜ 1)
(3) 1 point (outside ˜ 1) (6) 5 points (outside ˜ 1)

BS - 121
Side Sill Outer (partial replacement)

B: INSTALLATION
• Overall view

E
A F (2)
(1)

BS-00903

(1) 9 points (2) 16 points

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

(1) 3 points (3) 1 point (270 mm) (5) 29 points


(2) 7 points (4) 11 points

• The side sill outer is inside the front pillar.


• For continuous welds marked by *, apply anticorrosion wax thoroughly on the reverse side.

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

(1) 3 points (4) 2 points (6) 4 points


(2) 1 point (5) 6 points (7) 9 points
(3) 12 points

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

(2) (3) (4) 115 mm


(6)

A B

70 mm (7)

(1) (2) (5)

C D

BS-00907

(1) 7 points (outside ˜ 1) (4) 8 × 25 elongated hole (6) 12 mm dia. hole


(2) 5 points (outside ˜ 1) (5) 10 points (outside ˜ 1) (7) Front pillar
(3) 20 mm dia. hole

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)

(1) (2) (8)

C D

BS-00909

(1) 9 points (4) 8 × 25 elongated hole (7) Front pillar


(2) 7 points (5) 14 points (8) 13 points
(3) 20 mm dia. hole (6) 12 mm dia. hole

BS - 128
Rear Quarter Upper / Wagon (total replacement)

26.Rear Quarter Upper / Wagon (total replacement)


A: REMOVAL
1) Rear quarter and reinforcement D-pillar removed condition

(1)
(1)

(2)

(1)

(1)

(3)

(2)

(3)

(2)

(3)

BS-00910

(1) 1 point (inside ˜ 1) (2) 2 points (inside ˜ 1) (3) 3 points (inside ˜ 1)

BS - 129
Rear Quarter Upper / Wagon (total replacement)

B: INSTALLATION

(1)
(1)
(2)

(1)

(1)

(2)

(3)

(4)

(3)

(4)

BS-00911

(1) 1 point (3) 2 points (4) 4 points


(2) 3 points

BS - 130
Rear Quarter Inner Upper / Sedan (total replacement)

27.Rear Quarter Inner Upper / Sedan (total replacement)


A: REMOVAL
1) Rear quarter and reinforcement removed condition
• Overall view
(1)

(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

(1) 1 point (bottom ˜ 1) (4) 3 points (inside ˜ 1) (6) 4 points (inside ˜ 1)


(2) 3 points (bottom ˜ 1) (5) 1 point (inside ˜ 1) (7) 2 points (bottom ˜ 1)
(3) 4 points (bottom ˜ 1)

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

(1) 2 points (service) (5) 12 points (8) 2 points


(2) 6 points (service) (6) 6 points (9) 4 points
(3) 3 points (service) (7) 4 points (service) (10) 3 points
(4) 1 point

BS - 133
Rear Quarter Inner Upper / Sedan (total replacement)

• Views

(2)
(1) (3)

(4)
(4)
(4)

(6)

(5)

(5)

(3) (5)

BS-00915

(1) 1 point (service) (3) 4 points (service) (5) 1 point


(2) 3 points (service) (4) 2 points (service) (6) 5 points

BS - 134
Rear Quarter Inner Reinforcement / Sedan (total replacement)

28.Rear Quarter Inner Reinforcement / Sedan (total replacement)


A: REMOVAL
1) Rear quarter removal condition

(1)

(2)

(1)

(3)

(3)

(4)

(1)

(1)

(5)

(2) (6)

BS-00916

(1) 1 point (outside ˜ 1) (3) 5 points (outside ˜ 1) (5) 2 points (top ˜ 1)


(2) 3 points (top ˜ 1) (4) 3 points (outside ˜ 1) (6) 2 points (outside ˜ 1)

BS - 135
Rear Quarter Inner Reinforcement / Sedan (total replacement)

B: INSTALLATION

(1)

(2)

(1)

(3)

(8)

(4)

(5)

(5)

(6)

(2) (7)

BS-00917

(1) 1 point (4) 3 points (service) (7) 2 points


(2) 4 points (5) 1 point (service) (8) 6 points
(3) 5 points (service) (6) 3 points

BS - 136
Rear Bulkhead / Sedan (total replacement)

29.Rear Bulkhead / Sedan (total replacement)


A: REMOVAL
1) Rear quarter, rear quarter inner upper and reinforcement removed condition
• Overall view

A
(2)

(1)

(3)

(4)

(5)

(1)

(1)

(1) (2)

(7)
(6)

BS-00918

(1) 1 point (inside ˜ 1) (4) 5 points (inside ˜ 1) (6) 1 point (outside ˜ 1)


(2) 2 points (outside ˜ 1) (5) 2 points (top ˜ 1) (7) 2 points (inside ˜ 1)
(3) 3 points (inside ˜ 1)

BS - 137
Rear Bulkhead / Sedan (total replacement)

• Views

(1)

(2)
(3)

(1) (4)

(5)
(5)

BS-00919

(1) 1 point (top ˜ 1) (3) 2 points (top ˜ 1) (5) 2 points (outside ˜ 1)


(2) 2 points (top ˜ 2) (4) 3 points (top ˜ 1)

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

(1) 1 point (3) 1 point (service) (5) 3 points


(2) 2 points (service) (4) 5 points (service)

BS - 139
Rear Bulkhead / Sedan (total replacement)

• Views

(1)

(2)
(2)

(1) (3)

(2)
(2)

BS-00921

(1) 1 point (2) 2 points (3) 3 points

BS - 140
Rear Floor Side / Wagon (total replacement)

30.Rear Floor Side / Wagon (total replacement)


A: REMOVAL
1) Rear quarter and reinforcement D-pillar removed condition
• Overall view

(1)
(3)
(2)
A

B
(4) (4)

BS-00922

(1) 3 points (outside ˜ 1) (3) 2 points (outside ˜ 1) (4) 1 point (outside ˜ 1)


(2) 4 points (outside ˜ 1)

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)

(7) (6) (7)


(6)

B B (RH)

BS-00923

(1) 2 points (top ˜ 1) (4) 1 point (inside ˜ 1) (6) 2 points (outside ˜ 1)


(2) 1 point (top ˜ 1) (5) 13 points (top ˜ 1) (7) 3 points (outside ˜ 1)
(3) 14 points (top ˜ 1)

BS - 142
Rear Floor Side / Wagon (total replacement)

B: INSTALLATION
• Overall view

(1) (2) (3)

(4)

B
(4)

BS-00924

(1) 3 points (3) 2 points (4) 1 point


(2) 4 points

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

(1) 2 points (service) (4) 1 point (6) 2 points


(2) 1 point (service) (5) 13 points (service) (7) 3 points
(3) 14 points (service)

BS - 144
Rear Floor Side / Sedan (total replacement)

31.Rear Floor Side / Sedan (total replacement)


A: REMOVAL
1) Rear quarter and rear skirt removed condition
• Overall view

(2)

(1)

B
(1)

BS-00926

(1) 1 point (outside ˜ 2) (2) 1 point (outside ˜ 1)

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

(1) 4 points (top ˜ 1) (4) 13 points (top ˜ 1) (6) 3 points (inside ˜ 2)


(2) 1 point (top ˜ 1) (5) 2 points (inside ˜ 1) (7) 3 points (inside ˜ 1)
(3) 14 points (top ˜ 1)

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

(1) 4 points (service) (3) 14 points (service) (5) 2 points


(2) 1 point (service) (4) 13 points (service) (6) 3 points

BS - 148
Rear Skirt / Wagon (partial replacement)

32.Rear Skirt / Wagon (partial replacement)


A: REMOVAL
• Overall view

(1)
(1)

(2)
(3)
C D
(4)

(6)

(5)

A
20 mm 50 mm
B

BS-00930

(1) 1 point (outside ˜ 1) (4) 5 points (outside ˜ 1) (6) D-pillar outer


(2) 3 points (outside ˜ 1) (5) Cut (300 mm) (for butt welding)
(3) Cut position (320 mm) (for butt
welding)

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

(1) 1 point (2) 2 points (3) 3 points

BS - 152
Rear Skirt / Sedan (total replacement)

33.Rear Skirt / Sedan (total replacement)


A: REMOVAL
• Overall view

A (1)
(2) (1)
(2)
(3)

(1)
(1)

(4) (4)

B
(3) (5) (5)
(6) (6)

(1) (1)
(3)

BS-00934

(1) 1 point (outside ˜ 1) (3) 5 points (outside ˜ 1) (5) 2 points (outside ˜ 1)


(2) 3 points (outside ˜ 1) (4) 4 points (outside ˜ 1) (6) 6 points (outside ˜ 1)

BS - 153
Rear Skirt / Sedan (total replacement)

• Views

(1)

(5)
(2)

(5)

(4) (3)
(5)
A B

BS-00935

(1) 3 points (outside ˜ 1) (3) 2 points (outside ˜ 1) (5) 1 point (outside ˜ 1)


(2) 1 point (inside ˜ 1) (4) 10 points (outside ˜ 1)

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

(1) 1 point (3) 7 points (5) 3 points


(2) 4 points (4) 5 points (6) 8 points

BS - 155
Rear Skirt / Sedan (total replacement)

• Views

(1)

(2)
(2)

(2)

(4) (3)
(2)
A B

BS-00937

(1) 4 points (3) 3 points (4) 12 points


(2) 1 point

BS - 156
Rear Skirt Outer / Wagon (total replacement)

34.Rear Skirt Outer / Wagon (total replacement)


A: REMOVAL
1) D-pillar removed condition

(1) (3) (4)


(2) (2)
(1)
(1)
(3)

(1)

(5)
(5)
(6) (1)
(1)

BS-00938

(1) 1 point (outside ˜ 1) (3) 8 points (outside ˜ 1) (5) 4 points (outside ˜ 1)


(2) 2 points (outside ˜ 1) (4) 3 points (outside ˜ 1) (6) 10 points (outside ˜ 1)

BS - 157
Rear Skirt Outer / Wagon (total replacement)

B: INSTALLATION

(2) (3) (4)


(1) (5)
(8)
(2)

(3)

(8)

(6)
(6)
(7) (8)
(8)

BS-00939

(1) 3 points (4) 4 points (7) 12 points


(2) 1 point (5) 2 points (8) 1 point (service)
(3) 10 points (6) 5 points

BS - 158
Rear Skirt Inner / Wagon (partial replacement)

35.Rear Skirt Inner / Wagon (partial replacement)


A: REMOVAL
1) Rear quarter reinforcement D-pillar and rear skirt outer removed condition
• Overall view

(1) (2)
A
(3)
(4)

B
(5)

mm
100

(6) (7) (6) (7)

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

(1) (2) (3)


A

∗ (4)
B
(5)

mm
50

(6) (7) (8) (7)

BS-00942

(1) 5 points (4) 1 point (350 mm) (7) 7 points (service)


(2) 2 points (service) (5) 5 points (service) (8) 3 points (service)
(3) 1 point (service) (6) 4 points

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

(1) 2 points (service) (2) 3 points (service)

BS - 162
Rear Floor Pan (total replacement)

36.Rear Floor Pan (total replacement)


A: REMOVAL
1) Rear skirt outer and rear skirt inner removed condition
• Overall view

(1) (2)

B
A

(1)

(3) (4) (4)

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

(1) 15 points (top ˜ 2) (3) 3 points (top ˜ 1) (5) 1 point (top ˜ 1)


(2) 1 point (outside ˜ 1) (4) 2 points (top ˜ 1)

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

(1) 5 points (service) (2) 9 points (service) (3) 4 points (service)

BS - 165
Rear Floor Pan (total replacement)

• Views

(1)
(3)

(2)

(4)
(5)

A
(1)
(3)

(2)

(4)
(5)

BS-00947

(1) 15 points (3) 3 points (service) (5) 1 point (service)


(2) 1 point (4) 2 points (service)

POINT: To make removal easier, remove the rear floor side when working.

BS - 166
Closing Plate (total replacement)

37.Closing Plate (total replacement)


A: REMOVAL
• Views
(1) (3)

(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)

(8) (10) (8) (3)

F BS-00950

(1) 2 points (top ˜ 1) (5) 1 point (inside ˜ 1) (8) 5 points (top ˜ 1)


(2) 3 points (6) 3 points (inside ˜ 1) (9) 1 point (top ˜ 2)
(3) 1 point (top ˜ 1) (7) 4 points (top ˜ 1) (10) 2 points (top ˜ 2)
(4) 3 points (top ˜ 1)

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)

(8) (6) (8) (2)

BS-00953

(1) 3 points (4) 5 points (7) 1 point (matching)


(2) 1 point (5) 4 points (matching) (8) 5 points (matching)
(3) 2 points (6) 2 points (matching)

BS - 168
Rear Frame / Wagon (total replacement)

38.Rear Frame / Wagon (total replacement)


A: REMOVAL
1) Rear quarter, reinforcement, D-pillar, closing plate front CP, rear wheel apron, rear floor pan, rear skirt out-
er and rear skirt inner removed condition
• Overall view

(1) (2) (3) (4)

F
A

BS-00948

(1) 1 point (top ˜ 1) (3) 3 points (top ˜ 1) (4) 5 points (top ˜ 1)


(2) 4 points (top ˜ 1)

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)

View E shows the closing plate front complete removed.

BS - 170
Rear Frame / Wagon (total replacement)

B: INSTALLATION
• Overall view

(1) (2) (3) (4)

F
A

BS-00951

(1) 1 point (3) 3 points (4) 5 points


(2) 4 points

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

(1) 5 points (3) 1 point (5) 4 points


(2) 3 points (4) 2 points (6) 6 points

View E shows the closing plate front complete removed.

BS - 172
Rear Side Frame Rear (partial replacement)

39.Rear Side Frame Rear (partial replacement)


A: REMOVAL
• Overall view

(1)

(1)

BS-00954

(1) 2 points (top ˜ 2)

BS - 173
Rear Side Frame Rear (partial replacement)

• Views

(4)

(1)

(2)
(2)
(1)
(4) (3)

(3)
B

BS-00955

(1) 2 points (outside ˜ 1) (3) 2 points (inside ˜ 1) (4) 1 point (inside ˜ 1)


(2) 2 points (bottom ˜ 1)

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

(1) 1 point (2) 2 points

BS - 176
Plate Tractive (total replacement)

40.Plate Tractive (total replacement)


A: REMOVAL
1) Rear skirt outer and rear skirt inner removed condition

(1) (1)
(2)

(3) (4)

(3)

(5) (5)
BS-00958

(1) 1 point (outside ˜ 1) (3) 4 points (top ˜ 1) (5) 2 points (top ˜ 2)


(2) 5 points (outside ˜ 1) (4) 3 points (top ˜ 1)

On sedans: rear skirt outer removed condition

BS - 177
Plate Tractive (total replacement)

B: INSTALLATION
(1)

(2)

(1)

265 265

(3)

(4)

(4)

(5) (5)
BS-00959

(1) 1 point (3) 3 points (5) 2 points (service ˜ matching)


(2) 5 points (4) 4 points

On sedans: rear skirt outer removed condition

BS - 178
Rear Panel / Sedan (total replacement)

41.Rear Panel / Sedan (total replacement)


A: REMOVAL
1) Rear quarter, rear quarter inner upper and reinforcement removed condition
• Overall view

(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

(1) 1 point (top ˜ 1) (4) 2 points (top ˜ 1) (7) 3 points (inside ˜ 1)


(2) 1 point (outside ˜ 1) (5) 3 points (top ˜ 1) (8) 1 point (top ˜ 2)
(3) 4 points (top ˜ 1) (6) 1 point (inside ˜ 2)

BS - 179
Rear Panel / Sedan (total replacement)

• Views

(1) (1)

(1)

(2)

BS-00961

(1) 1 point (inside ˜ 2) (2) 3 points (inside ˜ 1)

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

(1) 1 point (3) 3 points (5) 1 point (service ˜ matching)


(2) 5 points (4) 4 points

BS - 181
Rear Panel / Sedan (total replacement)

• Views

(1) (1)

(1)

(2)

BS-00963

(1) 1 point (service ˜ matching) (2) 4 points

BS - 182
Roof Panel / Wagon (total replacement)

42.Roof Panel / Wagon (total replacement)


A: REMOVAL
• Overall view

(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

(1) 15 points (top ˜ 1) (4) 1 point (outside ˜ 1) (7) 7 points


(2) 16 points (top ˜ 1) (5) 3 points (top ˜ 1) (8) 2 points (top ˜ 1)
(3) 17 points (outside ˜ 1) (6) 5 points (top ˜ 1) (9) 1 point (top ˜ 1)

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

(1) 3 points (top ˜ 1) (3) 4 points (top ˜ 1) (4) 2 points (top ˜ 1)


(2) 1 point (top ˜ 1)

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

(1) 20 points (4) 1 point (10 mm) (7) 10 points


(2) 21 points (5) 4 points (8) 3 points
(3) 1 point (6) 6 points

BS - 185
Roof Panel / Wagon (total replacement)

• Views

★ (2)
★ (2)
★ (2)
★ (2)
★ (1)

★ (4)

★ (2) ★ (2)
★ (5)
★ (6)
★ (3)

A
B

BS-00967

(1) 4 points (3) 1 point (120 mm u 1) (5) 3 points


(2) 1 point (4) 5 points (6) 1 point (60 mm u 1)

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

(1) 15 points (4) 3 points (Only on overhead (5) 9 points


(2) 8 points console equipped vehicles) (6) 2 points
(3) 3 points

BS - 187
Roof Panel / Sedan (total replacement)

43.Roof Panel / Sedan (total replacement)


A: REMOVAL
• Overall view

(1)
★ (3) B

★ (4)
★ (5)
★ (6)
★ (5)

(2) ★ (8) ★ (7)

★ (5)

★ (9)
A

(1)
★ (4) B

★ (3)
★ (5)
★ (10)
★ (5)

(2) ★ (7)
★ (10)
★ (7)
A
★ (5)

★ (9)

BS-00969

(1) 17 points (top ˜ 1) (5) 1 point (top ˜ 1) (8) 5 points (top ˜ 1)


(2) 15 points (top ˜ 1) (6) 3 points (top ˜ 1) (9) 6 points (top ˜ 1)
(3) 1 point (outside ˜ 1) (7) 4 points (top ˜ 1) (10) 2 points (top ˜ 1)
(4) 4 points (outside ˜ 1)

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

(1) 2 points (top ˜ 1) (2) 1 point (top ˜ 1)

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

(1) 20 points (4) 3 points (7) 8 points


(2) 5 points (5) 1 point (8) 2 points
(3) 1 point (10 mm u 1) (6) 6 points

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

(1) 3 points (3) 1 point (60 mm u 1) (5) 1 point (130 mm u 1)


(2) 1 point (4) 2 points

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

(1) 9 points (3) 3 points (4) 11 points


(2) 17 points

BS - 192

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