Download: FOREWORD This repair manual has been prepared to provide essential in-

FOREWORD This repair manual has been prepared to provide essential in- formation on body panel repair methods (including cutting and welding operations, but excluding painting) for the TOYOTA YARIS. Applicable models: KSP90 series Applicable models: NCP90, 91 series This manual consists of body repair methods, exploded dia- grams and illustrations of the body components and other in- formation relating to body panel replacement such as handling precautions, etc. However, it should be noted that the front fend- ers of, this TOYOTA model are bolted on and require no welding. When repairing, don’...
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Content

FOREWORD

This repair manual has been prepared to provide essential in- formation on body panel repair methods (including cutting and welding operations, but excluding painting) for the TOYOTA YARIS. Applicable models: KSP90 series Applicable models: NCP90, 91 series This manual consists of body repair methods, exploded dia- grams and illustrations of the body components and other in- formation relating to body panel replacement such as handling precautions, etc. However, it should be noted that the front fend- ers of, this TOYOTA model are bolted on and require no welding. When repairing, don’t cut and join areas that are not shown in this manual. Only work on the specified contents to maintain body strength. Body construction will sometimes differ depending on specifica- tions and country of destination. Therefore, please keep in mind that the information contained herein is based on vehicles for general destinations. For the repair procedures and specifications other than collision- damaged body components of the TOYOTA YARIS refer to the repair manuals. If you require the above manuals, please contact your TOYOTA dealer. All information contained in this manual is the most up-to-date at the time of publication. However, specifications and procedures are subject to change without prior notice.,

VIEWS OF THIS TEXT Scope of the repair work explanation

This text explains the welding panel replacement instructions from the vehicle’s white body condi- tion. We have abbreviated the explanations of the removal and reinstallation of the equipment parts up to the white body condition and of the installation, inspection, adjustment and final inspection of equipment parts after replacing the weld panel.

Section categories

This manual has been divided as shown below. Section Title Contents Examples Explanation of general body repair. Cautionary items.

INTRODUCTION

Views of weld panel replacement instructions. Views of weld panel replacement instructions. Instructions for replacing the weld panels Front side member replacement. from the white body condition, from which Quarter panel replacement. BODY PANEL REPLACEMENT bolted parts have been removed, with individual supply parts. BODY DIMENSIONS Body aligning measurements. Dimension diagrams. Scope and type of anti-rust treatment, etc. Under coating. PAINT COATING together with weld panel replacement. Body sealer.

Contents omitted in this manual.

Make sure to perform the following essential procedures, although they are omitted in this manual. (1) Jack and lift operations. (2) Clean and wash removed parts, if necessary. (3) Visual inspection., INTRODUCTION IN-1

GENERAL REPAIR INSTRUCTIONS

1. WORK PRECAUTIONS (a) VEHICLE PROTECTION Glass Cover (1) When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fireproof covers. Seat Cover F10001A (b) SAFETY (1) Never stand in a direct line with the chain when using a puller on the body or frame, and be sure to attach a safety cable.

WRONG

F10002A (2) Before performing repair work, check for fuel leaks. If a leak is found, be sure to close the opening com- pletely. (3) If it is necessary to use a flame in the area of the fuel tank, first remove the tank and plug the fuel line. WRONG F10003A (c) SAFETY WORK CLOTHES (1) In addition to the usual mechanic’s wear, cap and safety shoes, the appropriate gloves, head protector, glasses, ear plugs, face protector, dust-prevention mask, etc. should be worn as the situation demands. Code Name A Dust-Prevention Mask B Face Protector F10004A C Eye Protector D Safety Shoes E Welder’s Glasses F Ear Plugs G Head Protector H Welder’s Gloves, IN-2 INTRODUCTION 2. HANDLING PRECAUTIONS OF PLASTIC BODY PARTS (1) The repair procedure for plastic body parts must conform with the type of plastic material. (2) Plastic body parts are identified by the codes in the following table. (3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, paint- ing etc.), consideration must be given to the properties of the plastic. Heat* Material resistant Resistance to Code Notes name temperature alcohol or gasoline limit C (F) Alcohol is harmless if applied only for Acrylonitrile 80 Avoid gasoline and organic AAS short time in small amounts (e.g., quick Acrylic Styrene (176) or aromatic solvents. wiping to remove grease). Alcohol is harmless if applied only for Acrylonitrile 80 Avoid gasoline and organic ABS short time in small amounts (e.g., quick Butadiene Styrene (176) or aromatic solvents. wiping to remove grease). Alcohol is harmless if applied only for Acrylonitrile 80 Avoid gasoline and organic AES short time in small amounts (e.g., quick Ethylene Styrene (176) or aromatic solvents. wiping to remove grease). Acrylonitrile Alcohol is harmless if applied only for 80 Avoid gasoline and organic ASA Styrene short time in small amounts (e.g., quick (176) or aromatic solvents. Acrylate wiping to remove grease). Alcohol is harmless if applied only for Cellulose 80 Avoid gasoline and organic CAB short time in small amounts (e.g., quick Acetate (176) or aromatic solvents. wiping to remove grease). Alcohol is harmless. Most solvents are harmless Ethylene 100 EPDM Gasoline is harmless if applied only for but avoid dipping in gasoline, Propylene (212) short time in small amounts. solvents, etc. Fiber FRP Reinforced Alcohol and gasoline are harmless. Avoid alkali. (356) Plastics Alcohol is harmless if applied only for Ethylene 70 Avoid gasoline and organic EVA short time in small amounts (e.g., quick Acetate (158) or aromatic solvents. wiping to remove grease). Ethylene/ Vinyl Alcohol is harmless if applied only for 70 Avoid gasoline and organic E/VAC Acetate short time in small amounts (e.g., quick (158) or aromatic solvents. Copolymer wiping to remove grease). Resin Polyamide 80 PA Alcohol and gasoline are harmless. Avoid battery acid. (Nylon) (176) Polybutylene 160 PBT Alcohol and gasoline are harmless. Most solvents are harmless. Terephthalate (320) Avoid gasoline, brake fluid, PC Polycarbonate Alcohol is harmless. wax, wax removers and (248) organic solvents. Avoid alkali. *Temperatures higher than those listed here may result in material deformation during repair., INTRODUCTION IN-3 Heat* Material resistant Resistance to Code Notes name temperature alcohol or gasoline limit C (F) PE Polyethylene Alcohol and gasoline are harmless. Most solvents are harmless. (176) Polyethylene 75 PET Alcohol and gasoline are harmless. Avoid dipping in water. Terephthalate (167) Avoid dipping or immersing Polymethyl 80 Alcohol is harmless if applied only for PMMA in alcohol, gasoline, Methacrylate (176) short time in small amounts. solvents, etc. Polyoxymethylene 100 POM Alcohol and gasoline are harmless. Most solvents are harmless. (Polyacetal) (212) PP Polypropylene Alcohol and gasoline are harmless. Most solvents are harmless. (176) Composite PPF Reinforced Alcohol and gasoline are harmless. Most solvents are harmless. (176) Polypropylene Modified Gasoline is harmless if PPO Polyphenylene Alcohol is harmless. applied only for quick wiping (212) Oxide to remove grease. Alcohol and gasoline are harmless if Avoid dipping or immersing PS Polystyrene applied only for short time in small in alcohol, gasoline, (140) amounts. solvents, etc. Alcohol is harmless if applied only for very Avoid dipping or immersing PUR Polyurethane short time in small amounts (e.g., quick in alcohol, gasoline, (176) wiping to remove grease). solvents, etc. Alcohol and gasoline are harmless if Avoid dipping or immersing Polyvinylchloride 80 applied only for short time in small PVC in alcohol, gasoline, (Vinyl) (176) amounts (e.g., quick wiping to remove solvents, etc. grease). Alcohol is harmless if applied only for Avoid dipping or immersing Styrene 80 SAN short time in small amounts (e.g., quick in alcohol, gasoline, Acrylonitrile (176) wiping to remove grease). solvents, etc. Alcohol is harmless. Most solvents are harmless Thermoplastic 80 TPO Gasoline is harmless if applied only for but avoid dipping in gasoline, Olefine (176) short time in small amounts. solvents, etc. Alcohol is harmless if applied only for Avoid dipping or immersing Thermoplastic 80 TPU short time in small amounts (e.g., quick in alcohol, gasoline, Polyurethane (176) wiping to remove grease). solvents, etc.

TOYOTA

TSOP Super Alcohol and gasoline are harmless. Most solvents are harmless. (176) Olefine Polymer Unsaturated 110 UP Alcohol and gasoline are harmless. Avoid alkali. Polyester (233) *Temperatures higher than those listed here may result in material deformation during repair., IN-4 INTRODUCTION 3. LOCATION OF PLASTIC BODY PARTS Parts Name Code Front Bumper Cover TSOP Radiator Grille TSOP Headlight PC/PP Fog Light TSOP Front Pillar Upper Cover AES Side Turn Signal Light PMMA/PC/ABS Cowl Top Ventilator Louver TSOP/PP/PE Rear Body Mudguard PP Door Outside Handle PA/PC/PBT Outer Rear View Mirror PP/PA/ABS ASA Front Door Window Frame Front Moulding ASA Front Spoiler Cover TSOP Front Fender Mudguard PP Back Door Outside Handle PA License Plate Light PC Rear Combination Light PMMA/ASA Rear Bumper Cover TSOP HINT: Resin material differs depending on mod- el. / Made up of 2 or more kinds of materials., INTRODUCTION IN-5

HOW TO USE THIS MANUAL

1. BODY PANEL REPLACEMENT IN THIS MANUAL BODY PANEL REPLACEMENT QUARTER PANEL (CUT)

REPLACEMENT REMOVAL POINT

1. Remove the [A] at the same time. PART NAME [A] Fuel filler opening lid 200 mm (7.87 in.) REPLACEMENT PART AND METHOD

QUARTER PANEL (CUT)

Replacement method (ASSY)...Assembly replacement (CUT)...Major cutting (less than 1/2 of part used) (CUT-H)...Half cutting (about 1/2 of part used) (CUT-P)...Partial cutting (most of part used) Replacement part REMOVAL CONDITIONS PART LOCATION REMOVAL DIAGRAM Describes in detail the removal of the damaged part involving repair by cutting. REMOVAL GUIDE Provides additional information to more efficiently help you perform the removal. F13890A,

IN-6 INTRODUCTION

BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.

POINT

1. Before temporarily installing the new parts, apply sealer to the wheel arch.

HINT

1) Apply body sealer about 5 mm (0.20 in.) front the flange, avoiding any oozing. 2) Apply sealer evenly, about 3−4 mm (0.12−0.16 in.) in diameter 3) For other sealing points, refer to section PC.

INSTALLATION CONDITIONS INSTALLATION DIAGRAM Describes in detail the installation of the new parts involving repair by welding and/or

cutting, but excluding painting.

INSTALLATION GUIDE Provides additional information to more efficiently help you perform the installation. SYMBOLS

(See page IN-7)

INSTALLATION OF WELD POINTS Weld method and panel position symbols (See page IN-9) PART NAME

F13891A, INTRODUCTION IN-7 2. SYMBOLS

The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas

and the types of weld required. SYMBOLS MEANING ILLUSTRATION CUT AND JOIN LOCATION (Saw Cut) CUT AND JOIN LOCATION (Cut Location for Supply Parts) CUT LOCATION CUT WITH DISC SANDER, ETC.

BRAZE

(Removal)

BRAZE

(Installation) WELD POINTS SPOT WELD OR MIG PLUG WELD (See page IN-9)

CONTINUOUS

MIG WELD (BUTT WELD)

CONTINUOUS

MIG WELD (TACK WELD) BODY SEALER F13893A, IN-8 INTRODUCTION

SYMBOLS MEANING ILLUSTRATION

— Assembly Mark — — BODY SEALER(Flat Finishing) — BODY SEALER(No Flat Finishing) F13894A, INTRODUCTION IN-9 3. ILLUSTRATION OF WELD POINT SYMBOLS

EXAMPLE:

REMOVAL INSTALLATION Weld points Weld points Remove weld point and panel position Weld method and panel position SYMBOLS MEANING ILLUSTRATION SYMBOLS MEANING ILLUSTRATION Remove Weld Points Spot Weld (Outside) MIG Plug Weld (Middle) (Inside) Spot MIG Weld HINT: Panel position symbols are as seen from the working posture. F13892A, IN-10 INTRODUCTION

PROPER AND EFFICIENT WORK PROCEDURES

1. REMOVAL (a) PRE-REMOVAL MEASURING (1) Before removal or cutting operations, take measure- ments in accordance with the dimensions diagram. Al- ways use a puller to straighten a damaged body or frame. F10007A (b) CUTTING AREA Cutting Okay (1) Always cut in a straight line and avoid reinforced Reinforcement areas. Corners F10008A (c) PRECAUTIONS FOR DRILLING OR CUTTING (1) Check behind any area to be drilled or cut to ensure that there are no hoses, wires, etc., that may be dam- aged. HINT: See “Handling Precautions on Related Compo- nents” on page IN-15. WRONG F10009A (d) REMOVAL OF ADJACENT COMPONENTS (1) When removing adjacent components, apply protec- tive tape to the surrounding body and your tools to pre- vent damage. HINT: See “Handling Precautions on Related Compo- nents” on page IN-15. F10010A, INTRODUCTION IN-11 2. PREPARATION FOR INSTALLATION (a) SPOT WELD POINTS (1) When welding panels with a combined thickness of Less than over 3 mm (0.12 in.), use a MIG (Metal Inert Gas) 3 mm welder for plug welding. HINT: Spot welding does not provide sufficient dura- bility for panels with a combined thickness of over 3 mm (0.12 in.). F10011A (b) APPLICATION OF WELD-THROUGH PRIMER (SPOT SEALER) (1) Remove the paint from the portion of the new parts and body to be welded, and apply weld-through prim- er. F10012A (c) MAKING HOLES FOR PLUG WELDING (1) For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding. REFERENCE: mm (in.) Thickness of welded portion Size of plug hole 1.0 (0.04) under 5 (0.20) ø over Puncher 1.0 (0.04) − 1.6 (0.06) 6.5 (0.26) ø over 1.7 (0.07) − 2.3 (0.09) 8 (0.31) ø over F10013A 2.4 (0.09) over 10 (0.39) ø over (d) SAFETY PRECAUTIONS FOR ELECTRICAL COM-

PONENTS

(1) When welding, there is a danger that electrical compo- nents will be damaged by the electrical current flowing through the body. (2) Before starting work, disconnect the negative terminal of the battery and ground the welder near the welding location of the body. F10014A (e) ROUGH CUTTING OF JOINTS 20 − 30 mm (1) For joint areas, rough cut the new parts, leaving 20 − Air Saw Overlap 30 mm (0.79 − 1.18 in.) of overlap. F10015A, IN-12 INTRODUCTION 3. INSTALLATION Body Measurement Diagrams (a) PRE-WELDING MEASUREMENTS (1) Always take measurements before installing under- body or engine components to ensure correct assem- bly. After installation, confirm proper fit. F10016A (b) WELDING PRECAUTIONS (1) The number of welding spots should be as follows. Spot weld: 1.3 X No. of manufacturer’s spots. Plug weld: More than No. of manufacturer’s plugs. (2) Plug welding should be done with a MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at areas other than specified. WRONG F10017A (c) POST-WELDING REFINISHING (1) Always check the welded spots to ensure they are se- cure. (2) When smoothing out the weld spots with a disc grind- er, be careful not to grind off too much as this will weak- en the weld. CORRECT WRONG F10018A (d) SPOT WELD LOCATIONS New Spot Old Locations (1) Avoid welding over previously welded areas. Spot Locations F10020A (e) SPOT WELDING PRECAUTIONS (1) The shape of the tip point of the spot welder signifi- cantly affects the strength of the weld. Therefore, maintain the tip point in the proper shape, and allow it to cool after every five or six spots. (2) Completely remove the paint from the areas to be spot welded, including the seams and the surfaces that come in contact with the welding tip. (3) Use a sander to remove any burrs that are created Tip Cutter F10019A during spot welding., INTRODUCTION IN-13 Sealer Gun 4. ANTI-RUST TREATMENT AFTER INSTALLATION (BEFORE PAINTING PROCESS) (a) BODY SEALER APPLICATION (1) For water-proofing and anti-corrosion measures, al- ways apply the body sealer to the body panel seams and hems of the doors, hood, etc. F10021A (b) UNDERCOAT APPLICATION (1) To prevent corrosion and protect the body from dam- age by flying stones, always apply sufficient under- coating to the bottom surface of the under body and inside of the wheel housings. F10022A 5. ANTI-RUST TREATMENT AFTER INSTALLATION (AFTER PAINTING PROCESS) (a) ANTI-RUST AGENT (WAX) APPLICATION (1) To preserve impossible to paint areas from corrosion, always apply sufficient anti-rust agent (wax) to the in- side of the hemming areas of the doors and hood, and around the hinges, or the welded surfaces inside the box-shaped cross sections of the side members, body pillar, etc. F10023A, IN-14 INTRODUCTION 6. ANTI-RUST TREATMENT BY PAINTING REFERENCE: Painting prevents corrosion and protects the sheet metal from damage. In this section, anti-chipping paint only for anti-corrosion purpose is described. (a) ANTI-CHIPPING PAINT (1) To prevent corrosion and protect the body from dam- age by flying stones, etc., apply anti-chipping paint to the rocker panel, wheel arch areas, balance panel, etc. HINT: Depending on the model or the application area, there are cases where the application of anti-chipping paint is necessary before the second coat or after the top coat. Apply the anti-chipping paint after Apply the anti-chipping paint before the top coat. the second coat. Top Coat Anti-Chipping Paint Second Coat Top Coat Anti-Chipping Paint Second Coat Under Coat (ED Primer) Under Coat (ED Primer) Steel Metal Steel Metal F10024A, INTRODUCTION IN-15

HANDLING PRECAUTIONS ON RELATED COMPONENTS

1. BRAKE SYSTEM The brake system is one of the most important safety components. Always follow the directions and notes given in the brake (32) section of the repair manual for the relevant model when handling brake system parts. NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC sys- tem. 2. DRIVE TRAIN AND CHASSIS The drive train and chassis are components that can have great effects on the running performance and vibration resistance of the vehicle. After installing components in the sections listed in the table below, perform alignments to ensure correct mounting angles and dimensions. Body repair must be particularly accurate to ensure correct alignment. HINT: Correct procedures and special tools are required for alignment. Always follow the directions giv- en in the repair manual for the relevant model during alignment and section DI of this section. Section of repair manual Component to be aligned for relevant model Front Wheels Front Suspension (26) section Rear Wheels Rear Suspension (27) section 3. COMPONENTS ADJACENT TO THE BODY PANELS Various types of component parts are mounted directly on or adjacently to the body panels. Strictly ob- serve the following precautions to prevent damaging these components and the body panels during han- dling. Before repairing the body panels, remove their components or apply protective covers over the com- ponents. Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool tip or blade to prevent damaging the components and the body paint. Before removing components from the outer surface of the body, attach protective tape to the body to ensure no damage to painted areas. HINT: Apply touch-up paint to any damaged paint surfaces. Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side. 4. ECU (ELECTRONIC CONTROL UNIT) Many ECUs are mounted in this vehicle. Take the following precautions during body repair to prevent damage to the ECUs. Before starting electric welding operations, disconnect the negative (−) terminal cable from the bat- tery. When the negative (−) terminal cable is disconnected from the battery, memory of the clock and audio systems will be canceled. So before starting work, make a record of the contents memorized by each memory system. Then when work is finished, reset the clock and audio systems as before. When the vehicle has tilt and telescopic steering, power seats and outside rear view mirrors, which are all equipped with a memory function, it is not possible to make a record of the memory contents. So when the operation is finished, it will be necessary to explain this fact to the customer, and request the customer to adjust the features and reset the memory. Do not expose the ECUs to ambient temperatures above 80C (176F). NOTICE: If it is possible the ambient temperature may reach 80C (176F) or more, remove the ECUs from the vehicle before starting work. Be careful not to drop the ECUs and not to apply physical shocks to them., IN-16 INTRODUCTION

PRECAUTIONS FOR REPAIRING BODY STRUCTURE PANELS

1. HEAT REPAIR FOR BODY STRUCTURE

PANELS

Toyota prohibits the use of the heat repair method on body structure panels when repairing a vehicle damaged in a col- lision. Panels that have high strength and rigidity, as well as a long life span for the automobile body are in high demand. At Toyota, in order to fulfill these requirement, we use high tensile strength steel sheets and rust preventive steel sheets on the body. High tensile steel sheets are made with alloy additives and a special heat treatment in order to im- prove the strength. To prevent the occurrence of rust for a long period of time, the surface of the steel is coated with a zinc alloy. If body structure parts are heat repaired with an acetylene torch or other heating source, the crystalline organization of the steel sheet will change and the strength of the steel sheet will be reduced. The ability of the body to resist rust is significantly lowered as well since the rust resistant zinc coating is destroyed by heat and the steel sheet surface is oxidized. 2. STRUCTURE PANEL KINKS A sharp deformation angle on a panel that cannot be re- turned to its original shape by pulling or hammering is called a kink. Structural parts are designed to perform in their original shape. If parts are deformed in an accident, or if the de- formed parts are repaired and reused, the parts may be un- able to perform as intended. It is necessary to replace the part where the kink has oc- curred., INTRODUCTION IN-17 3. IMPACT BEAM REPAIR The impact beam and bracket are necessary and important parts that help reduce the probability of injury to passen- gers in side collisions. For impact beams, we use special high tensile strength steel. The high tensile strength steel maintains its special crystal- line organization by heat treatment or alloy additives. Structural parts are designed to perform in their original shape. If parts are deformed in an accident, or if the de- formed parts are repaired and reused, the parts may be un- able to perform as intended. If the impact beam or bracket is damaged, replace the door assembly with the damaged beam. Also, the bumper reinforcement is a necessary and impor- tant part that helps reduce the probability of injury to pas- sengers in front collisions, and for the same reasons ex- plained above, should be replaced if damaged., IN-18 INTRODUCTION

ABBREVIATIONS USED IN THIS MANUAL

For convenience, the following abbreviations are used in this manual. ABS Antilock Brake System A/C Air Conditioner assy assembly ECT Electronic Controlled Transmission ECU Electronic Control Unit e.g. Exempli Gratia (for Example) Ex. Except FWD Front Wheel Drive Vehicles 2WD Two Wheel Drive Vehicles 4WD Four Wheel Drive Vehicles in. inch LH Left-hand LHD Left-hand Drive MIG Metal Inert Gas M/Y Model Year PPS Progressive Power Steering RH Right-hand RHD Right-hand Drive SRS Supplemental Restraint System SSM Special Service Materials w/ with w/o without, BODY PANEL REPLACEMENT BP-1

RADIATOR SUPPORT (ASSY) REPLACEMENT

F22816A

REMOVAL

F22816

POINT

1 *1: Bolt, BP-2 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F22817

POINT

1 Inspect the fitting of the headlight, front fender, hood and other related parts, before welding as this affects the appearance of the finish. 2 *1: Bolt, BODY PANEL REPLACEMENT BP-3 1,324 mm 530 mm 944 mm 742 mm F22818

POINT

1 Measure the dimensions before installing the headlight. 2 These values are reference values. 530 mm (20.87 in.) 742 mm (29.21 in.) 944 mm (37.17 in.) 1,324 mm (52.13 in.), BP-4 BODY PANEL REPLACEMENT

FRONT FENDER MOUNTING BRACKET

(ASSY)

REPLACEMENT

F22819A

REMOVAL

F22819, BODY PANEL REPLACEMENT BP-5

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F22820

POINT

1 Inspect the fitting of the front fender and other related parts before welding as this affects the appearance of the finish., BP-110 BODY PANEL REPLACEMENT

QUARTER PANEL UPPER EXTENSION

(CUT): Hatchback

REPLACEMENT

With the back door opening trough removed. F22867A

REMOVAL

130 mm F22867 130 mm (5.12 in.), BODY PANEL REPLACEMENT BP-111

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F22868, BP-112 BODY PANEL REPLACEMENT

FLOOR SIDE RAIL FRONT PANEL (ASSY): Hatchback REPLACEMENT

With the body lower back panel removed. F22869A

REMOVAL

F23327, BODY PANEL REPLACEMENT BP-113

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. (10 mm 2) F23328 10 mm ( 0.39 in.), BP-114 BODY PANEL REPLACEMENT

FLOOR SIDE RAIL FRONT PANEL (ASSY): Sedan REPLACEMENT

With the body lower back panel removed. F24846A

REMOVAL

F24846-1

POINT

1 Remove [A] at the same time. PART NAME [A] Rear Floor Pan Extension, BODY PANEL REPLACEMENT BP-115

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. (10 mm x 2) F24846-2 10 mm (0.39 in.), BODY PANEL REPLACEMENT BP-123

REAR FLOOR SIDE PANEL EXTENSION

(ASSY): Hatchback

REPLACEMENT

With the quarter panel and body lower back panel removed. F22875A

REMOVAL

F22875

POINT

1 After removing the rear floor side panel extension, remove [A]. PART NAME [A] Quarter Wheel Housing Extension, BP-124 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F22876

POINT

1 After installing [A], install the new parts. PART NAME [A] Quarter Wheel Housing Extension, BP-116 BODY PANEL REPLACEMENT

REAR FLOOR PAN (ASSY): Hatchback REPLACEMENT

With the body lower back panel and floor side rail front panel removed. F22871A

REMOVAL

[EX. U.S.A., CANADA] F23347, BODY PANEL REPLACEMENT BP-117 [U.S.A., CANADA] F23345

POINT

1 After removing [A], remove the rear floor pan. PART NAME [A] Rear Floor Brace Braket, BP-118 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. [EX. U.S.A., CANADA] F23348 PART NAME [B] Spare Wheel Clamp Bracket [C] Actuator Cover No.3 Bracket, BODY PANEL REPLACEMENT BP-119 [U.S.A., CANADA] F23346

POINT

1 After installing the new parts, install [A]. PART NAME [A] Rear Floor Brace Bracket [B] Spare Wheel Clamp Bracket [D] Fuel Tube No.2 Bracket [E] Fuel Tube Bracket, BODY PANEL REPLACEMENT BP-125

REAR FLOOR PAN EXTENSION (ASSY): Sedan REPLACEMENT

With the body lower back panel removed. F24852A

REMOVAL

50 mm F24852-1

POINT

1 Remove [A] at the same time. PART NAME [A] Floor Side Rail Front Panel 50 mm (1.97 in.), BP-126 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F24852-2 PART NAME [A] Floor Side Rail Front Panel, BP-120 BODY PANEL REPLACEMENT

REAR FLOOR PAN (ASSY): Sedan REPLACEMENT

With the floor side rail front panel removed. F24848A

REMOVAL

F24848, BODY PANEL REPLACEMENT BP-121

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. [EX. U.S.A., CANADA] [U.S.A., CANADA] F24849-1 PART NAME [A] Actuator Cover No.3 Bracket [B] Spare Wheel Clamp Bracket [C] Weld Bolt [D] Fuel Tube Bracket [E] Fuel Tube No.2 Bracket, BP-122 BODY PANEL REPLACEMENT F24849-2, BODY PANEL REPLACEMENT BP-127

REAR FLOOR CROSSMEMBER NO.2

(ASSY): Hatchback

REPLACEMENT

F22877A

REMOVAL

F22877, BP-128 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F22878, BODY PANEL REPLACEMENT BP-129

REAR FLOOR CROSSMEMBER NO.2

(ASSY): Sedan

REPLACEMENT

F24853A

REMOVAL

F24853-1, BP-130 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F24853-2, BODY PANEL REPLACEMENT BP-135

ROOF PANEL (ASSY): Hatchback REPLACEMENT

F22885A

REMOVAL

3 Door : 5 Door : 3 Door : 5 Door : F23331, BP-136 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. 3 Door : 5 Door : 3 Door : 5 Door : F23332

POINT

1 Before temporarily installing the new parts, apply body sealer to the window shield header panel, roof panel reinforcement and back window upper frame. HINT: 1) Apply just enough sealer for the new parts to make contact., BP-6 BODY PANEL REPLACEMENT

FRONT FENDER APRON (ASSY) REPLACEMENT

With the cowl top side panel removed. F22821A

REMOVAL

[RH] [LH] F22821, BODY PANEL REPLACEMENT BP-7 F22822, BP-8 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. [RH] [LH] F22823

POINT

1 Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front wheel alignment. 2 Inspect the fitting of the front fender, hood and other related parts before welding as this affects the appearance of the finish., BODY PANEL REPLACEMENT BP-9 F22824, BODY PANEL REPLACEMENT BP-137

ROOF PANEL (ASSY): Sedan REPLACEMENT

F24859A

REMOVAL

F24859-1, BP-138 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F248860-1

POINT

1 Before temporarily installing the new parts, apply body sealer to the window shield header panel, roof panel reinforcement and back window upper frame. HINT: 1) Apply just enough sealer for the new parts to make contact., BODY PANEL REPLACEMENT BP-131

REAR FLOOR SIDEMEMBER (CUT): Hatchback REPLACEMENT

With the body lower back panel removed. F22881A

REMOVAL

110 mm 40 mm F23329

POINT

1 After removing [A], remove the rear floor sidemember. PART NAME [A] Floor Side Rail Front Panel 40 mm (1.57 in.) 110 mm (4.33 in.), BP-132 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F23330 PART NAME [A] Floor Side Rail Front Panel, BODY PANEL REPLACEMENT BP-139

OUTER PANEL INSTALLATION TORQUE

[Hatchback] T = 13.0 N.m T = 11.5 N.m T = 5.5 N.m T = 5.5 N.m T = 5.5 N.m T = 5.5 N.m T = 5.0 N .m T = 40.0 N.m T = 40.0 N.m T = 5.0 N.m T = 5.5 N.m T = 5.0 N.m F22801 5.0 N.m (51 kgf.cm, 44 in..lbf) 5.5 N.m (56 kgf.cm, 49 in..lbf) 11.5 N.m (117 kgf.cm, 8 ft..lbf) 13.0 N.m (133 kgf.cm, 10 ft..lbf) 40.0 N.m (408 kgf.cm, 30 ft..lbf) —, BP-140 BODY PANEL REPLACEMENT [Sedan] T = 13.0 N.m T = 5.5 N.m T = 11.5 N.m T = 5.5 N.m T = 5.5 N.m T = 5.5 N.m T = 5.0 N.m T = 40.0 N.m T = 40.0 N.m T = 5.0 N.m T = 5.0 N.m T = 5.5 N.m T = 5.0 N.m F24861-1 5.0 N.m (51 kgf.cm, 44 in..lbf) 5.5 N.m (56 kgf.cm, 49 in..lbf) 11.5 N.m (117 kgf.cm, 8 ft..lbf) 13.0 N.m (133 kgf.cm, 10 ft..lbf) 40.0 N.m (408 kgf.cm, 30 ft..lbf) —, BODY PANEL REPLACEMENT BP-141 [Hatchback 3 Door] T = 26.0 N.m T = 26.0 N.m F23333 26.0 N.m (265 kgf.cm, 19 ft..lbf) — —, BP-142 BODY PANEL REPLACEMENT [Hatchback 5 Door] T = 26.0 N.m T = 26.0 N.m T = 26.0 N.m T = 26.0 N.m F23334 26.0 N.m (265 kgf.cm, 19 ft..lbf) — —, BODY PANEL REPLACEMENT BP-143 [Sedan] T = 26.0 N.m T = 26.0 N.m T = 26.0 N.m T = 26.0 N.m F24862-1 26.0 N.m (265 kgf.cm, 19 ft..lbf) — —, BP-144 BODY PANEL REPLACEMENT [Hatchback] T = 11.5 N.m T = 27.0 N.m T = 19.0 N.m F22803 11.5 N.m (117 kgf.cm, 8 ft..lbf) 19.0 N.m (194 kgf.cm, 14 ft..lbf) 27.0 N.m (275 kgf.cm, 20 ft..lbf), BODY PANEL REPLACEMENT BP-145 [Sedan] T = 7.0 N.m T = 19.0 N.m F24863-1 7.0 N.m (71 kgf.cm, 62 in..lbf) 19.0 N.m (194 kgf.cm, 14 ft..lbf) —, BODY PANEL REPLACEMENT BP-133

REAR FLOOR SIDEMEMBER (ASSY): Sedan REPLACEMENT

With the rear floor pan removed. F24855A

REMOVAL

F24855-1, BP-134 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F24855-2, BP-146 BODY PANEL REPLACEMENT

FIT STANDARDS

[Hatchback] 7.5 mm 2.0 mm 3.5 mm 3.7 mm 3.7 mm 6.0 mm 5.4 mm 2.8 mm 6.0 mm F23343 2.0 mm (0.079 in.) 2.8 mm (0.110 in.) 3.5 mm (0.138 in.) 3.7 mm (0.146 in.) 5.4 mm (0.213 in.) 6.0 mm (0.236 in.) 7.5 mm (0.295 in.) — —, BODY PANEL REPLACEMENT BP-147 [Sedan] 11.85 mm 2.7 mm 4.35 mm 3.5 mm 4.65 mm 4.1 mm 4.0 mm 2.7 mm 6.45 mm F24864-1 2.7 mm (0.106 in.) 3.5 mm (0.138 in.) 4.0 mm (0.157 in.) 4.1 mm (0.161 in.) 4.35 mm (0.171 in.) 4.65 mm (0.183 in.) 6.45 mm (0.254 in.) 11.85 mm (0.467 in.) —, BP-148 BODY PANEL REPLACEMENT [Hatchback 3 Door] 5.0 mm 4.0 mm 4.0 mm 5.6 mm [Hatchback 5 Door] 5.0 mm 5.0 mm 4.0 mm 4.8 mm 4.0 mm 5.6 mm 5.6 mm F23335 4.0 mm (0.157 in.) 4.8 mm (0.189 in.) 5.0 mm (0.197 in.) 5.6 mm (0.220 in.) — —, BODY PANEL REPLACEMENT BP-149 [Sedan] 4.7 mm 4.7 mm 4.0 mm 4.8 mm 4.0 mm 5.7 mm 5.7 mm F24865-1 4.0 mm (0.157 in.) 4.7 mm (0.185 in.) 4.8 mm (0.189 in.) 5.7 mm (0.224 in.) — —, PAINT COATING PC-1

BODY PANEL SEALING AREAS

HINT: 1) Prior to applying body sealer, clean the area with a rag soaked in silicone remover. 2) If weld-through primer was used, first wipe off any excess and than coat with anti-corrosion primer before ap- plying body sealer. 3) Wipe off excess body sealer with a rag soaked in silicone remover. 4) Besure to repair as necessary if the body sealer shows signs of damage such as peeling or cracking. Flat Finishing No Flat Finishing 1. ENGINE COMPARTMENT [Hatchback] F22806, PC-2 PAINT COATING [Sedan] F24801-1, PAINT COATING PC-3 2. INSIDE [Hatchback] F22336, PC-4 PAINT COATING [Sedan] F24802-1, PAINT COATING PC-5 3. OUTSIDE [Hatchback] F22337, PC-6 PAINT COATING [Sedan] F24803-1, PAINT COATING PC-7 4. DOOR PARTS [Hatchback 3 Door] F22338, PC-8 PAINT COATING [Hatchback 5 Door] F23339, PAINT COATING PC-9 [Sedan] F24804-1, PC-10 PAINT COATING [Hatchback] F22810, PAINT COATING PC-11 [Sedan] F24805-1, PC-12 PAINT COATING

BODY PANEL UNDER COATING AREAS

HINT: 1) First wipe off any dirt, grease or oil with a rag soaked in silicone remover. 2) Cover the surrounding areas with masking paper to avoid coating unnecessary areas. If other areas are acci- dently coated, wipe off the coating immediately. 3) Apply the first coating of undercoat to all welded areas and panel joints, then apply a second coat over the entire area. 4) Do not coat parts which become hot such as the tailpipe, and moving parts such as the propeller shaft. 5) Apply under coating to all weld points under the body to ensure corrosion prevention at every location except the areas below. 6) Be sure to seal the edge of the flange of the member and bracket with undercoating. 7) Be sure to repair the under coating as necessary if there are signs of damage such as cracking or peeling. 8) Apply sealer before applying the under coat for rust prevention. [Hatchback] [LH] [RH] F23340

POINT

1 The film thickness of the interior portion of the rear wheel housing should be 1.0 mm (0.04 in.) or more for the front half and 2.0 mm (0.08 in.) of more for the rear half.

REFERENCE

The under coating should be applied according to the specifications for your country while referring to the notes above., PAINT COATING PC-13 [Sedan] [LH] [RH] F24806-1

POINT

1 The film thickness of the interior portion of the rear wheel housing should be 1.0 mm (0.04 in.) or more for the front half and 1.3 mm (0.05 in.) of more for the rear half.

REFERENCE

The under coating should be applied according to the specifications for your country while referring to the notes above., PC-14 PAINT COATING

FOAMED MATERIAL APPLICATION AREAS

The sections shown in the figure below are filled with foamed material to provide noise insulation. Refill with foamed materials after repairing these sections and their surrounding sections. HINT: 1) Use the service holes located on the reverse side of the body panel to refill foamed materials. 2) Follow manufacturer directions when handling the foamed material. [Hatchback] [5 Door Only] F23341, PAINT COATING PC-15 [Sedan] F24808-1, PC-16 PAINT COATING

BODY PANEL ANTI-RUST AGENT (WAX) APPLICATION AREAS

HINT: 1) Apply anti-rust agent (wax) around the hinges whenever adjusting the doors and hoods. 2) Even if partially repairing a part, apply anti-rust agent (wax) over the entire application area of the part. 3) Wipe off the anti-rust agent immediately with a rag soaked in silicone remover if it is accidentally applied to other areas. [Hatchback] F23344, PAINT COATING PC-17 [Sedan] F24809-1, PC-18 PAINT COATING

SILENCER SHEET INSTALLATION AREAS

[Sedan] F24810-1 0.8 mm (0.031 in.), BP-10 BODY PANEL REPLACEMENT

FRONT SIDEMEMBER REINFORCEMENT

(CUT-P)

REPLACEMENT

With the radiator support removed. F22825A

REMOVAL

[LH] 140 mm 65 mm F23301

POINT

1 Remove [A] at the same time. PART NAME [A] Front Sidemember Outer Plate 65 mm (2.56 in.) 140 mm (5.51 in.), BODY PANEL REPLACEMENT BP-11 [RH] 70 mm 140 mm F23302

POINT

1 Remove [B] before conducting this work. 2 Remove [A] at the same time. PART NAME [A] Front Sidemember Outer Plate [B] Engine Front Mounting Bracket 70 mm (2.76 in.) 140 mm (5.51 in.), BP-12 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. [LH] F23303 PART NAME [A] Front Sidemember Outer Plate, BODY PANEL REPLACEMENT BP-13 [RH] F23304

POINT

1 Remove the [B] from the new parts of the front sidemember reinforcement. 2 After installing the new parts, install [B]. PART NAME [A] Front Sidemember Outer Plate [B] Engine Front Mounting Bracket, PAINT COATING PC-19

BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS

HINT: 1[)SedAannti]-chipping paint should be applied to some areas before the second coat and to other areas after the top coat. 2) Wipe off the paint immediately with a rag soaked in silicone remover if unrelated areas are accidentally coated. [Hatchback] F24811-1 PVC Urethane Adheshion Primer F23342 PrVoCtection Tape — Soft−Chip (—Poly Olefine) — —, PC-20

MEMO

, PC-21

MEMO

,

BODY DIMENSIONS DI-3 BODY DIMENSION DRAWINGS ENGINE COMPARTMENT Hatchback

(Three-Dimensional Distance) 1,373 (54.06) (29.33) 1,361 (53.58) (27.17) (22.68) 680 (26.77) 1,261 1,131 1,126 (49.65) (44.53) 749 (44.33)572 620 (22.52) (29.49) (24.41) 1,026646 1,047(40.39) (25.43) (41.22) (30.16) 584 1,433 (22.99) (56.42) (37.17) (37.68) (36.89) (10.31) (33.31) Vehicle Dimensions Height from Imaginary Standard Line A-C B-C B-c B-K B-k A-a or or or or or K-k A, a C, c G, g a-c b-c b-C b-k b-K 1,324 170 209 1,261 564 942 505 810 815 614 (52.13) (6.69) (8.23) (49.65) (22.20) (37.09) (19.88) (31.89) (32.09) (24.17) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Front fender installation nut M6 (0.24) G, g Headlight bracket standard hole ø 10 (0.39) B, b Front spring support hole−inner ø 11 (0.43) H, h Radiator side support installation hole ø 6.3 (0.248) C, c Hood hinge installation nut-rear M8 (0.31) I, i Radiator seal installation holeø9(0.35) D Cowl panel center mark — J, j Front fender mounting bracket standard hole ø 10 (0.39) E, e Front side member standard hole ø 15 (0.59) K, k Front bumper installation holeø7(0.28) F, f Front side member standard hole ø 10 (0.39) — — —,

DI-4 BODY DIMENSIONS BODY DIMENSION DRAWINGS ENGINE COMPARTMENT Sedan

(Three-Dimensional Distance) 1,374 (54.09) (30.20) 1,376 (54.17) (7.01) 692 1,347 (27.24) 684 (53.03) (26.93) (29.06) 1,205 704 (47.44) 1,126(27.72) 567 1,408 (44.33) 665 1,336 (22.32) (55.43) (26.18) 1,279 (52.60) 509 (50.35) (20.04) 1,047 1,433 (41.22) 1,098 (56.42) (43.23) 820 743 597(32.28) (29.25) (23.50) 1,008 (39.69) 950 (22.32) (37.40) (37.68) (36.89) (10.31) (33.31) Vehicle Dimensions Height from imaginary standard line B-C B-c B-D B-K B-k C-L or or or or or or A, a C, c G, g b-c b-C b-D b-k b-K c-l 223 1,264 575 998 597 381 778 792 615 (8.78) (49.76) (22.64) (39.29) (23.50) (15.00) (30.63) (31.18) (24.21) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Front fender installation nut M6 (0.24) G, g Headlight bracket installation hole 9 (0.35) B, b Front spring support hole-inner ø11 (0.43) H, h Radiator side support inatallation hole ø6.3 (0.248) C, c Hood hinge installation nut-rear M8 (0.31) I, i Radiator seal installation hole ø9 (0.35) D Cowl panel center mark — J, j Front fender mounting bracket standard hole ø10 (0.39) E, e Front side member standard hole ø15 (0.59) K, k Radiator upper support standard hole ø13 (0.51) F, f Front side member standard hole ø10 (0.39) L, l Front fender installation nut M6 (0.24),

BODY DIMENSIONS DI-5 BODY OPENING AREAS (Side View) Hatchback 3 Door

(Three-Dimensional Distance) 1,050 (41.34) (35.55) 1,502 663 (59.13) (26.10) (38.66) 1,373 (54.06) 894 1,239 (35.20) (48.78) 1,085 (42.72) 1,266 (49.84) 1,060 (41.73) 1,145 (45.08) Vehicle Dimensions E-e F-f G-g H-h I-i J-j K-k 1,147 1,379 1,417 1,417 1,090 1,258 1,395 (45.16) (54.29) (55.79) (55.79) (42.91) (49.53) (54.92) E-f E-h E-j E-k F-j F-k G-h H-i J-k or or or or or or or or or e-F e-H e-J e-K f-J f-K g-H h-I j-K 1,532 1,609 1,372 1,549 1,826 1,745 1,440 1,650 1,429 (60.31) (63.35) (54.02) (60.98) (71.89) (68.70) (56.69) (64.96) (56.26) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Roof panel corner — G, g Rocker panel assembly mark — B, b Hood hinge installation nut M8 (0.31) H, h Rocker panel assembly mark — C, c Front door hinge installation nut M8 (0.31) I, i Roof side rail assembly mark — D, d Front door hinge installation nut M8 (0.31) J, j Quarter panel assembly mark — E, e Front body pillar assembly mark — K, k Quarter panel assembly mark — F, f Front body pillar assembly mark — — — —,

DI-6 BODY DIMENSIONS BODY OPENING AREAS (Side View: Front) Hatchback 5 Door

(Three-Dimensional Distance) 1,050 (41.34) 903 522 (35.55) 1,502 (20.55) (59.13) (38.66) 1,373 1,085 (54.06) (42.72) 1,062 761 (41.81) (29.96) 1,147 (45.16) (33.70) (39.33) Vehicle Dimensions E-e F-f G-g H-h I-i J-j K-k 1,147 1,379 1,417 1,417 1,090 1,263 1,391 (45.16) (54.29) (55.79) (55.79) (42.91) (49.72) (54.76) E-f E-h E-j F-j F-k H-i I-q J-k or or or or or or or or e-F e-H e-J f-J f-K h-I i-Q j-K 1,532 1,609 1,312 1,748 1,628 1,650 1,260 1,431 (60.31) (63.35) (51.65) (68.82) (64.09) (64.96) (49.61) (56.34) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Roof panel corner — H, h Rocker panel assembly mark — B, b Hood hinge installation nut M8 (0.31) I, i Roof side rail assembly mark — C, c Front door hinge installation nut M8 (0.31) J, j Center body pillar assembly mark — D, d Front door hinge installation nut M8 (0.31) K, k Center body pillar assembly mark — E, e Front body pillar assembly mark — L, l Rear door hinge installation nut M8 (0.31) F, f Front body pillar assembly mark — M, m Rear door hinge installation nut M8 (0.31) G, g Rocker panel assembly mark — Q, q Roof side rail assembly mark —,

BODY DIMENSIONS DI-7 BODY OPENING AREAS (Side View: Rear) Hatchback 5 Door

(Three-Dimensional Distance) (28.46) 905 1,076 (38.31) (35.63) (42.36) (33.31) (32.09) (23.54) Vehicle Dimensions N-n O-o P-p Q-q R-r S-s 1,263 1,381 1,417 1,068 1,130 1,405 (49.72) (54.37) (55.79) (42.05) (44.49) (55.31) G-p N-r N-s O-r O-s P-q R-s or or or or or or or g-P n-R n-S o-R o-S p-Q r-S 1,717 1,397 1,578 1,584 1,516 1,634 1,451 (67.60) (55.00) (62.13) (62.36) (59.69) (64.33) (57.13) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. G, g Rocker panel assembly mark — Q, q Roof side rail assembly mark — N, n Center body pillar assembly mark — R, r Quarter panel assembly mark — O, o Center body pillar assembly mark — S, s Quarter panel assembly mark — P, p Quarter panel assembly mark — — — —,

DI-8 BODY DIMENSIONS BODY OPENING AREAS (Side View: Front) Sedan

(Three-Dimensional Distance) 1,044 (41.10) (35.98) 1,507 (59.33) 853 (33.58) 946 1,173 (37.24) (46.18) 1,374 885 (54.09) (34.84) 1,112 867 (43.78) (34.13) 1,064 (41.89) (36.14) 1,040 1,069 (40.94) (42.09) Vehicle Dimensions E-e F-f G-g H-h I-i J-j K-k L-l 1,266 1,378 1,418 1,418 1,128 1,240 1,378 1,480 (49.84) (54.25) (55.83) (55.83) (44.41) (48.82) (54.25) (58.27) E-f E-h E-j F-j F-k H-i J-k or or or or or or or e-F e-H e-J f-J f-K h-I j-K 1,443 1,596 1,515 1,756 1,656 1,579 1,403 (56.81) (62.83) (59.65) (69.13) (65.20) (62.17) (55.24) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Roof panel corner — H, h Rocker panel assembly mark — B, b Hood hinge installation nut M8 (0.31) I, i Roof side rail assembly mark — C, c Front door hinge installation nut M8 (0.31) J, j Center body pillar assembly mark — D, d Front door hinge installation nut M8 (0.31) K, k Center body pillar assembly mark — E, e Front body pillar assembly mark — L, l Front door lock striker installation nut M8 (0.31) F, f Front body pillar assembly mark — M, m Rear door hinge installation nut M8 (0.31) G, g Rocker panel assembly mark — N, n Rear door hinge installation nut M8 (0.31),

BODY DIMENSIONS DI-9 BODY OPENING AREAS (Side View: Rear) Sedan

(Three-Dimensional Distance) (28.98) 863 827 915 (33.98) (32.56) (36.02) (35.28) 1,000 904 (39.37) (35.59) (25.24) 1,009 (39.72) Vehicle Dimensions O-o P-p Q-q R-r S-s T-t U-u 1,240 1,373 1,418 1,084 1,197 1,405 1,489 (48.82) (54.06) (55.83) (42.68) (47.13) (55.31) (58.62) G-q I-r O-s O-t P-t Q-r S-t or or or or or or or g-Q i-R o-S o-T p-T q-R s-T 1,770 1,375 1,424 1,577 1,529 1,593 1,430 (69.69) (54.13) (56.06) (62.09) (60.20) (62.72) (56.30) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. G, g Rocker panel assembly mark — Q, q Rocker panel assembly mark — I, i Roof side rail assembly mark — R, r Roof side rail assembly mark — M, m Rear door hinge installation nut M8 (0.31) S, s Quarter panel assembly mrak — N, n Rear door hinge installation nut M8 (0.31) T, t Quarter panel assembly mark — O, o Center body pillar assembly mark — U, u Rear door lock striker installation nut M8 (0.31) P, p Center body pillar assembly mark — — — —,

BODY DIMENSIONS DI-11 BODY OPENING AREAS (Rear View) Hatchback 5 Door

(Three-Dimensional Distance) 1,624 (63.94) 1,020 (40.16) 1,122 1,152 (44.17) 907 (45.35) 441 (35.71) 725 (17.36) 1,247 (28.54) (49.09) (36.10) 1,333 1,090 410 (52.48) (42.91) (16.14) (25.55) 678 1,103 (26.69) (43.43) (30.98) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. ø 10.2 (0.402): RH A, a Back door hinge installation hole ø 10.2 (0.402) E, e Back door lock striker installation nut — 12 (0.47): LH B, b Back door stay installation nut M6 (0.24) F, f Rear shock absorber installation hole−inner M8 (0.31) C, c Back door opening trough standard hole ø 10 (0.39) G, g Center body pillar assembly mark ø 18 (0.71) Back door opening trough/Body lower back D, d — — — — panel adjoining point,

DI-10 BODY DIMENSIONS BODY OPENING AREAS (Rear View) Hatchback 3 Door

(Three-Dimensional Distance) 1,793 (70.59) 1,020 (40.16) 917 1,1521,423 (56.02) (36.10) (45.35) 441 1,247 (28.54) (17.36) (49.09) (35.71) 1,333 (52.48) 1,090 410 1,103 (42.91) (16.14) (43.43) 678 (26.69) (25.55) 787 (30.98) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. ø 10.2 (0.402): RH A, a Back door hinge installation hole ø 10.2 (0.402) E, e Back door lock striker installation nut M8 (0.31) 12 (0.47): LH B, b Back door stay installation nut M6 (0.24) F, f Rear shock absorber installation hole−inner ø 18 (0.71) C, c Back door opening trough standard hole ø 10 (0.39) G, g Roof side rail assembly mark — Back door opening trough/Body lower back D, d — — — — panel adjoining point, BP-14 BODY PANEL REPLACEMENT

FRONT SIDEMEMBER REINFORCEMENT

(ASSY)

REPLACEMENT

With the radiator support and front fender apron removed. F22829A

REMOVAL

F22829

POINT

1 Remove [A] at the same time. PART NAME [A] Front Sidemember Outer Plate, BODY PANEL REPLACEMENT BP-15

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F22830

POINT

1 Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front wheel alignment., BP-16 BODY PANEL REPLACEMENT [LH] [RH] F22831 PART NAME [A] Front Sidemember Outer Plate,

DI-12 BODY DIMENSIONS BODY OPENING AREAS (Rear View) Sedan

(Three-Dimensional Distance) 1,007 (39.65) 1,215 (21.65) 1,636 (47.83) (64.41) 1,166 1,150 (45.91) 1,135 (45.28) (44.69) 441 (17.36) 1,053 (41.46) 1,011(39.80) 1,090 (42.91) 1,196 (47.09) 1,432 743 (56.38) (29.25) (31.69) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Roof panel corner — E, e Quarter panel standard hole ø13 (0.51) B, b Upper back panel corner — F, f Body lower back reinforcement corner — C, c Back door opening trough corner — G, g Rear shock absorber installation hole ø18 (0.71) D, d Luggage door opening front trough corner — H, h Center body pillar assembly mark —,

BODY DIMENSIONS DI-13 UNDER BODY Hatchback

(Three-Dimensional Distance) (23.54) (17.83) 795 (31.30)

RH 991 276 536

(39.02) 872 796 1,231 (10.87) (21.10) 1,096 1,120 (34.33) (31.34) 844 (43.15) (48.46) (44.09) 967 930 (33.23) 796 1,060 (38.07) (36.61) (31.34) 1,266 (41.73) 727 759 410 (49.84) 920 1,096 854 (28.62)(33.62) 637 (29.88) (16.14) (36.22) 1,228 957 (43.15) 1,100 (25.08) (48.35) (37.68) (43.31) 998 768 645 (39.29) 1,068 478(30.24) (25.39) (42.05) (18.82) 1,085 1,331

LH 453 (42.72) (52.40)

(38.54) 415 (17.83) (16.34) 462 (18.19) (12.20) (25.71) G-g123

Front

390 100 100 100 (15.35) (3.94) (3.94) (3.94) A, a B, b C, c D, d E, e F, f G, g H, h I, i J, j K, k L, l M, m N, n 152 396 304 243 141 54 75 51 56 98 137 276 271 288 (5.98) (15.59) (11.97) (9.57)(5.55) (2.13) (2.95) (2.01) (2.20) (3.86) (5.39) (10.87) (10.67) (11.34)

Imaginary Standard Line HINT: For symbols, capital letters indicate right side of vehicle, small

letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Radiator side support installation nut M6 (0.24) H, h Front side member standard hole ø 18 (0.71) B, b Radiator side support installation hole ø 6.3 (0.248) I, i Front floor pan standard hole ø 18 (0.71) C, c Front side member standard hole ø 18 (0.71) J, j Floor side inner rear member standard hole ø 18 (0.71) D, d Front suspension installation nut M12 (0.47) K, k Rear axle beam installation outer hole-inner ø 15 (0.59) E, e Front suspension installation nut M14 (0.55) L, l Rear floor side member standard hole ø 18 (0.71) F, f Torque box front standard hole ø 25 (0.98) M, m Rear spring plate standard hole ø 18 (0.71) G, g Front floor pan standard hole ø 18 (0.71) N, n Rear floor side member standard hole ø 18 (0.71),

DI-14 BODY DIMENSIONS UNDER BODY Sedan

(Three-Dimensional Distance) (33.66) 825 453 (32.48) (17.83) 869 957 643 796 (34.21) (37.68) (25.31) (31.34) 276 872 (10.87) (21.10) 1,182

RH (34.33) (46.54)

1,318 768 1,060 991 (30.24) 796 (51.89) (41.73) (39.02) 727 390 (31.34) 1,341 440 854 (28.62)893 (15.35) 410 (52.80) 759 (16.14) 1,227 1,231 950 (17.32) (33.62) (48.31)(35.16) (48.46) (37.40)1,100 844 (29.88) 930 (43.31) (33.23) (38.54)

LH (36.61) 645

1,331 1,156 (18.82) (25.39) (52.40) (45.51) 1,068 1,141 (42.05) (44.92)453 415 (17.83) 638 (16.34) (25.12) (18.19) (25.71) Vehicle Dimensions C-f F-h G-h or or or123c-F f-H g-H 1,305 1,065 637 100 100 100 (51.38) (41.93) (25.08) (3.94) (3.94) (3.94)

Front

A,a B,b C,c D,d E,e F,f G,g H,h I,i J,j K,k M,m N,n 138 396 304 243 141 54 75 51 56 98 137 269 269 (5.43)(15.59)(11.97) (9.57) (5.55) (2.13) (2.95) (2.01) (2.20) (3.86)(5.39) (10.59) (10.59) 123L,l276 Imaginary (10.87) Standard

Line HINT: For symbols, capital letters indicate right side of vehicle, small

letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Radiator lower support standard hole ø18 (0.71) H, h Front side member standard hole ø18 (0.71) B, b Radiator side support inatallation hole ø6.3 (0.248) I, i Front floor pan standard hole ø18 (0.71) C, c Front side member standard hole ø18 (0.71) J, j Floor side inner rear member standard hole ø18 (0.71) D, d Front suspension member installation nut M12 (0.47) K, k Rear axle beam installation outer hole-inner ø15 (0.59) E, e Front suspension member installation nut M14 (0.55) L, l Rear floor side member standard hole ø18 (0.71) F, f Torque box front standard hole ø25 (0.98) M, m Rear spring plate standard hole ø18 (0.71) G, g Front floor pan standard hole ø18 (0.71) N, n Rear floor side member standard hole ø18 (0.71),

BODY DIMENSIONS DI-15 UNDER BODY Hatchback

(Two-Dimensional Distance) 1,887 1,707 1,271 925 490 646 822 1,149 (74.29) (67.20) (50.04) (36.42) (19.29) 0 (25.43)(32.36) (45.24)

RH 665

550 (26.18)484 465 614 546 (19.06) (18.31) (21.65)(24.17) 422 530 (21.50)(16.61) (20.87) (8.07) 195 205 (7.68) (8.07) 479 436 (15.12) 489 460 (18.86) (17.17) 614 (19.25) (18.11)

LH (24.17)

1,781 1,298 1,080 645 0 718 1,037 1,345 (70.12) (51.10) (42.52) (25.39) (28.27) (40.83) (52.95)

Front

Wheel Base 2,460 (96.85) 123100 100 100 (3.94) (3.94) (3.94) A, a B, b C, c E, e D, d F, f G, g H, h I, i J, j K, k M, m N, n O, o P, p 152 396 304 734 243 141 54 75 51 56 98 276 271 607 288 (5.98)(15.59)(11.97) (28.90) (9.57) (5.55) (2.13) (2.95) (2.01) (2.20) (3.86) (10.87) (10.67) (23.90) (11.34)

Imaginary

L, l 137 Standard (5.39) Line

HINT: For symbols, capital letters indicate right side of vehicle, small

letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Radiator side support installation nut M6 (0.24) I, i Front side member standard hole ø 18 (0.71) B, b Radiator side support installation hole ø 6.3 (0.248) J, j Front floor pan standard hole ø 18 (0.71) C, c Front side member standard hole ø 18 (0.71) K, k Floor side inner rear member standard hole ø 18 (0.71) D, d Front suspension member installation nut M12 (0.47) L, l Rear axle beam installation outer hole-inner ø 15 (0.59) E, e Front spring support plate standard hole−outer ø 11 (0.43) M, m Rear floor side member standard hole ø 18 (0.71) F, f Front suspension member installation nut M14 (0.55) N, n Rear spring plate standard hole ø 18 (0.71) G, g Torque box front standard hole ø 25 (0.98) O, o Rear shock absorber installation hole ø 18 (0.71) H, h Front floor pan standard hole ø 18 (0.71) P, p Rear floor side member standard hole ø 18 (0.71),

DI-16 BODY DIMENSIONS UNDER BODY Sedan

(Two-Dimensional Distance) 1,895 1,707 1,271 925 490 736 912 1,239 (74.61)(67.20) (50.04) (36.42) (19.29) 0 (28.98) (35.91) (48.78) (26.18) 465 550 530 546

RH (18.31)

614 (21.65) 422 (20.87) (21.50) (24.17) (16.61) 220 205 (8.66) (8.07) 195 205 (7.68) (8.07)

LH 479 436(17.17) (15.12) 489 475(18.86) 614 (19.25) (18.70)

(24.17) 1,781 1,298 1,080 645 0 808 1,127 1,765 (70.12) (51.10) (42.52) (25.39) (31.81) (44.37) (69.49) 123Wheel Base 2,460 (96.85)

Front 100 100 100(3.94) (3.94) (3.94)

A,a B,b C,c D,d F,f G,g H,h I,i J,j K,k L,l N,n O,o P,p 138 396 304 243 141 54 75 51 56 98 137 269 607 269 (5.43)(15.59)(11.97) (9.57) (5.55) (2.13) (2.95) (2.01) (2.20) (3.86)(5.39) (10.59) (23.90) (10.59) E,e M,m Imaginary 734123276 Standard (28.90) (10.87) Line

HINT: For symbols, capital letters indicate right side of vehicle, small

letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Radiator lower support standard hole ø18 (0.71) I, i Front side member standard hole ø18 (0.71) B, b Radiator side support inatallation hole ø6.3 (0.248) J, j Front floor pan standard hole ø18 (0.71) C, c Front side member standard hole ø18 (0.71) K, k Floor side inner rear member standard hole ø18 (0.71) D, d Front suspension member installation nut M12 (0.47) L, l Rear axle beam installation outer hole-inner ø15 (0.59) E, e Front spring support plate standard hole ø11 (0.43) M, m Rear floor side member standard hole ø18 (0.71) F, f Front suspension member installation nut M14 (0.55) N, n Rear spring plate standard hole ø18 (0.71) G, g Torque box front standard hole ø25 (0.98) O, o Rear shock absorber installation hole ø18 (0.71) H, h Front floor pan standard hole ø18 (0.71) P, p Rear floor side member standard hole ø18 (0.71), BODY DIMENSIONS DI-17

REFERENCE VALUE ENGINE COMPARTMENT Hatchboack

(Three-Dimensional Distance) 1,324 (52.13) 1,361 (53.58) 1,025 (40.35) 1,008618 (39.69) (24.33) 590 (23.23) (19.88) C-D C-c or c-d 1,324 38 (52.13) (1.50) HINT: These values are actual measurements made on a vehicle. Use these reference values. mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Front bumper cover installation bolt — C, c Headlight installation bolt — B, b Front end of fender — D, d Front fender installation bolt —,

DI-18 BODY DIMENSIONS REFERENCE VALUE ENGINE COMPARTMENT Sedan

(Three-Dimensional Distance) (9.21) 1,347 1,357 (53.03) (53.43) 1,357 (53.43) 1,336 205 (52.60) (8.07) 1,327 965 1,070 (52.24) 533 (37.99) (42.13) (20.98) 979 (38.54) 682 512 (26.85) (20.16) (19.84) HINT: These values are actual measurements made on a vehicle. Use these reference values. mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Front bumper cover installation clip — C, c Front fender installation bolt — B, b Headlight installation bolt — D, d Front fender installation bolt —, BODY DIMENSIONS DI-19

UNDER BODY

(Two-Dimensional Distance)

Radiator support installation

25.0 4 M10 NUT 2.3 2.3 1.6

Front spring support Rear shock absorber installation

63.6 34.1 2 11 2.3 2.0 2.0 5.5 mm 0.6 51.2 13.6 2.8 20.6 52 142.6 15 15 11 11 4.9, BODY PANEL REPLACEMENT BP-17

COWL TOP SIDE PANEL (ASSY) REPLACEMENT

F22832A

REMOVAL

F22832, BP-18 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. (20 mm) (25 mm) (30 mm) (15 mm) F22833 15 mm (0.59 in.) 20 mm (0.79 in.) 25 mm (0.98 in.) 30 mm (1.18 in.), BODY PANEL REPLACEMENT BP-19

COWL TOP SIDE UPPER PANEL (ASSY) REPLACEMENT

With the cowl top side panel removed. F22834A

REMOVAL

F22834, BP-20 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. (25 mm) (25 mm) F22835

POINT

1 Inspect the fitting of the hood and related parts before welding as this affects the appearance of the finish. 25 mm (0.98 in.), BODY PANEL REPLACEMENT BP-21

FRONT BODY PILLAR (CUT) REPLACEMENT

With the cowl top side upper panel removed. F22836A

REMOVAL

100 mm 80 mm 160 mm 70 mm F22836

POINT

1 *1: This part of the outer panel is reused because the rocker panel section is cut off at a position behind the service part cut position of the outer panel. 70 mm (2.76 in.) 80 mm (3.15 in.) 100 mm (3.94 in.) 160 mm (6.30 in.), BP-22 BODY PANEL REPLACEMENT F22837, BODY PANEL REPLACEMENT BP-23

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld spots. 230 mm (10 mm 3) (15 mm 3) F22838

POINT

1 Before temporarily installing the new parts, weld [A], [B], [C] and [D] with standard welding number. PART NAME [A] Rocker Outer Reinforce [B] Front Body Pillar Lower Reinforce [C] Front Body Inner Pillar [D] Front Body Outer Pillar 10 mm (0.39 in.) 15 mm (0.59 in.) 230 mm (9.06 in.), BP-24 BODY PANEL REPLACEMENT (10 mm) (15 mm 2) F22839

POINT

1 Inspect the fitting of the front fender, front door, windshield glass and other related parts before welding as this affects the appearance of the finish. 10 mm (0.39 in.) 15 mm (0.59 in.), BODY PANEL REPLACEMENT BP-25

CENTER BODY PILLAR (CUT): 5-Door REPLACEMENT

F22840A

REMOVAL

50 mm 30 mm 30 mm 50 mm 50 mm F22840 30 mm (1.18 in.) 50 mm (1.97 in.), BP-26 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. 80 mm 45 mm (10 mm 7) F22841

POINT

1 Before temporarily installing the new parts, weld [A], [B] and [C] with standard welding number. PART NAME [A] Rocker Outer Reinforce [B] Center Body Pillar Reinforcement [C] Center Body Inner Pillar 10 mm (0.39 in.) 45 mm (1.77 in.) 80 mm (3.15 in.), BODY PANEL REPLACEMENT BP-27 (10 mm 4) F22842

POINT

1 Inspect the fitting of the front door, rear door and other related parts before welding as this affects the appear- ance of the finish. 2 After welding [A], [B] and [C] to the vehicle, install [D]. PART NAME [A] Rocker Outer Reinforce [B] Center Body Pillar Reinforcement [C] Center Body Inner Pillar [D] Center Body Outer Pillar 10 mm (0.39 in.), BP-28 BODY PANEL REPLACEMENT

FRONT DOOR OUTER PANEL (CUT): 3-Door REPLACEMENT

F23305A

REMOVAL

Hemming Location Disc Sander F23305

POINT

1 After grinding off the hemming location, remove the outer panel., BODY PANEL REPLACEMENT BP-29

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. 10 mm Do not close the drain hole. Cloth Tape Hemming Tool F23306

POINT

1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make con- tact. 2 Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly., BP-30 BODY PANEL REPLACEMENT

FRONT DOOR OUTER PANEL (CUT): 5-Door REPLACEMENT

F23307A

REMOVAL

Hemming Location Disc Sander F23307

POINT

1 After grinding off the hemming location, remove the outer panel., BODY PANEL REPLACEMENT BP-31

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. 10 mm Do not close the drain hole. Cloth Tape Hemming Tool F23308

POINT

1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make con- tact. 2 Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly., BP-32 BODY PANEL REPLACEMENT

REAR DOOR OUTER PANEL (CUT): 5-Door REPLACEMENT

F23309A

REMOVAL

Hemming Location Disc Sander F23309

POINT

1 After grinding off the hemming location, remove the outer panel., BODY PANEL REPLACEMENT BP-33

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. 10 mm Do not close the drain hole. Cloth Tape Hemming Tool F23310

POINT

1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make con- tact. 2 Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly., BP-34 BODY PANEL REPLACEMENT

ROCKER OUTER PANEL (CUT-H): 5-Door REPLACEMENT

F22843A

REMOVAL

380 mm F22843 380 mm (14.96 in.), BODY PANEL REPLACEMENT BP-35

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F22844

POINT

1 Inspect the fitting of the front door and other related parts before welding as this affects the appearance of the finish., BP-36 BODY PANEL REPLACEMENT

ROCKER OUTER PANEL (CUT): 3-Door REPLACEMENT

F23311A

REMOVAL

F23311, BODY PANEL REPLACEMENT BP-37

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F23312

POINT

1 Inspect the fitting of the front door and other related parts before welding as this affects the appearance of the finish., BP-38 BODY PANEL REPLACEMENT

ROCKER OUTER PANEL (CUT): 5-Door REPLACEMENT

F22845A

REMOVAL

100 mm F22845 100 mm (3.94 in.), BODY PANEL REPLACEMENT BP-39

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F22846

POINT

1 Inspect the fitting of the front door, rear door and other related parts before welding as this affects the appear- ance of the finish., BP-40 BODY PANEL REPLACEMENT

Adhesive Application Area Work Procedure NOTE

This vehicle has areas on the Quarter Panel and Quarter Wheel Housing Outer Panel that are joined together only with adhesive. It is necessary to conduct the correct repair procedures for high durability so make sure to follow the instructions below for the adhesive application areas. Type of adhesive used: 3M8115 Auto Mix Panel Bond 1. Removal of the Quarter Panel Adhesive Application Area Cut and Join (A) Remove the body sealer from the Quarter Panel and cut at Location the cut and join location. Remove the spot welded portions. (B) After rough cutting the Wheel Arch portion, heat the adhe- sive applied area and remove the panel. {Heat the Wheel Arch portion of the Quarter Panel at 110 to 140C (230 to 284F) with a dryer or gas burner and remove the Quarter Panel.} Spot Weld Cut and Join Location 010L23a 2. Removal of the previous adhesive coating (A) Heat at 110 to 140C (230 to 284F) with a dryer or gas burner. (B) Scrape away the adhesive with a scraper, and scuff while sanding with a disc grinder or a belt sander.

NOTE

Make sure to use either a disc grinder or belt sander to sand coarsely and deeply to improve adhesiveness. Scuff at a width of approximately 10 mm (0.39 in.) over the previous adhesive coating. 010L06 3. Treatment of the spot welded portions on the body (A) After the adhesive has been removed from the body, re- move the paint from the underside of the spot welded points blow air and degrease. (B) Apply spot sealer at the joined portion between panels. approx.10 mm After sanding 010L07a, BODY PANEL REPLACEMENT BP-41 4. Attachment of the New Quarter Panel (A) Temporarily attach the new panel and check the fitting condition, the cut and join locations, the welded areas, and the adhesive applied area.

NOTE

Check the adhesive applied condition to ensure adhe- sive strength. Conduct hammering to fix the non-adhered portions. Cross-Sectional view Adhesive 1 mm gap 010L10a 5. Adhesive Application to New Quarter Panel Scuffed Area (A) Scuff with #60-120 grit sandpaper at the adhesive applica-Application Area tion area.

POINT

10 mm Sand deeply into the ED coat. 28 mm (B) Blow air around the scuffed portion and then degrease. (C) Apply adhesive.

POINT

010L11a Apply adhesive at a width of approximately 10 mm (0.39 in.) at a location 28 mm (1.10 in.) from the panel flange edge. Spread the adhesive flatly within the scuffed area {approxi- mately 10 mm (0.39 in.) in width} to remove trapped air. 010L12 Approx. 3 mm 3 mm Adhesive 010L12-1a 010L13, BP-42 BODY PANEL REPLACEMENT 6. Application of Adhesive to the Body (A) Degrease the adhesive aplication area. (B) Apply adhesive. Refer to the diagram of step 5 for the application amount. The application location is 7.5 mm (0.295 in.) from the flange edge. (C) Flatten out the applied adhesive with a spatula until it is at an even level. 010L15 Apply adhesive at exposed metal plate portions to pre- vent corrosion. It is not necessary to flatten out adhesive after it has been reapplied. 7.5 mm Flange Edge 010L16 010L17a 7. Attachment of the new Quarter Panel (A) Set the new panel in the position for temporary attachment. (Be careful of where you hold the panel so as not to touch the adhesive applied surfaces.) (B) Secure in a vice grip or equivalent and check the fitting condition. (C) Press on the entire surface so that the adhesive between the Quarter Panel and Quarter Wheel Housing Outer panel becomes an even thickness.

NOTE

Be careful that adhesive that spills over does not contact the Brake Drum. (D) Tack weld at the cut and join welded portion. (E) Tack weld by spot welding at one point on both ends of the adhesive applied portions. (F) Conduct actual welding using procedures in the BP section of this manual. Tack Weld 010L20a, BODY PANEL REPLACEMENT BP-43 8. Drying (A) Clean away adhesive that has spilled over with a degreaser Infrared Ray or equivalent. Hearter (B) After all welding works have been completed, dry the adhe- sive with a heater. Hardening Time Forced drying 60C (140F) at 90 minutes. Natural drying 010L22a 24C (75F) (room temperature) for 24 hours. 9. Other work (A) After applying Primer Surfacer to the underside of the Wheel Arch of the Quarter Panel, apply body sealer to the locations indicated in the body repair manual. Adhesive Body Sealer 010L21a, BP-44 BODY PANEL REPLACEMENT

QUARTER PANEL (CUT): 3-Door REPLACEMENT

F23313A

REMOVAL

205 mm 645 mm F23313

POINT

1 *1: The hatched area indicates the adhesive application area. PART NAME [A] Quarter Wheel Housing Outer Panel 205 mm (8.07 in.) 645 mm (25.39 in.), BODY PANEL REPLACEMENT BP-45 F23314, BP-46 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. 1.0 mm F23315

POINT

1 *1: The hatched area indicates the adhesive application area. PART NAME [A] Quarter Wheel Housing Outer Panel [B] Fuel Filler Opening Lid [C] Rivet 1.0 mm (0.04 in.), BODY PANEL REPLACEMENT BP-47 F23316

POINT

1 Inspect the front door, back door, rear combination light and other related parts before welding as this affects the appearance of the finish., BP-48 BODY PANEL REPLACEMENT

QUARTER PANEL (CUT): 5-Door REPLACEMENT

F22847A

REMOVAL

F23317

POINT

1 *1: The hatched area indicates the adhesive application area. PART NAME [A] Quarter Wheel Housing Outer Panel, BODY PANEL REPLACEMENT BP-49 150 mm F23318 150 mm (5.91in.), BP-50 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. 1.0 mm F23319

POINT

1 *1: The hatched area indicates the adhesive application area. PART NAME [A] Quarter Wheel Housing Outer Panel [B] Fuel Filler Opening Lid [C] Rivet 1.0 mm (0.04 in.), BODY PANEL REPLACEMENT BP-51 F23320

POINT

1 Inspect the front door, back door, rear combination light and other related parts before welding as this affects the appearance of the finish., BP-52 BODY PANEL REPLACEMENT

QUARTER WHEEL HOUSING OUTER PANEL

(ASSY)

REPLACEMENT

With the quarter panel removed. F22851A

REMOVAL

[LH] 3 Door : 5 Door : 3 Door : 5 Door : F23321

POINT

1 After removing [A], remove the quarter wheel housing outer panel. PART NAME [A] Rocker Outer Extension, BODY PANEL REPLACEMENT BP-53 [LH] 40 mm F22852

POINT

1 After removing [B], remove the quarter wheel housing outer panel. PART NAME [B] Roof Side Outer Panel 40 mm (1.57 in.), BP-54 BODY PANEL REPLACEMENT [RH] 3 Door : 5 Door : 3 Door : 5 Door : F23322

POINT

1 After removing [A], remove the quarter wheel housing outer panel. PART NAME [A] Rocker Outer Extension, BODY PANEL REPLACEMENT BP-55 [RH] 30 mm F22854

POINT

1 After removing [B], remove the quarter wheel housing outer panel. PART NAME [B] Roof Side Outer Panel 30 mm (1.18 in.), BP-56 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. [LH] F22856

POINT

1 After installing the new parts, install [B]. PART NAME [B] Roof Side Outer Panel, BODY PANEL REPLACEMENT BP-57 [LH] 3 Door : 5 Door : 3 Door : 5 Door : F23323

POINT

1 After installing the new parts, install [A]. PART NAME [A] Rocker Outer Extension, BP-58 BODY PANEL REPLACEMENT [RH] F22858

POINT

1 After installing the new parts, install [B]. PART NAME [B] Roof Side Outer Panel, BODY PANEL REPLACEMENT BP-59 [RH] 3 Door : 5 Door : 3 Door : 5 Door : F23324

POINT

1 After installing the new parts, install [A]. PART NAME [A] Rocker Outer Extension, BP-60 BODY PANEL REPLACEMENT

LOWER BACK UPPER GUSSET (ASSY) REPLACEMENT

F22859A

REMOVAL

F22859, BODY PANEL REPLACEMENT BP-61

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F22860, BP-62 BODY PANEL REPLACEMENT

BODY LOWER BACK PANEL (ASSY) REPLACEMENT

F22861A

REMOVAL

F23325, BODY PANEL REPLACEMENT BP-63

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F23326

POINT

1 Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects the appearance of the finish., BP-64 BODY PANEL REPLACEMENT

BACK DOOR OPENING TROUGH (ASSY) REPLACEMENT

With the quarter panel and body lower back panel removed. F22865A

REMOVAL

F22865

POINT

1 Remove [A] at the same time. PART NAME [A] Back Door Opening Lower Reinforcement, BODY PANEL REPLACEMENT BP-65

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F22866

POINT

1 Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects the appearance of the finish. PART NAME [A] Back Door Opening Lower Reinforcement [B] Rear Bumper Side Retainer, BP-66 BODY PANEL REPLACEMENT

QUARTER PANEL UPPER EXTENSION (CUT) REPLACEMENT

With the back door opening trough removed. F22867A

REMOVAL

130 mm F22867 130 mm (5.12 in.), BODY PANEL REPLACEMENT BP-67

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F22868, BP-68 BODY PANEL REPLACEMENT

FLOOR SIDE RAIL FRONT PANEL (ASSY) REPLACEMENT

With the body lower back panel removed. F22869A

REMOVAL

F23327, BODY PANEL REPLACEMENT BP-69

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. (10 mm 2) F23328 10 mm ( 0.39 in.), BP-70 BODY PANEL REPLACEMENT

REAR FLOOR PAN (ASSY) REPLACEMENT

With the body lower back panel and floor side rail front panel removed. F22871A

REMOVAL

[EX. U.S.A., CANADA] F23347, BODY PANEL REPLACEMENT BP-71 [U.S.A., CANADA] F23345

POINT

1 After removing [A], remove the rear floor pan. PART NAME [A] Rear Floor Brace Braket, BP-72 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. [EX. U.S.A., CANADA] F23348 PART NAME [B] Spare Wheel Clamp Bracket [C] Actuator Cover No.3 Bracket, BODY PANEL REPLACEMENT BP-73 [U.S.A., CANADA] F23346

POINT

1 After installing the new parts, install [A]. PART NAME [A] Rear Floor Brace Bracket [B] Spare Wheel Clamp Bracket [D] Fuel Tube No.2 Bracket [E] Fuel Tube Bracket, BP-74 BODY PANEL REPLACEMENT

REAR FLOOR SIDE PANEL EXTENSION

(ASSY)

REPLACEMENT

With the quarter panel and body lower back panel removed. F22875A

REMOVAL

F22875

POINT

1 After removing the rear floor side panel extension, remove [A]. PART NAME [A] Quarter Wheel Housing Extension, BODY PANEL REPLACEMENT BP-75

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F22876

POINT

1 After installing [A], install the new parts. PART NAME [A] Quarter Wheel Housing Extension, BP-76 BODY PANEL REPLACEMENT

REAR FLOOR CROSSMEMBER NO.2 (ASSY) REPLACEMENT

F22877A

REMOVAL

F22877, BODY PANEL REPLACEMENT BP-77

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F22878, BP-78 BODY PANEL REPLACEMENT

REAR FLOOR SIDEMEMBER (CUT) REPLACEMENT

With the body lower back panel removed. F22881A

REMOVAL

110 mm 40 mm F23329

POINT

1 After removing [A], remove the rear floor sidemember. PART NAME [A] Floor Side Rail Front Panel 40 mm (1.57 in.) 110 mm (4.33 in.), BODY PANEL REPLACEMENT BP-79

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F23330 PART NAME [A] Floor Side Rail Front Panel, BP-80 BODY PANEL REPLACEMENT

ROOF PANEL (ASSY) REPLACEMENT

F22885A

REMOVAL

3 Door : 5 Door : 3 Door : 5 Door : F23331, BODY PANEL REPLACEMENT BP-81

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. 3 Door : 5 Door : 3 Door : 5 Door : F23332

POINT

1 Before temporarily installing the new parts, apply body sealer to the window shield header panel, roof panel reinforcement and back window upper frame. HINT: 1) Apply just enough sealer for the new parts to make contact., BP-82 BODY PANEL REPLACEMENT

OUTER PANEL INSTALLATION TORQUE

T = 13.0 N.m T = 11.5 N.m T = 5.5 N.m T = 5.5 N.m T = 5.5 N.m T = 5.5 N.m T = 5.0 N .m T = 40.0 N.m T = 40.0 N.m T = 5.0 N.m T = 5.5 N.m T = 5.0 N.m F22801 5.0 N.m (51 kgf.cm, 44 in..lbf) 5.5 N.m (56 kgf.cm, 49 in..lbf) 11.5 N.m (117 kgf.cm, 8 ft..lbf) 13.0 N.m (133 kgf.cm, 10 ft..lbf) 40.0 N.m (408 kgf.cm, 30 ft..lbf) —, BODY PANEL REPLACEMENT BP-83 [3 Door] T = 26.0 N.m T = 26.0 N.m F23333 26.0 N.m (265 kgf.cm, 19 ft..lbf) — —, BP-84 BODY PANEL REPLACEMENT [5 Door] T = 26.0 N.m T = 26.0 N.m T = 26.0 N.m T = 26.0 N.m F23334 26.0 N.m (265 kgf.cm, 19 ft..lbf) — —, BODY PANEL REPLACEMENT BP-85 T = 11.5 N.m T = 27.0 N.m T = 19.0 N.m F22803 11.5 N.m (117 kgf.cm, 8 ft..lbf) 19.0 N.m (194 kgf.cm, 14 ft..lbf) 27.0 N.m (275 kgf.cm, 20 ft..lbf), BP-86 BODY PANEL REPLACEMENT

FIT STANDARDS

7.5 mm 2.0 mm 3.5 mm 3.7 mm 3.7 mm 6.0 mm 5.4 mm 2.8 mm 6.0 mm F23343 2.0 mm (0.079 in.) 2.8 mm (0.110 in.) 3.5 mm (0.138 in.) 3.7 mm (0.146 in.) 5.4 mm (0.213 in.) 6.0 mm (0.236 in.) 7.5 mm (0.295 in.) — —, BODY PANEL REPLACEMENT BP-87 [3 Door] 5.0 mm 4.0 mm 4.0 mm 5.6 mm [5 Door] 5.0 mm 5.0 mm 4.0 mm 4.8 mm 4.0 mm 5.6 mm 5.6 mm F23335 4.0 mm (0.157 in.) 4.8 mm (0.189 in.) 5.0 mm (0.197 in.) 5.6 mm (0.220 in.) — —, PAINT COATING PC-1

BODY PANEL SEALING AREAS

HINT: 1) Prior to applying body sealer, clean the area with a rag soaked in silicone remover. 2) If weld-through primer was used, first wipe off any excess and than coat with anti-corrosion primer before ap- plying body sealer. 3) Wipe off excess body sealer with a rag soaked in silicone remover. 4) Besure to repair as necessary if the body sealer shows signs of damage such as peeling or cracking. Flat Finishing No Flat Finishing 1. ENGINE COMPARTMENT F22806, PC-2 PAINT COATING 2. INSIDE F22336, PAINT COATING PC-3 3. OUTSIDE F22337, PC-4 PAINT COATING 4. DOOR PARTS [3 Door] F22338, PAINT COATING PC-5 [5 Door] F23339, PC-6 PAINT COATING F22810, PAINT COATING PC-7

BODY PANEL UNDER COATING AREAS

HINT: 1) First wipe off any dirt, grease or oil with a rag soaked in silicone remover. 2) Cover the surrounding areas with masking paper to avoid coating unnecessary areas. If other areas are acci- dently coated, wipe off the coating immediately. 3) Apply the first coating of undercoat to all welded areas and panel joints, then apply a second coat over the entire area. 4) Do not coat parts which become hot such as the tailpipe, and moving parts such as the propeller shaft. 5) Apply under coating to all weld points under the body to ensure corrosion prevention at every location except the areas below. 6) Be sure to seal the edge of the flange of the member and bracket with undercoating. 7) Be sure to repair the under coating as necessary if there are signs of damage such as cracking or peeling. 8) Apply sealer before applying the under coat for rust prevention. [LH] [RH] F23340

POINT

1 The film thickness of the interior portion of the rear wheel housing should be 1.0 mm (0.04 in.) or more for the front half and 2.0 mm (0.08 in.) of more for the rear half.

REFERENCE

The under coating should be applied according to the specifications for your country while referring to the notes above., PC-8 PAINT COATING

FOAMED MATERIAL APPLICATION AREAS

The sections shown in the figure below are filled with foamed material to provide noise insulation. Refill with foamed materials after repairing these sections and their surrounding sections. HINT: 1) Use the service holes located on the reverse side of the body panel to refill foamed materials. 2) Follow manufacturer directions when handling the foamed material. [5 Door Only] F23341, PAINT COATING PC-9

BODY PANEL ANTI-RUST AGENT (WAX) APPLICATION AREAS

HINT: 1) Apply anti-rust agent (wax) around the hinges whenever adjusting the doors and hoods. 2) Even if partially repairing a part, apply anti-rust agent (wax) over the entire application area of the part. 3) Wipe off the anti-rust agent immediately with a rag soaked in silicone remover if it is accidentally applied to other areas. F23344, PC-10 PAINT COATING

BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS

HINT: 1) Anti-chipping paint should be applied to some areas before the second coat and to other areas after the top coat. 2) Wipe off the paint immediately with a rag soaked in silicone remover if unrelated areas are accidentally coated. F23342 PVC Soft−Chip (Poly Olefine) — —, BODY DIMENSIONS DI-1 Three-dimensional Center-to-center GENERAL INFORMATION distance straight-line 1. BASIC DIMENSIONS distance (a) There are two types of dimensions in the diagram. (1) (Three-dimensional distance) Straight-line distance between the centers of two measuring points. Two-dimensional Center-to-center horizontal (2) (Two-dimensional distance) distance distance in forward/ rearward direction Horizontal distance in forward/rearward direction be- tween the centers of two measuring points. The height from an imaginary standard line. (b) In cases in which only one dimension is given, left and right are symmetrical. Vertical distance Vertical distance (c) The dimensions in the following drawing indicate actual dis- to center to lower surface tance. Therefore, please use the dimensions as a refer- ence. Imaginary Standard Line (d) The line that connects the places listed below is the imagi- nary standard line when measuring the height. (The dimen- sions are printed in the text.) Under Surface of SYMBOL Name The Rocker Panel The place that was lowered A mm from the under surface of the rocker panel centered on the front jack up point. A mm B mm C mm The place that was lowered B mm from the under surface of the rocker panel centered between 1 and 3. Imaginary Standard Line The place that was lowered C mm from the under surface of the rocker panel centered on the rear jack up point., DI-2 BODY DIMENSIONS Plate Looseness 2. MEASURING (a) Basically, all measurements are to be done with a tracking Body Looseness gauge. For portions where it is not possible to use a track- ing gauge, a tape measure should be used. (b) Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers. Pointer Looseness Pointer Master Gauge HINT: Wrong Correct 1) The height of the left and right pointers must be equal. 2) Always calibrate the tracking gauge before measuring or after adjusting the pointer height. 3) Take care not to drop the tracking gauge or otherwise shock it. Pointer 4) Confirm that the pointers are securely in the holes. (c) When using a tape measure, avoid twists and bends in the tape.,

BODY DIMENSIONS DI-3 BODY DIMENSION DRAWINGS ENGINE COMPARTMENT

(Three-Dimensional Distance) 1,373 (54.06) (29.33) 1,361 (53.58) (27.17) (22.68) 680 (26.77) 1,261 1,131 1,126 (49.65) (44.53) (44.33)572 749 620 (22.52) (29.49) (24.41) 1,026646 1,047(40.39) 766 (25.43) (41.22) (30.16) 584 1,433 (22.99) (56.42) (37.17) (37.68) (36.89) (10.31) (33.31) Vehicle Dimensions Height from Imaginary Standard Line A-C B-C B-c B-K B-k A-a or or or or or K-k A, a C, c G, g a-c b-c b-C b-k b-K 1,324 170 209 1,261 564 942 505 810 815 614 (52.13) (6.69) (8.23) (49.65) (22.20) (37.09) (19.88) (31.89) (32.09) (24.17) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Front fender installation nut M6 (0.24) G, g Headlight bracket standard hole ø 10 (0.39) B, b Front spring support hole−inner ø 11 (0.43) H, h Crush box installation hole ø 6.3 (0.248) C, c Hood hinge installation nut-rear M8 (0.31) I, i Radiator seal installation holeø9(0.35) D Cowl panel center mark — J, j Front fender mounting bracket standard hole ø 10 (0.39) E, e Front side member standard hole ø 15 (0.59) K, k Front bumper installation holeø7(0.28) F, f Front side member standard hole ø 10 (0.39) — — —,

DI-4 BODY DIMENSIONS BODY OPENING AREAS (Side View)

3-Door (Three-Dimensional Distance) 1,050 (41.34) (35.55) 1,502 663 (59.13) (26.10) (38.66) 1,373 (54.06) 894 1,239 (35.20) (48.78) 1,085 (42.72) 1,266 (49.84) 1,060 (41.73) 1,145 (45.08) Vehicle Dimensions E-e F-f G-g H-h I-i J-j K-k 1,147 1,379 1,417 1,417 1,090 1,258 1,395 (45.16) (54.29) (55.79) (55.79) (42.91) (49.53) (54.92) E-f E-h E-j E-k F-j F-k G-h H-i J-k or or or or or or or or or e-F e-H e-J e-K f-J f-K g-H h-I j-K 1,532 1,609 1,372 1,549 1,826 1,745 1,440 1,650 1,429 (60.31) (63.35) (54.02) (60.98) (71.89) (68.70) (56.69) (64.96) (56.26) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Roof panel corner — G, g Rocker panel assembly mark — B, b Hood hinge installation nut M8 (0.31) H, h Rocker panel assembly mark — C, c Front door hinge installation nut M8 (0.31) I, i Roof side rail assembly mark — D, d Front door hinge installation nut M8 (0.31) J, j Quarter panel assembly mark — E, e Front body pillar assembly mark — K, k Quarter panel assembly mark — F, f Front body pillar assembly mark — — — —,

BODY DIMENSIONS DI-5 BODY OPENING AREAS (Side View: Front)

5-Door (Three-Dimensional Distance) 1,050 (41.34) 903 522 (35.55) 1,502 (20.55) (59.13) (38.66) 1,373 1,085 (54.06) (42.72) 1,062 761 (41.81) (29.96) 1,147 (45.16) (33.70) (39.33) Vehicle Dimensions Left Right E-e F-f G-g H-h I-i J-j K-k 1,147 1,379 1,417 1,417 1,090 1,263 1,391 (45.16) (54.29) (55.79) (55.79) (42.91) (49.72) (54.76) E-f E-h E-j F-j F-k H-i I-q J-k or or or or or or or or e-F e-H e-J f-J f-K h-I I-Q j-K 1,532 1,609 1,312 1,748 1,628 1,650 1,260 1,431 (60.31) (63.35) (51.65) (68.82) (64.09) (64.96) (49.61) (56.34) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Roof panel corner — H, h Rocker panel assembly mark — B, b Hood hinge installation nut M8 (0.31) I, i Roof side rail assembly mark — C, c Front door hinge installation nut M8 (0.31) J, j Center body pillar assembly mark — D, d Front door hinge installation nut M8 (0.31) K, k Center body pillar assembly mark — E, e Front body pillar assembly mark — L, l Rear door hinge installation nut M8 (0.31) F, f Front body pillar assembly mark — M, m Rear door hinge installation nut M8 (0.31) G, g Rocker panel assembly mark — Q, q Roof side rail assembly mark —,

DI-6 BODY DIMENSIONS BODY OPENING AREAS (Side View: Rear)

5-Door (Three-Dimensional Distance) (28.46) 905 1,076 (38.31) (35.63) (42.36) (33.31) (32.09) (23.54) Vehicle Dimensions Left Right N-n O-o P-p Q-q R-r S-s 1,263 1,381 1,417 1,068 1,130 1,405 (49.72) (54.37) (55.79) (42.05) (44.49) (55.31) G-p N-r N-s O-r O-s P-q R-s or or or or or or or g-P n-R n-S o-R o-S p-Q r-S 1,717 1,397 1,578 1,584 1,516 1,634 1,451 (67.60) (55.00) (62.13) (62.36) (59.69) (64.33) (57.13) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. G, g Rocker panel assembly mark — Q, q Roof side rail assembly mark — N, n Center body pillar assembly mark — R, r Quarter panel assembly mark — O, o Center body pillar assembly mark — S, s Quarter panel assembly mark — P, p Quarter panel assembly mark — — — —,

BODY DIMENSIONS DI-7 BODY OPENING AREAS (Rear View)

3-Door (Three-Dimensional Distance) 1,793 (70.59) 1,020 (40.16) 1,423 917 1,152 (56.02) (36.10) (45.35) 441 1,247 (28.54) (17.36) (49.09) (35.71) 1,333 (52.48) 1,090 410 1,103 (42.91) (16.14) (43.43) 678 (26.69) (25.55) 787 (30.98) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. ø 10.2 (0.402): RH A, a Back door hinge installation hole ø 10.2 (0.402) E, e Back door lock striker installation nut M8 (0.31) 12 (0.47): LH B, b Back door stay installation nut M6 (0.24) F, f Rear shock absorber installation hole−inner ø 18 (0.71) C, c Back door opening trough standard hole ø 10 (0.39) G, g Roof side rail assembly mark — Back door opening trough/Body lower back D, d — — — — panel adjoining point,

DI-8 BODY DIMENSIONS BODY OPENING AREAS (Rear View)

5-Door (Three-Dimensional Distance) 1,624 (63.94) 1,020 (40.16) 1,122 1,152 (44.17) 907 (45.35) 441 (35.71) 725 (17.36) 1,247 (28.54) (49.09) (36.10) 1,333 1,090 410 (52.48) (42.91) (16.14) (25.55) 678 1,103 (26.69) (43.43) (30.98) HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. ø 10.2 (0.402): RH A, a Back door hinge installation hole ø 10.2 (0.402) E, e Back door lock striker installation nut — 12 (0.47): LH B, b Back door stay installation nut M6 (0.24) F, f Rear shock absorber installation hole−inner M8 (0.31) C, c Back door opening trough standard hole ø 10 (0.39) G, g Center body pillar assembly mark ø 18 (0.71) Back door opening trough/Body lower back D, d — — — — panel adjoining point,

BODY DIMENSIONS DI-9 UNDER BODY

(Three-Dimensional Distance) (23.54) (17.83) 795 (31.30)

RH 991 276 536

(39.02) 872 796 (10.87) (21.10) 1,096 1,231 1,120 (34.33) (31.34) 844 (43.15) (48.46) (44.09) 967 930 (33.23) 796 1,060 (38.07) (36.61) (31.34) 1,266 (41.73) 727 759 410 (49.84) 920 1,096 854 (28.62) (36.22) (43.15) (33.62) 637 (29.88) (16.14) 1,228 957 1,100 (25.08) (48.35) (37.68) (43.31) 998 768 645 (39.29) 1,068 478(30.24) (25.39) (42.05) (18.82) 1,085 1,331 (42.72) (52.40) 979LH 453 (38.54) 415 (17.83) 462 310(16.34) (18.19) (12.20) (25.71) G-g123390 100 100 100

Front (15.35) (3.94) (3.94) (3.94)

A, a B, b C, c D, d E, e F, f G, g H, h I, i J, j K, k L, l M, m N, n 152 396 304 243 141 54 75 51 56 98 137 276 271 288 (5.98) (15.59) (11.97) (9.57)(5.55) (2.13) (2.95) (2.01) (2.20) (3.86) (5.39) (10.87) (10.67) (11.34)

Imaginary Standard Line HINT: For symbols, capital letters indicate right side of vehicle, small

letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Radiator side support installation nut M6 (0.24) H, h Front side member standard hole ø 18 (0.71) B, b Crush box installation hole ø 6.3 (0.248) I, i Front floor pan standard hole ø 18 (0.71) C, c Front side member standard hole ø 18 (0.71) J, j Floor side inner rear member standard hole ø 18 (0.71) D, d Front suspension installation nut M12 (0.47) K, k Trading arm installation outer hole−inner ø 15 (0.59) E, e Front suspension installation nut M14 (0.55) L, l Rear floor sidemember standard hole ø 18 (0.71) F, f Torque box front standard hole ø 25 (0.98) M, m Rear spring plate standard hole ø 18 (0.71) G, g Front floor pan standard hole ø 18 (0.71) N, n Rear floor sidemember standard hole ø 18 (0.71),

DI-10 BODY DIMENSIONS UNDER BODY

(Two-Dimensional Distance) 1,887 1,707 1,271 925 490 646 822 1,149 (74.29) (67.20) (50.04) (36.42) (19.29) 0 (25.43)(32.36) (45.24)

RH 665

550 (26.18)484 465 614 546 (19.06) (18.31) (21.65)(24.17) 422 530 (21.50)(16.61) (20.87) (8.07) 195 205 (7.68) (8.07) 479 436 (15.12) 489 460 (18.86) (17.17) 614 (19.25) (18.11)

LH (24.17)

1,781 1,298 1,080 645 0 718 1,037 1,345 (70.12) (51.10) (42.52) (25.39) (28.27) (40.83) (52.95) Wheel Base 2,460 (96.85) 123

Front

100 100 100 (3.94) (3.94) (3.94) A, a B, b C, c E, e D, d F, f G, g H, h I, i J, j K, k M, m N, n O, o P, p 152 396 304 734 243 141 54 75 51 56 98 276 271 607 288 (5.98)(15.59)(11.97) (28.90) (9.57) (5.55) (2.13) (2.95) (2.01) (2.20) (3.86) (10.87) (10.67) (23.90) (11.34)

Imaginary

L, l 137 Standard (5.39) Line

HINT: For symbols, capital letters indicate right side of vehicle, small

letters indicate left side of vehicle (seen from rear). mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Radiator side support installation nut M6 (0.24) I, i Front side member standard hole ø 18 (0.71) B, b Crush box installation hole ø 6.3 (0.248) J, j Front floor pan standard hole ø 18 (0.71) C, c Front side member standard hole ø 18 (0.71) K, k Floor side inner rear member standard hole ø 18 (0.71) D, d Front suspension member installation nut M12 (0.47) L, l Trading arm installation outer hole−inner ø 15 (0.59) E, e Front spring support plate standard hole−outer ø 11 (0.43) M, m Rear floor sidemember standard hole ø 18 (0.71) F, f Front suspension member installation nut M14 (0.55) N, n Rear spring plate standard hole ø 18 (0.71) G, g Torque box front standard hole ø 25 (0.98) O, o Rear shock absorber installation hole ø 18 (0.71) H, h Front floor pan standard hole ø 18 (0.71) P, p Rear floor sidemember standard hole ø 18 (0.71),

BODY DIMENSIONS DI-11 REFERENCE VALUE ENGINE COMPARTMENT

(Three-Dimensional Distance) 1,324 (52.13) 1,361 (53.58) 1,025 618 (40.35) 1,008 (39.69) (24.33) 590 (23.23) (19.88) C-D C-c or c-d 1,324 38 (52.13) (1.50) HINT: These values are actual measurements made on a vehicle. Use these reference values. mm (in.) Symbol Name Hole dia. Symbol Name Hole dia. A, a Front bumper cover installation bolt — C, c Headlight installation bolt — B, b Front end of fender — D, d Front fender installation bolt —, DI-12 BODY DIMENSIONS

UNDER BODY

(Two-Dimensional Distance)

Radiator support installation

25.0 4 M10 NUT 2.3 2.3 1.6

Front spring support Rear shock absorber installation

63.6 34.1 2 11 2.3 2.0 2.0 5.5 mm 0.6 51.2 13.6 2.8 20.6 52 142.6 15 15 11 11 4.9,

FOREWORD

This repair manual has been prepared to provide essential in- formation on body panel repair methods (including cutting and welding operations, but excluding painting) for the TOYOTA YARIS. Applicable models: KSP90 series NCP90, 91, 92, 93 series SCP90 series NLP90 series This manual consists of body repair methods, exploded dia- grams and illustrations of the body components and other in- formation relating to body panel replacement such as handling precautions, etc. However, it should be noted that the front fend- ers of, this TOYOTA model are bolted on and require no welding. When repairing, don’t cut and join areas that are not shown in this manual. Only work on the specified contents to maintain body strength. Body construction will sometimes differ depending on specifica- tions and country of destination. Therefore, please keep in mind that the information contained herein is based on vehicles for general destinations. For the repair procedures and specifications other than collision- damaged body components of the TOYOTA YARIS refer to the repair manuals. If you require the above manuals, please contact your TOYOTA dealer. All information contained in this manual is the most up-to-date at the time of publication. However, specifications and procedures are subject to change without prior notice.,

HOW TO USE THIS MANUAL Scope of the repair work explanation

This text explains the welding panel replacement instructions from the vehicle’s white body condi- tion. We have abbreviated the explanations of the removal and reinstallation of the equipment parts up to the white body condition and of the installation, inspection, adjustment and final inspection of equipment parts after replacing the weld panel.

Section categories

This manual has been divided as shown below. Section Title Contents Examples Explanation of general body repair. Cautionary items.

INTRODUCTION

Views of weld panel replacement instructions. Views of weld panel replacement instructions. Instructions for replacing the weld panels Front side member replacement. from the white body condition, from which Quarter panel replacement. BODY PANEL REPLACEMENT bolted parts have been removed, with individual supply parts. BODY DIMENSIONS Body aligning measurements. Dimension diagrams. Scope and type of anti-rust treatment, etc. Under coating. PAINT COATING together with weld panel replacement. Body sealer.

Contents omitted in this manual.

Make sure to perform the following essential procedures, although they are omitted in this manual. (1) Jack and lift operations. (2) Clean and wash removed parts, if necessary. (3) Visual inspection., INTRODUCTION IN-1

GENERAL REPAIR INSTRUCTIONS

1. WORK PRECAUTIONS (a) VEHICLE PROTECTION Glass Cover (1) When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fireproof covers. Seat Cover F10001A (b) SAFETY (1) Never stand in a direct line with the chain when using a puller on the body or frame, and be sure to attach a safety cable.

WRONG

F10002A (2) Before performing repair work, check for fuel leaks. If a leak is found, be sure to close the opening com- pletely. (3) If it is necessary to use a flame in the area of the fuel tank, first remove the tank and plug the fuel line. WRONG F10003A (c) SAFETY WORK CLOTHES (1) In addition to the usual mechanic’s wear, cap and safety shoes, the appropriate gloves, head protector, glasses, ear plugs, face protector, dust-prevention mask, etc. should be worn as the situation demands. Code Name A Dust-Prevention Mask B Face Protector F10004A C Eye Protector D Safety Shoes E Welder’s Glasses F Ear Plugs G Head Protector H Welder’s Gloves, IN-2 INTRODUCTION 2. HANDLING PRECAUTIONS OF PLASTIC BODY PARTS (1) The repair procedure for plastic body parts must conform with the type of plastic material. (2) Plastic body parts are identified by the codes in the following table. (3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, paint- ing etc.), consideration must be given to the properties of the plastic. Heat* Material resistant Resistance to Code Notes name temperature alcohol or gasoline limit C (F) Alcohol is harmless if applied only for Acrylonitrile 80 Avoid gasoline and organic AAS short time in small amounts (e.g., quick Acrylic Styrene (176) or aromatic solvents. wiping to remove grease). Alcohol is harmless if applied only for Acrylonitrile 80 Avoid gasoline and organic ABS short time in small amounts (e.g., quick Butadiene Styrene (176) or aromatic solvents. wiping to remove grease). Alcohol is harmless if applied only for Acrylonitrile 80 Avoid gasoline and organic AES short time in small amounts (e.g., quick Ethylene Styrene (176) or aromatic solvents. wiping to remove grease). Acrylonitrile Alcohol is harmless if applied only for 80 Avoid gasoline and organic ASA Styrene short time in small amounts (e.g., quick (176) or aromatic solvents. Acrylate wiping to remove grease). Alcohol is harmless if applied only for Cellulose 80 Avoid gasoline and organic CAB short time in small amounts (e.g., quick Acetate (176) or aromatic solvents. wiping to remove grease). Alcohol is harmless. Most solvents are harmless Ethylene 100 EPDM Gasoline is harmless if applied only for but avoid dipping in gasoline, Propylene (212) short time in small amounts. solvents, etc. Fiber FRP Reinforced Alcohol and gasoline are harmless. Avoid alkali. (356) Plastics Alcohol is harmless if applied only for Ethylene 70 Avoid gasoline and organic EVA short time in small amounts (e.g., quick Acetate (158) or aromatic solvents. wiping to remove grease). Ethylene/ Vinyl Alcohol is harmless if applied only for 70 Avoid gasoline and organic E/VAC Acetate short time in small amounts (e.g., quick (158) or aromatic solvents. Copolymer wiping to remove grease). Resin Polyamide 80 PA Alcohol and gasoline are harmless. Avoid battery acid. (Nylon) (176) Polybutylene 160 PBT Alcohol and gasoline are harmless. Most solvents are harmless. Terephthalate (320) Avoid gasoline, brake fluid, PC Polycarbonate Alcohol is harmless. wax, wax removers and (248) organic solvents. Avoid alkali. *Temperatures higher than those listed here may result in material deformation during repair., INTRODUCTION IN-3 Heat* Material resistant Resistance to Code Notes name temperature alcohol or gasoline limit C (F) PE Polyethylene Alcohol and gasoline are harmless. Most solvents are harmless. (176) Polyethylene 75 PET Alcohol and gasoline are harmless. Avoid dipping in water. Terephthalate (167) Avoid dipping or immersing Polymethyl 80 Alcohol is harmless if applied only for PMMA in alcohol, gasoline, Methacrylate (176) short time in small amounts. solvents, etc. Polyoxymethylene 100 POM Alcohol and gasoline are harmless. Most solvents are harmless. (Polyacetal) (212) PP Polypropylene Alcohol and gasoline are harmless. Most solvents are harmless. (176) Composite PPF Reinforced Alcohol and gasoline are harmless. Most solvents are harmless. (176) Polypropylene Modified Gasoline is harmless if PPO Polyphenylene Alcohol is harmless. applied only for quick wiping (212) Oxide to remove grease. Alcohol and gasoline are harmless if Avoid dipping or immersing PS Polystyrene applied only for short time in small in alcohol, gasoline, (140) amounts. solvents, etc. Alcohol is harmless if applied only for very Avoid dipping or immersing PUR Polyurethane short time in small amounts (e.g., quick in alcohol, gasoline, (176) wiping to remove grease). solvents, etc. Alcohol and gasoline are harmless if Avoid dipping or immersing Polyvinylchloride 80 applied only for short time in small PVC in alcohol, gasoline, (Vinyl) (176) amounts (e.g., quick wiping to remove solvents, etc. grease). Alcohol is harmless if applied only for Avoid dipping or immersing Styrene 80 SAN short time in small amounts (e.g., quick in alcohol, gasoline, Acrylonitrile (176) wiping to remove grease). solvents, etc. Alcohol is harmless. Most solvents are harmless Thermoplastic 80 TPO Gasoline is harmless if applied only for but avoid dipping in gasoline, Olefine (176) short time in small amounts. solvents, etc. Alcohol is harmless if applied only for Avoid dipping or immersing Thermoplastic 80 TPU short time in small amounts (e.g., quick in alcohol, gasoline, Polyurethane (176) wiping to remove grease). solvents, etc.

TOYOTA

TSOP Super Alcohol and gasoline are harmless. Most solvents are harmless. (176) Olefine Polymer Unsaturated 110 UP Alcohol and gasoline are harmless. Avoid alkali. Polyester (233) *Temperatures higher than those listed here may result in material deformation during repair., IN-4 INTRODUCTION 3. LOCATION OF PLASTIC BODY PARTS Parts Name Code Front Bumper Cover TSOP Front Spoiler Cover TSOP TPO Radiator Grille AES Headlight PC/PP Foglight PBT/ASA Front Pillar Upper Cover (Hatchback) AES Front Pillar Cover (Sedan) AES Side Turn Signal Light PMMA/PC/ABS Cowl Top Ventilator Louver TSOP Outer Rear View Mirror PA/ABS ASA PP Door Outside Handle PA/PC/PBT Mudguard PP Back Door Outside Handle (Hatchback) PA Luggage Compartment Door Outside Garnish (Sedan) ABS Rear Spoiler (Sedan) ABS License Plate Light PC Rear Combination Light PMMA/ABS Rear Bumper Cover TSOP HINT: Resin material differs depending on model. / Made up of 2 or more kinds of materials., INTRODUCTION IN-5

HOW TO USE THIS MANUAL

1. BODY PANEL REPLACEMENT IN THIS MANUAL BODY PANEL REPLACEMENT QUARTER PANEL (CUT)

REPLACEMENT REMOVAL POINT

1. Remove the [A] at the same time. PART NAME [A] Fuel filler opening lid 200 mm (7.87 in.) REPLACEMENT PART AND METHOD

QUARTER PANEL (CUT)

Replacement method (ASSY)...Assembly replacement (CUT)...Major cutting (less than 1/2 of part used) (CUT-H)...Half cutting (about 1/2 of part used) (CUT-P)...Partial cutting (most of part used) Replacement part REMOVAL CONDITIONS PART LOCATION REMOVAL DIAGRAM Describes in detail the removal of the damaged part involving repair by cutting. REMOVAL GUIDE Provides additional information to more efficiently help you perform the removal. F13890A,

IN-6 INTRODUCTION

BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.

POINT

1. Before temporarily installing the new parts, apply sealer to the wheel arch.

HINT

1) Apply body sealer about 5 mm (0.20 in.) front the flange, avoiding any oozing. 2) Apply sealer evenly, about 3−4 mm (0.12−0.16 in.) in diameter 3) For other sealing points, refer to section PC.

INSTALLATION CONDITIONS INSTALLATION DIAGRAM Describes in detail the installation of the new parts involving repair by welding and/or

cutting, but excluding painting.

INSTALLATION GUIDE Provides additional information to more efficiently help you perform the installation. SYMBOLS

(See page IN-7)

INSTALLATION OF WELD POINTS Weld method and panel position symbols (See page IN-9) PART NAME

F13891A, INTRODUCTION IN-7 2. SYMBOLS

The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas

and the types of weld required. SYMBOLS MEANING ILLUSTRATION CUT AND JOIN LOCATION (Saw Cut) CUT AND JOIN LOCATION (Cut Location for Supply Parts) CUT LOCATION CUT WITH DISC SANDER, ETC.

BRAZE

(Removal)

BRAZE

(Installation) WELD POINTS SPOT WELD OR MIG PLUG WELD (See page IN-9)

CONTINUOUS

MIG WELD (BUTT WELD)

CONTINUOUS

MIG WELD (TACK WELD) BODY SEALER F13893A, IN-8 INTRODUCTION

SYMBOLS MEANING ILLUSTRATION

— Assembly Mark — — BODY SEALER(Flat Finishing) — BODY SEALER(No Flat Finishing) F13894A, INTRODUCTION IN-9 3. ILLUSTRATION OF WELD POINT SYMBOLS

EXAMPLE:

REMOVAL INSTALLATION Weld points Weld points Remove weld point and panel position Weld method and panel position SYMBOLS MEANING ILLUSTRATION SYMBOLS MEANING ILLUSTRATION Remove Weld Points Spot Weld (Outside) MIG Plug Weld (Middle) (Inside) Spot MIG Weld HINT: Panel position symbols are as seen from the working posture. F13892A, IN-10 INTRODUCTION

PROPER AND EFFICIENT WORK PROCEDURES

1. REMOVAL (a) PRE-REMOVAL MEASURING (1) Before removal or cutting operations, take measure- ments in accordance with the dimensions diagram. Al- ways use a puller to straighten a damaged body or frame. F10007A (b) CUTTING AREA Cutting Okay (1) Always cut in a straight line and avoid reinforced Reinforcement areas. Corners F10008A (c) PRECAUTIONS FOR DRILLING OR CUTTING (1) Check behind any area to be drilled or cut to ensure that there are no hoses, wires, etc., that may be dam- aged. HINT: See “Handling Precautions on Related Compo- nents” on page IN-15. WRONG F10009A (d) REMOVAL OF ADJACENT COMPONENTS (1) When removing adjacent components, apply protec- tive tape to the surrounding body and your tools to pre- vent damage. HINT: See “Handling Precautions on Related Compo- nents” on page IN-15. F10010A, INTRODUCTION IN-11 2. PREPARATION FOR INSTALLATION (a) SPOT WELD POINTS (1) When welding panels with a combined thickness of Less than over 3 mm (0.12 in.), use a MIG (Metal Inert Gas) 3 mm welder for plug welding. HINT: Spot welding does not provide sufficient dura- bility for panels with a combined thickness of over 3 mm (0.12 in.). F10011A (b) APPLICATION OF WELD-THROUGH PRIMER (SPOT SEALER) (1) Remove the paint from the portion of the new parts and body to be welded, and apply weld-through prim- er. F10012A (c) MAKING HOLES FOR PLUG WELDING (1) For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding. REFERENCE: mm (in.) Thickness of welded portion Size of plug hole 1.0 (0.04) under 5 (0.20) ø over Puncher 1.0 (0.04) − 1.6 (0.06) 6.5 (0.26) ø over 1.7 (0.07) − 2.3 (0.09) 8 (0.31) ø over F10013A 2.4 (0.09) over 10 (0.39) ø over (d) SAFETY PRECAUTIONS FOR ELECTRICAL COM-

PONENTS

(1) When welding, there is a danger that electrical compo- nents will be damaged by the electrical current flowing through the body. (2) Before starting work, disconnect the negative terminal of the battery and ground the welder near the welding location of the body. F10014A (e) ROUGH CUTTING OF JOINTS 20 − 30 mm (1) For joint areas, rough cut the new parts, leaving 20 − Air Saw Overlap 30 mm (0.79 − 1.18 in.) of overlap. F10015A, IN-12 INTRODUCTION 3. INSTALLATION Body Measurement Diagrams (a) PRE-WELDING MEASUREMENTS (1) Always take measurements before installing under- body or engine components to ensure correct assem- bly. After installation, confirm proper fit. F10016A (b) WELDING PRECAUTIONS (1) The number of welding spots should be as follows. Spot weld: 1.3 X No. of manufacturer’s spots. Plug weld: More than No. of manufacturer’s plugs. (2) Plug welding should be done with a MIG (Metal Inert Gas) welder. Do not gas weld or braze panels at areas other than specified. WRONG F10017A (c) POST-WELDING REFINISHING (1) Always check the welded spots to ensure they are se- cure. (2) When smoothing out the weld spots with a disc grind- er, be careful not to grind off too much as this will weak- en the weld. CORRECT WRONG F10018A (d) SPOT WELD LOCATIONS New Spot Old Locations (1) Avoid welding over previously welded areas. Spot Locations F10020A (e) SPOT WELDING PRECAUTIONS (1) The shape of the tip point of the spot welder signifi- cantly affects the strength of the weld. Therefore, maintain the tip point in the proper shape, and allow it to cool after every five or six spots. (2) Completely remove the paint from the areas to be spot welded, including the seams and the surfaces that come in contact with the welding tip. (3) Use a sander to remove any burrs that are created Tip Cutter F10019A during spot welding., INTRODUCTION IN-13 Sealer Gun 4. ANTI-RUST TREATMENT AFTER INSTALLATION (BEFORE PAINTING PROCESS) (a) BODY SEALER APPLICATION (1) For water-proofing and anti-corrosion measures, al- ways apply the body sealer to the body panel seams and hems of the doors, hood, etc. F10021A (b) UNDERCOAT APPLICATION (1) To prevent corrosion and protect the body from dam- age by flying stones, always apply sufficient under- coating to the bottom surface of the under body and inside of the wheel housings. F10022A 5. ANTI-RUST TREATMENT AFTER INSTALLATION (AFTER PAINTING PROCESS) (a) ANTI-RUST AGENT (WAX) APPLICATION (1) To preserve impossible to paint areas from corrosion, always apply sufficient anti-rust agent (wax) to the in- side of the hemming areas of the doors and hood, and around the hinges, or the welded surfaces inside the box-shaped cross sections of the side members, body pillar, etc. F10023A, IN-14 INTRODUCTION 6. ANTI-RUST TREATMENT BY PAINTING REFERENCE: Painting prevents corrosion and protects the sheet metal from damage. In this section, anti-chipping paint only for anti-corrosion purpose is described. (a) ANTI-CHIPPING PAINT (1) To prevent corrosion and protect the body from dam- age by flying stones, etc., apply anti-chipping paint to the rocker panel, wheel arch areas, balance panel, etc. HINT: Depending on the model or the application area, there are cases where the application of anti-chipping paint is necessary before the second coat or after the top coat. Apply the anti-chipping paint after Apply the anti-chipping paint before the top coat. the second coat. Top Coat Anti-Chipping Paint Second Coat Top Coat Anti-Chipping Paint Second Coat Under Coat (ED Primer) Under Coat (ED Primer) Steel Metal Steel Metal F10024A, INTRODUCTION IN-15

HANDLING PRECAUTIONS ON RELATED COMPONENTS

1. BRAKE SYSTEM The brake system is one of the most important safety components. Always follow the directions and notes given in the brake (32) section of the repair manual for the relevant model when handling brake system parts. NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC sys- tem. 2. DRIVE TRAIN AND CHASSIS The drive train and chassis are components that can have great effects on the running performance and vibration resistance of the vehicle. After installing components in the sections listed in the table below, perform alignments to ensure correct mounting angles and dimensions. Body repair must be particularly accurate to ensure correct alignment. HINT: Correct procedures and special tools are required for alignment. Always follow the directions giv- en in the repair manual for the relevant model during alignment and section DI of this section. Section of repair manual Component to be aligned for relevant model Front Wheels Front Suspension (26) section Rear Wheels Rear Suspension (27) section 3. COMPONENTS ADJACENT TO THE BODY PANELS Various types of component parts are mounted directly on or adjacently to the body panels. Strictly ob- serve the following precautions to prevent damaging these components and the body panels during han- dling. Before repairing the body panels, remove their components or apply protective covers over the com- ponents. Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool tip or blade to prevent damaging the components and the body paint. Before removing components from the outer surface of the body, attach protective tape to the body to ensure no damage to painted areas. HINT: Apply touch-up paint to any damaged paint surfaces. Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side. 4. ECU (ELECTRONIC CONTROL UNIT) Many ECUs are mounted in this vehicle. Take the following precautions during body repair to prevent damage to the ECUs. Before starting electric welding operations, disconnect the negative (−) terminal cable from the bat- tery. When the negative (−) terminal cable is disconnected from the battery, memory of the clock and audio systems will be canceled. So before starting work, make a record of the contents memorized by each memory system. Then when work is finished, reset the clock and audio systems as before. When the vehicle has tilt and telescopic steering, power seats and outside rear view mirrors, which are all equipped with a memory function, it is not possible to make a record of the memory contents. So when the operation is finished, it will be necessary to explain this fact to the customer, and request the customer to adjust the features and reset the memory. Do not expose the ECUs to ambient temperatures above 80C (176F). NOTICE: If it is possible the ambient temperature may reach 80C (176F) or more, remove the ECUs from the vehicle before starting work. Be careful not to drop the ECUs and not to apply physical shocks to them., IN-16 INTRODUCTION

PRECAUTIONS FOR REPAIRING BODY STRUCTURE PANELS

1. HEAT REPAIR FOR BODY STRUCTURE

PANELS

Toyota prohibits the use of the heat repair method on body structure panels when repairing a vehicle damaged in a col- lision. Panels that have high strength and rigidity, as well as a long life span for the automobile body are in high demand. At Toyota, in order to fulfill these requirement, we use high tensile strength steel sheets and rust preventive steel sheets on the body. High tensile steel sheets are made with alloy additives and a special heat treatment in order to im- prove the strength. To prevent the occurrence of rust for a long period of time, the surface of the steel is coated with a zinc alloy. If body structure parts are heat repaired with an acetylene torch or other heating source, the crystalline organization of the steel sheet will change and the strength of the steel sheet will be reduced. The ability of the body to resist rust is significantly lowered as well since the rust resistant zinc coating is destroyed by heat and the steel sheet surface is oxidized. 2. STRUCTURE PANEL KINKS A sharp deformation angle on a panel that cannot be re- turned to its original shape by pulling or hammering is called a kink. Structural parts are designed to perform in their original shape. If parts are deformed in an accident, or if the de- formed parts are repaired and reused, the parts may be un- able to perform as intended. It is necessary to replace the part where the kink has oc- curred., INTRODUCTION IN-17 3. IMPACT BEAM REPAIR The impact beam and bracket are necessary and important parts that help reduce the probability of injury to passen- gers in side collisions. For impact beams, we use special high tensile strength steel. The high tensile strength steel maintains its special crystal- line organization by heat treatment or alloy additives. Structural parts are designed to perform in their original shape. If parts are deformed in an accident, or if the de- formed parts are repaired and reused, the parts may be un- able to perform as intended. If the impact beam or bracket is damaged, replace the door assembly with the damaged beam. Also, the bumper reinforcement is a necessary and impor- tant part that helps reduce the probability of injury to pas- sengers in front collisions, and for the same reasons ex- plained above, should be replaced if damaged., IN-18 INTRODUCTION

ABBREVIATIONS USED IN THIS MANUAL

For convenience, the following abbreviations are used in this manual. ABS Antilock Brake System A/C Air Conditioner assy assembly ECT Electronic Controlled Transmission ECU Electronic Control Unit e.g. Exempli Gratia (for Example) Ex. Except FWD Front Wheel Drive Vehicles 2WD Two Wheel Drive Vehicles 4WD Four Wheel Drive Vehicles in. inch LH Left-hand LHD Left-hand Drive MIG Metal Inert Gas M/Y Model Year PPS Progressive Power Steering RH Right-hand RHD Right-hand Drive SRS Supplemental Restraint System SSM Special Service Materials w/ with w/o without, BODY PANEL REPLACEMENT BP-1

RADIATOR SUPPORT (ASSY) REPLACEMENT

F22816A

REMOVAL

F22816

POINT

1 *1: Bolt, BP-2 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F22817

POINT

1 Inspect the fitting of the headlight, front fender, hood and other related parts, before welding as this affects the appearance of the finish. 2 *1: Bolt, BODY PANEL REPLACEMENT BP-3 [Hatchback] 1,324 mm 530 mm 944 mm [Sedan] 1,327 mm 380 mm 950 mm F22818-1

POINT

1 Measure the dimensions before installing the headlight. 2 These values are reference values. 380 mm (14.96 in.) 530 mm (20.87 in.) 944 mm (37.17 in.) 950 mm (37.40 in.) 1,324 mm (52.13 in.) 1,327 mm (52.24 in.), BP-10 BODY PANEL REPLACEMENT

FRONT SIDEMEMBER REINFORCEMENT

(CUT-P)

REPLACEMENT

With the radiator support removed. F22825A

REMOVAL

[LH] 140 mm 65 mm F23301

POINT

1 Remove [A] at the same time. PART NAME [A] Front Sidemember Outer Plate 65 mm (2.56 in.) 140 mm (5.51 in.), BODY PANEL REPLACEMENT BP-11 [RH] 70 mm 140 mm F23302

POINT

1 Remove [B] before conducting this work. 2 Remove [A] at the same time. PART NAME [A] Front Sidemember Outer Plate [B] Engine Front Mounting Bracket 70 mm (2.76 in.) 140 mm (5.51 in.), BP-12 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. [LH] F23303 PART NAME [A] Front Sidemember Outer Plate, BODY PANEL REPLACEMENT BP-13 [RH] F23304

POINT

1 Remove the [B] from the new parts of the front sidemember reinforcement. 2 After installing the new parts, install [B]. PART NAME [A] Front Sidemember Outer Plate [B] Engine Front Mounting Bracket, BP-4 BODY PANEL REPLACEMENT

FRONT FENDER MOUNTING BRACKET

(ASSY)

REPLACEMENT

F22819A

REMOVAL

F22819, BODY PANEL REPLACEMENT BP-5

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F22820

POINT

1 Inspect the fitting of the front fender and other related parts before welding as this affects the appearance of the finish., BP-6 BODY PANEL REPLACEMENT

FRONT FENDER APRON (ASSY) REPLACEMENT

With the cowl top side panel removed. F22821A

REMOVAL

[RH] [LH] F22821, BODY PANEL REPLACEMENT BP-7 F22822, BP-8 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. [RH] [LH] F22823

POINT

1 Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front wheel alignment. 2 Inspect the fitting of the front fender, hood and other related parts before welding as this affects the appearance of the finish., BODY PANEL REPLACEMENT BP-9 F22824, BP-14 BODY PANEL REPLACEMENT

FRONT SIDEMEMBER REINFORCEMENT

(ASSY)

REPLACEMENT

With the radiator support and front fender apron removed. F22829A

REMOVAL

F22829

POINT

1 Remove [A] at the same time. PART NAME [A] Front Sidemember Outer Plate, BODY PANEL REPLACEMENT BP-15

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F22830

POINT

1 Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front wheel alignment., BP-16 BODY PANEL REPLACEMENT [LH] [RH] F22831 PART NAME [A] Front Sidemember Outer Plate, BODY PANEL REPLACEMENT BP-17

COWL TOP SIDE PANEL (ASSY): Hatchback REPLACEMENT

F22832A

REMOVAL

F22832, BP-18 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. (20 mm) (25 mm) (30 mm) (15 mm) F22833 15 mm (0.59 in.) 20 mm (0.79 in.) 25 mm (0.98 in.) 30 mm (1.18 in.), BODY PANEL REPLACEMENT BP-19

COWL TOP SIDE PANEL (ASSY): Sedan REPLACEMENT

F24821A

REMOVAL

F24821-1, BP-20 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. (20 mm) (25 mm) (30 mm) (15 mm) F24821-2 15 mm (0.59 in.) 20 mm (0.79 in.) 25 mm (0.98 in.) 30 mm (1.18 in.), BODY PANEL REPLACEMENT BP-21

COWL TOP SIDE UPPER PANEL (ASSY): Hatchback REPLACEMENT

With the cowl top side panel removed. F22834A

REMOVAL

F22834, BP-22 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. (25 mm) (25 mm) F22835

POINT

1 Inspect the fitting of the hood and related parts before welding as this affects the appearance of the finish. 25 mm (0.98 in.), BODY PANEL REPLACEMENT BP-23

COWL TOP SIDE UPPER PANEL (ASSY): Sedan REPLACEMENT

With the cowl top side panel removed. F24822A

REMOVAL

F24822-1, BP-24 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. (23 mm) F24822-2

POINT

1 Inspect the fitting of the hood and related parts before welding as this affects the appearance of the finish. 23 mm (0.91 in.), BP-34 BODY PANEL REPLACEMENT

CENTER BODY PILLAR (CUT): Hatchback 5 Door REPLACEMENT

F22840A

REMOVAL

50 mm 30 mm 30 mm 50 mm 50 mm F22840 30 mm (1.18 in.) 50 mm (1.97 in.), BODY PANEL REPLACEMENT BP-35

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. 80 mm 45 mm (10 mm 7) F22841

POINT

1 Before temporarily installing the new parts, weld [A], [B] and [C] with standard welding number. PART NAME [A] Rocker Outer Reinforce [B] Center Body Pillar Reinforcement [C] Center Body Inner Pillar 10 mm (0.39 in.) 45 mm (1.77 in.) 80 mm (3.15 in.), BP-36 BODY PANEL REPLACEMENT (10 mm 4) F22842

POINT

1 Inspect the fitting of the front door, rear door and other related parts before welding as this affects the appear- ance of the finish. 2 After welding [A], [B] and [C] to the vehicle, install [D]. PART NAME [A] Rocker Outer Reinforce [B] Center Body Pillar Reinforcement [C] Center Body Inner Pillar [D] Center Body Outer Pillar 10 mm (0.39 in.), BODY PANEL REPLACEMENT BP-25

FRONT BODY PILLAR (CUT): Hatchback REPLACEMENT

With the cowl top side upper panel removed. F22836A

REMOVAL

100 mm 80 mm 160 mm 70 mm F22836

POINT

1 *1: This part of the outer panel is reused because the rocker panel section is cut off at a position behind the service part cut position of the outer panel. 70 mm (2.76 in.) 80 mm (3.15 in.) 100 mm (3.94 in.) 160 mm (6.30 in.), BP-26 BODY PANEL REPLACEMENT F22837, BODY PANEL REPLACEMENT BP-27

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. 230 mm (10 mm 3) (15 mm 3) F22838

POINT

1 Before temporarily installing the new parts, weld [A], [B], [C] and [D] with standard welding number. PART NAME [A] Rocker Outer Reinforce [B] Front Body Pillar Lower Reinforce [C] Front Body Inner Pillar [D] Front Body Outer Pillar 10 mm (0.39 in.) 15 mm (0.59 in.) 230 mm (9.06 in.), BP-28 BODY PANEL REPLACEMENT (10 mm) (15 mm 2) F22839

POINT

1 Inspect the fitting of the front fender, front door, windshield glass and other related parts before welding as this affects the appearance of the finish. 10 mm (0.39 in.) 15 mm (0.59 in.), BODY PANEL REPLACEMENT BP-29

FRONT BODY PILLAR (CUT): Sedan REPLACEMENT

With the cowl top side upper panel removed. F24823A

REMOVAL

140 mm 160 mm 40 mm F24823-1

POINT

1 After removing [A], remove the front body pillar. 2 *1: This part of the outer panel is reused because the rocker panel section is cut off at a position behind the service part cut position of the outer panel. PART NAME [A] Front Panel No.1 Bracket 40 mm (1.57 in.) 140 mm (5.51 in.) 160 mm (6.30 in.), BP-30 BODY PANEL REPLACEMENT F24824, BODY PANEL REPLACEMENT BP-31

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. 200 mm (10 mm3) (15 mm2) (15 mm) F24825-1

POINT

1 Before temporarily installing the new parts, weld [B], [C], [D] and [E] with standard welding number. PART NAME [B] Rocker Outer Reinforce [C] Front Body Pillar Lower Reinforce [D] Front Body Inner Pillar [E] Front Body Upper Outer Pillar 10 mm (0.39 in.) 15 mm (0.59 in.) 200 mm (7.87 in.), BP-32 BODY PANEL REPLACEMENT (15 mm) (15 mm) (10 mm) F24826 10 mm (0.39 in.) 15 mm (0.59 in.), BODY PANEL REPLACEMENT BP-33 F24827-1

POINT

1 Inspect the fitting of the front fender, front door, window shield glass and other related parts before welding as this affects the appearance of the finish. 2 After installing the new parts, install [A] PART NAME [A] Front Panel No.1 Bracket, BODY PANEL REPLACEMENT BP-43

FRONT DOOR OUTER PANEL (CUT): Hatchback 5 Door REPLACEMENT

F23307A

REMOVAL

Hemming Location Disc Sander F23307

POINT

1 After grinding off the hemming location, remove the outer panel., BP-44 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. 10 mm Do not close the drain hole. Cloth Tape Hemming Tool F23308

POINT

1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make con- tact. 2 Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly., BODY PANEL REPLACEMENT BP-37

CENTER BODY PILLAR (CUT): Sedan REPLACEMENT

F24828A

REMOVAL

40 mm 30 mm 70 mm 90 mm F24828-1 30 mm (1.18 in.) 40 mm (1.57 in.) 70 mm (2.76 in.) 90 mm (3.54 in.), BP-38 BODY PANEL REPLACEMENT 15 mm 130 mm F24829

POINT

1 *1: Take care not to damage the internal reinforcement. 15 mm (0.59 in.) 130 mm (5.12 in.), BODY PANEL REPLACEMENT BP-39

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. 110 mm 50 mm (10 mm7) 15 mm 130 mm F24830-1

POINT

1 Before temporarily installing the new parts, weld [A], [B] and [C] with standard welding number. PART NAME [A] Rocker Outer Reinforce [B] Center Body Pillar Reinforcement [C] Center Body Inner Pillar 10 mm (0.39 in.) 15 mm (0.59 in.) 50 mm (1.97 in.) 110 mm (4.33 in.) 130 mm (5.12 in.), BP-40 BODY PANEL REPLACEMENT ( 10 mm2) (10 mm) (10 mm) F24831-1

POINT

1 Inspect the fitting of the front door, rear door and other related parts before welding as this affects the appear- ance of the finish. 2 After welding [A], [B] and [C] to the vehicle, install [D]. PART NAME [A] Rocker Outer Reinforce [B] Center Body Pillar Reinforcement [C] Center Body Inner Pillar [D] Rocker Outer Panel 10 mm (0.39 in.), BODY PANEL REPLACEMENT BP-45

FRONT DOOR OUTER PANEL (CUT): Sedan Ex. U.S.A., CANADA REPLACEMENT

F24875A

REMOVAL

Hemming Location Disc Sander F24875

POINT

1 Afer grinding off the hemming location, remove the outer panel., BP-46 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. 10 mm Do not close the drain hole. Cloth Tape Hemming Tool F24876

POINT

1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make con- tact. 2 Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly., BODY PANEL REPLACEMENT BP-41

FRONT DOOR OUTER PANEL (CUT): Hatchback 3 Door REPLACEMENT

F23305A

REMOVAL

Hemming Location Disc Sander F23305

POINT

1 After grinding off the hemming location, remove the outer panel., BP-42 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. 10 mm Do not close the drain hole. Cloth Tape Hemming Tool F23306

POINT

1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make con- tact. 2 Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly., BODY PANEL REPLACEMENT BP-47

FRONT DOOR OUTER PANEL (CUT): Sedan U.S.A., CANADA REPLACEMENT

F24875A

REMOVAL

Hemming Location Disc Sander F24877

POINT

1 After grinding off the hemming location, remove the outer panel., BP-48 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. 10 mm Do not close the drain hole. Cloth Tape Hemming Tool F24878

POINT

1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make con- tact. 2 Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly., BODY PANEL REPLACEMENT BP-49

REAR DOOR OUTER PANEL (CUT): Hatchback 5 Door REPLACEMENT

F23309A

REMOVAL

Hemming Location Disc Sander F23309

POINT

1 After grinding off the hemming location, remove the outer panel., BP-50 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. 10 mm Do not close the drain hole. Cloth Tape Hemming Tool F23310

POINT

1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make con- tact. 2 Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly., BODY PANEL REPLACEMENT BP-51

REAR DOOR OUTER PANEL (CUT): Sedan Ex. U.S.A., CANADA REPLACEMENT

F24879A

REMOVAL

Hemming Location Disc Sander F24879

POINT

1 After grinding off the hemming location, remove the outer panel., BP-52 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. 10 mm Do not close the drain hole. Cloth Tape Hemming Tool F24880

POINT

1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make con- tact. 2 Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly., BODY PANEL REPLACEMENT BP-53

REAR DOOR OUTER PANEL (CUT): Sedan U.S.A., CANADA REPLACEMENT

F24879A

REMOVAL

Hemming Location Disc Sander F24881

POINT

1 After grinding off the hemming location, remove the outer panel., BP-54 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. 10 mm Do not close the drain hole. Cloth Tape Hemming Tool F24882

POINT

1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make con- tact. 2 Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly., BODY PANEL REPLACEMENT BP-55

ROCKER OUTER PANEL (CUT-H): Hatchback 5 Door REPLACEMENT

F22843A

REMOVAL

380 mm F22843 380 mm (14.96 in.), BP-56 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F22844

POINT

1 Inspect the fitting of the front door and other related parts before welding as this affects the appearance of the finish., BODY PANEL REPLACEMENT BP-61

ROCKER OUTER PANEL (CUT): Hatchback 5 Door REPLACEMENT

F22845A

REMOVAL

100 mm F22845 100 mm (3.94 in.), BP-62 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F22846

POINT

1 Inspect the fitting of the front door, rear door and other related parts before welding as this affects the appear- ance of the finish., BODY PANEL REPLACEMENT BP-57

ROCKER OUTER PANEL (CUT-H): Sedan REPLACEMENT

F24832A

REMOVAL

420 mm F24832-1 420 mm (16.54 in.), BP-58 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F24832-2

POINT

1 Inspect the fitting of the front door and other related parts before welding as this affects the appearance of the finish., BODY PANEL REPLACEMENT BP-59

ROCKER OUTER PANEL (CUT): Hatchback 3 Door REPLACEMENT

F23311A

REMOVAL

F23311, BP-60 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F23312

POINT

1 Inspect the fitting of the front door and other related parts before welding as this affects the appearance of the finish., BODY PANEL REPLACEMENT BP-69

QUARTER PANEL (CUT): Hatchback 3 Door REPLACEMENT

F23313A

REMOVAL

205 mm 645 mm F23313

POINT

1 *1: The hatched area indicates the adhesive application area. PART NAME [A] Quarter Wheel Housing Outer Panel 205 mm (8.07 in.) 645 mm (25.39 in.), BP-70 BODY PANEL REPLACEMENT F23314, BODY PANEL REPLACEMENT BP-71

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. 1.0 mm F23315

POINT

1 *1: The hatched area indicates the adhesive application area. PART NAME [A] Quarter Wheel Housing Outer Panel [B] Fuel Filler Opening Lid [C] Rivet 1.0 mm (0.04 in.), BP-72 BODY PANEL REPLACEMENT F23316

POINT

1 Inspect the front door, back door, rear combination light and other related parts before welding as this affects the appearance of the finish., BODY PANEL REPLACEMENT BP-63

ROCKER OUTER PANEL (CUT): Sedan REPLACEMENT

F24833A

REMOVAL

245 mm F24833-1 245 mm (9.65 in.), BP-64 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F24833-2

POINT

1 Inspect the fitting of the front door, rear door and other related parts before welding as this affects the appearance of the finish., BP-82 BODY PANEL REPLACEMENT

QUARTER WHEEL HOUSING OUTER PANEL

(ASSY): Hatchback

REPLACEMENT

With the quarter panel removed. F22851A

REMOVAL

[LH] 3 Door : 5 Door : 3 Door : 5 Door : F23321

POINT

1 After removing [A], remove the quarter wheel housing outer panel. PART NAME [A] Rocker Outer Reinforce, BODY PANEL REPLACEMENT BP-83 [LH] 40 mm F22852

POINT

1 After removing [B], remove the quarter wheel housing outer panel. PART NAME [B] Roof Side Outer Panel 40 mm (1.57 in.), BP-84 BODY PANEL REPLACEMENT [RH] 3 Door : 5 Door : 3 Door : 5 Door : F23322

POINT

1 After removing [A], remove the quarter wheel housing outer panel. PART NAME [A] Rocker Outer Reinforce, BODY PANEL REPLACEMENT BP-85 [RH] 30 mm F22854

POINT

1 After removing [B], remove the quarter wheel housing outer panel. PART NAME [B] Roof Side Outer Panel 30 mm (1.18 in.), BP-86 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. [LH] F22856

POINT

1 After installing the new parts, install [B]. PART NAME [B] Roof Side Outer Panel, BODY PANEL REPLACEMENT BP-87 [LH] 3 Door : 5 Door : 3 Door : 5 Door : F23323

POINT

1 After installing the new parts, install [A]. PART NAME [A] Rocker Outer Reinforce, BP-88 BODY PANEL REPLACEMENT [RH] F22858

POINT

1 After installing the new parts, install [B]. PART NAME [B] Roof Side Outer Panel, BODY PANEL REPLACEMENT BP-89 [RH] 3 Door : 5 Door : 3 Door : 5 Door : F23324

POINT

1 After installing the new parts, install [A]. PART NAME [A] Rocker Outer Reinforce, BODY PANEL REPLACEMENT BP-73

QUARTER PANEL (CUT): Hatchback 5 Door REPLACEMENT

F22847A

REMOVAL

F23317

POINT

1 *1: The hatched area indicates the adhesive application area. PART NAME [A] Quarter Wheel Housing Outer Panel, BP-74 BODY PANEL REPLACEMENT 150 mm F23318 150 mm (5.91in.), BODY PANEL REPLACEMENT BP-75

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. 1.0 mm F23319

POINT

1 *1: The hatched area indicates the adhesive application area. PART NAME [A] Quarter Wheel Housing Outer Panel [B] Fuel Filler Opening Lid [C] Rivet 1.0 mm (0.04 in.), BP-76 BODY PANEL REPLACEMENT F23320

POINT

1 Inspect the front door, back door, rear combination light and other related parts before welding as this affects the appearance of the finish., BODY PANEL REPLACEMENT BP-65

Adhesive Application Area Work Procedure NOTE

This vehicle has areas on the Quarter Panel and Quarter Wheel Housing Outer Panel that are joined together only with adhesive. It is necessary to conduct the correct repair procedures for high durability so make sure to follow the instructions below for the adhesive application areas. Type of adhesive used: 3M8115 Auto Mix Panel Bond 1. Removal of the Quarter Panel Adhesive Application Area Cut and Join (A) Remove the body sealer from the Quarter Panel and cut at Location the cut and join location. Remove the spot welded portions. (B) After rough cutting the Wheel Arch portion, heat the adhe- sive applied area and remove the panel. {Heat the Wheel Arch portion of the Quarter Panel at 110 to 140C (230 to 284F) with a dryer or gas burner and remove the Quarter Panel.} Spot Weld Cut and Join Location 010L23a 2. Removal of the previous adhesive coating (A) Heat at 110 to 140C (230 to 284F) with a dryer or gas burner. (B) Scrape away the adhesive with a scraper, and scuff while sanding with a disc grinder or a belt sander.

NOTE

Make sure to use either a disc grinder or belt sander to sand coarsely and deeply to improve adhesiveness. Scuff at a width of approximately 10 mm (0.39 in.) over the previous adhesive coating. 010L06 3. Treatment of the spot welded portions on the body (A) After the adhesive has been removed from the body, re- move the paint from the underside of the spot welded points blow air and degrease. (B) Apply spot sealer at the joined portion between panels. approx.10 mm After sanding 010L07a, BP-66 BODY PANEL REPLACEMENT 4. Attachment of the New Quarter Panel (A) Temporarily attach the new panel and check the fitting condition, the cut and join locations, the welded areas, and the adhesive applied area.

NOTE

Check the adhesive applied condition to ensure adhe- sive strength. Conduct hammering to fix the non-adhered portions. Cross-Sectional view Adhesive 1 mm gap 010L10a 5. Adhesive Application to New Quarter Panel Scuffed Area (A) Scuff with #60-120 grit sandpaper at the adhesive applica-Application Area tion area.

POINT

10 mm Sand deeply into the ED coat. 28 mm (B) Blow air around the scuffed portion and then degrease. (C) Apply adhesive.

POINT

010L11a Apply adhesive at a width of approximately 10 mm (0.39 in.) at a location 28 mm (1.10 in.) from the panel flange edge. Spread the adhesive flatly within the scuffed area {approxi- mately 10 mm (0.39 in.) in width} to remove trapped air. 010L12 Approx. 3 mm 3 mm Adhesive 010L12-1a 010L13, BODY PANEL REPLACEMENT BP-67 6. Application of Adhesive to the Body (A) Degrease the adhesive aplication area. (B) Apply adhesive. Refer to the diagram of step 5 for the application amount. The application location is 7.5 mm (0.295 in.) from the flange edge. (C) Flatten out the applied adhesive with a spatula until it is at an even level. 010L15 Apply adhesive at exposed metal plate portions to pre- vent corrosion. It is not necessary to flatten out adhesive after it has been reapplied. 7.5 mm Flange Edge 010L16 010L17a 7. Attachment of the new Quarter Panel (A) Set the new panel in the position for temporary attachment. (Be careful of where you hold the panel so as not to touch the adhesive applied surfaces.) (B) Secure in a vice grip or equivalent and check the fitting condition. (C) Press on the entire surface so that the adhesive between the Quarter Panel and Quarter Wheel Housing Outer panel becomes an even thickness.

NOTE

Be careful that adhesive that spills over does not contact the Brake Drum. (D) Tack weld at the cut and join welded portion. (E) Tack weld by spot welding at one point on both ends of the adhesive applied portions. (F) Conduct actual welding using procedures in the BP section of this manual. Tack Weld 010L20a, BP-68 BODY PANEL REPLACEMENT 8. Drying (A) Clean away adhesive that has spilled over with a degreaser Infrared Ray or equivalent. Hearter (B) After all welding works have been completed, dry the adhe- sive with a heater. Hardening Time Forced drying 60C (140F) at 90 minutes. Natural drying 010L22a 24C (75F) (room temperature) for 24 hours. 9. Other work (A) After applying Primer Surfacer to the underside of the Wheel Arch of the Quarter Panel, apply body sealer to the locations indicated in the body repair manual. Adhesive Body Sealer 010L21a, BP-90 BODY PANEL REPLACEMENT

QUARTER WHEEL HOUSING OUTER PANEL

(ASSY): Sedan

REPLACEMENT

With the quarter panel removed. F24839A

REMOVAL

[LH] F24839-1

POINT

1 After removing [A], remove the quarter wheel housing outer panel. PART NAME [A] Rocker Outer Reinforce, BODY PANEL REPLACEMENT BP-91 [LH] F24840-1

POINT

1 After removing [B], remove the quarter wheel housing outer panel. PART NAME [B] Roof Side Outer Panel, BP-92 BODY PANEL REPLACEMENT [RH] F24841-1

POINT

1 After removing [A], remove the quarter wheel housing outer panel. PART NAME [A] Rocker Outer Reinforce, BODY PANEL REPLACEMENT BP-93 [RH] F24842-1

POINT

1 After removing [B], remove the quarter wheel housing outer panel. PART NAME [B] Roof Side Outer Panel, BP-94 BODY PANEL REPLACEMENT

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. [LH] F24840-2

POINT

1 After installing the new parts, install [B]. PART NAME [B] Roof Side Outer Panel, BODY PANEL REPLACEMENT BP-95 [LH] F24839-2

POINT

1 After installing the new parts,install [A]. PART NAME [A] Rocker Outer Reinforce, BP-96 BODY PANEL REPLACEMENT [RH] F24842-2

POINT

1 After installing the new parts, install [B]. PART NAME [B] Roof Side Outer Panel, BODY PANEL REPLACEMENT BP-97 [RH] F24841-2

POINT

1 After installing the new parts, install [A]. PART NAME [A] Rocker Outer Reinforce, BODY PANEL REPLACEMENT BP-77

QUARTER PANEL (CUT): Sedan REPLACEMENT

F24834A

REMOVAL

130 mm 150 mm F24834-1

POINT

1 1: in illustration above indicates where the adhesive is. * 2 Roughly cut open the wheel arch of the panel so that the adhesive can be reached. Cut through the adhesive with a cut chisel to remove the panel. HINT: 1) If the cut chisel cannot reach the adhesive, heat the adhesive with a heat gun, oxygen-acetylene burner. When heating, do not deform the quarter housing outer panel. 130 mm (5.12 in.) 150 mm (5.91 in.), BP-78 BODY PANEL REPLACEMENT F24835, BODY PANEL REPLACEMENT BP-79

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. Spot Tip 3 mm 5 mm F24836-1

POINT

1 Inspect the fitting of the rear door, luggage compartment door, rear combination light and other related parts before welding as this affects the appearance of the finish. 2 Apply adhesive (3MTM AutomixTM Panel Bonding Adhesive #8115) to the area indicated by 1 in illustration. * HINT: 1) Apply enough adhesive for the panels to sick to each other. 3 Perform spot-welding on the flange indicated by 2 in the illustration. Modify/cut the spot tip as shown in the * illustration ( 3) so that it can fit into the narrow flange. * 3 mm (0.12 in.) 5 mm (0.20 in.), BP-80 BODY PANEL REPLACEMENT 5 mm F24837-1

POINT

1 Before temporarily installing the new parts, apply body sealer to the wheel arch. HINT: 1) Apply body sealer evenly about 5 mm (0.20 in.) form the flange, avoiding any oozing. 2) Apply sealer evenly, about 3 − 4 mm (0.12 − 0.16 in.) in diameter. 5 mm (0.20 in.), BODY PANEL REPLACEMENT BP-81 (13 mm) F24838-1 PART NAME [A] Fuel Filler Opening Lid [B] Rivets 13 mm (0.51 in.), BP-98 BODY PANEL REPLACEMENT

LOWER BACK UPPER GUSSET (ASSY): Hatchback REPLACEMENT

F22859A

REMOVAL

F22859, BODY PANEL REPLACEMENT BP-99

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots. F22860, BP-100 BODY PANEL REPLACEMENT

LOWER BACK UPPER QUSSET (ASSY): Sedan REPLACEMENT

F24843A

REMOVAL

F24843-1, BODY PANEL REPLACEMENT BP-101

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F24843-2, BP-102 BODY PANEL REPLACEMENT

BODY LOWER BACK PANEL (ASSY): Hatchback REPLACEMENT

F22861A

REMOVAL

F23325, BODY PANEL REPLACEMENT BP-103

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F23326

POINT

1 Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects the appearance of the finish., BP-104 BODY PANEL REPLACEMENT

BODY LOWER BACK PANEL (ASSY): Sedan REPLACEMENT

F24844A

REMOVAL

F24844-1, BODY PANEL REPLACEMENT BP-105

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F24844-2

POINT

1 Inspect the fitting of the back door and rear combination light and other related parts before welding as this affects the appearance of the finish., BP-106 BODY PANEL REPLACEMENT

BACK DOOR OPENING TROUGH (ASSY): Hatchback REPLACEMENT

With the quarter panel and body lower back panel removed. F22865A

REMOVAL

F22865

POINT

1 Remove [A] at the same time. PART NAME [A] Back Door Opening Lower Reinforcement, BODY PANEL REPLACEMENT BP-107

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points. F22866

POINT

1 Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects the appearance of the finish. PART NAME [A] Back Door Opening Lower Reinforcement [B] Rear Bumper Side Retainer, BP-108 BODY PANEL REPLACEMENT

LUGGAGE DOOR OPENING FRONT TROUGH (ASSY): Sedan REPLACEMENT

F24845A

REMOVAL

F24845-1, BODY PANEL REPLACEMENT BP-109

INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top, apply anti-rust agent to the internal panel portion of the closed section structural weld points. (13 mm) F24845-2

POINT

1 Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects the appearance of the finish. 13 mm (0.51 in.)]
15

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FOREWORD This wiring diagram manual has been prepared to provide information on the electrical system of the 2007 YARIS. Applicable models: NCP91, 93 Series Refer to the following manuals for additional service specifications and repair procedures for these models: Manual Name Pub. No. 2007 YARIS Re
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U340E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE SYSTEM AX–1 X AUTOMATIC TRANSAXLE SYSTEM PRECAUTION NOTICE: • Perform the RESET MEMORY (AT initialization) when replacing the automatic transaxle assembly, engine assembly or ECM (See page AX-14). • Perform the REGISTRATION (VIN registration) when repl
ON Semiconductor 2N5550 Amplifier Transistors NPN Silicon 2N5551*
ON Semiconductor 2N5550 Amplifier Transistors NPN Silicon 2N5551* *ON Semiconductor Preferred Device MAXIMUM RATINGS Rating Symbol 2N5550 2N5551 Unit Collector–Emitter Voltage VCEO 140 160 Vdc Collector–Base Voltage VCBO 160 180 Vdc Emitter–Base Voltage VEBO 6.0 Vdc Collector Current — Continuous IC
GENERAL DESCRIPTION QUICK REFERENCE DATA PINNING - TO92 variant PIN CONFIGURATION SYMBOL
GENERAL DESCRIPTION QUICK REFERENCE DATA Glass passivated sensitive gate SYMBOL PARAMETER MAX. UNIT thyristor in a plastic envelope, intended for use in general purpose VDRM, Repetitive peak off-state voltages 200 V switching and phase control VRRM applications. This device is intended IT(AV) Averag
N-Channel JFETs
N-Channel JFETs 2N4117A PN4117A SST4117 2N4118A PN4118A SST4118 2N4119A PN4119A SST4119 Part Number VGS(off) (V) V(BR)GSS Min (V) gfs Min (S) IDSS Min (A) 4117 –0.6 to –1.8 –40 70 30 4118 –1 to –3 –40 80 80 4119 –2 to –6 –40 100 200 Ultra-Low Leakage: 0.2 pA Insignificant Signal Loss/Error Voltage
Order this document SEMICONDUCTOR TECHNICAL DATA by 2N3903/D NPN Silicon
Order this document SEMICONDUCTOR TECHNICAL DATA by 2N3903/D NPN Silicon *Motorola Preferred Device COLLECTOR BASE EMITTER 1 MAXIMUM RATINGS Rating Symbol Value Unit CASE 29–04, STYLE 1 TO–92 (TO–226AA) Collector–Emitter Voltage VCEO 40 Vdc Collector–Base Voltage VCBO 60 Vdc Emitter–Base Voltage VEB
DISCRETE SEMICONDUCTORS DATA SHEET 2N2222; 2N2222A NPN switching transistors Product specification 1997 May 29 Supersedes data of September 1994 File under Discrete Semiconductors, SC04
DISCRETE SEMICONDUCTORS DATA SHEET M3D125 2N2222; 2N2222A NPN switching transistors Product specification 1997 May 29 Supersedes data of September 1994 File under Discrete Semiconductors, SC04 FEATURES PINNING • High current (max. 800 mA) PIN DESCRIPTION • Low voltage (max. 40 V). 1 emitter 2 base A
Small-signal Transistors Selection guide
Philips Semiconductors Small-signal Transistors Selection guide V TYPE CEO IC Ptot fhhTPNP PACKAGE max. max. max. FE FE min. PAGE NUMBER min. max. COMPL. (V) (mA) (mW) (MHz) BC846 SOT23 65 100 250 110 450 100 BC856 305 BC846A SOT23 65 100 250 110 220 100 BC856A 305 BC846AT SC-75 65 100 150 110 220 1
Small-signal Transistors Selection guide
Philips Semiconductors Small-signal Transistors Selection guide SURFACE-MOUNT DEVICES NPN GENERAL PURPOSE LOW-POWER TRANSISTORSVIPfTYPE CEO C tothhTPNP PACKAGE max. max. max. FE FE min. PAGE NUMBER min. max. COMPL. (V) (mA) (mW) (MHz) 2PC4081 SC-70 40 100 200 120 560 100 2PA1576 210 2PC4081Q SC-70 4
Small-signal Transistors Selection guide
Philips Semiconductors Small-signal Transistors Selection guide LEADED DEVICES (continued) NPN HIGH-VOLTAGE POWER TRANSISTORSVIPfTYPE CEO C tothhTPACKAGE max. max. max. FE FE PNP min. PAGE NUMBER min. max. COMPL. (V) (mA) (mW) (MHz) BF419 TO-126 250 300 6000 45 typ. >45 90 – 532 BF457 TO-126 160 100
DISCRETE SEMICONDUCTORS DATA SHEET 1PS302 High-speed double diode Product specification 1996 Apr 03 File under Discrete Semiconductors, SC01
DISCRETE SEMICONDUCTORS DATA SHEET handbook, halfpage M3D114 1PS302 High-speed double diode Product specification 1996 Apr 03 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION PINNING • Very small plastic SMD package The 1PS302 consists of two PIN DESCRIPTION • High switching speed: max.
Small-signal Transistors Selection guide
Philips Semiconductors Small-signal Transistors Selection guide LEADED DEVICES NPN GENERAL PURPOSE LOW-POWER TRANSISTORSVIPfTYPE CEO C tothhTPACKAGE max. max. max. FE FE PNP min. PAGE NUMBER min. max. COMPL. (V) (mA) (mW) (MHz) 2N2484 TO-18 60 50 360 250 800 60 – 131 2N4124 TO-92 25 200 500 120 360
DISCRETE SEMICONDUCTORS DATA SHEET 1PS301 High-speed double diode Product specification 1996 Apr 03 File under Discrete Semiconductors, SC01
DISCRETE SEMICONDUCTORS DATA SHEET handbook, halfpage M3D114 1PS301 High-speed double diode Product specification 1996 Apr 03 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION PINNING • Very small plastic SMD package The 1PS301 consists of two PIN DESCRIPTION • High switching speed: max.
DISCRETE SEMICONDUCTORS DATA SHEET 1PS300 High-speed double diode Product specification 1996 Apr 03 File under Discrete Semiconductors, SC01
DISCRETE SEMICONDUCTORS DATA SHEET handbook, halfpage M3D114 1PS300 High-speed double diode Product specification 1996 Apr 03 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION PINNING • Very small plastic SMD package The 1PS300 consists of two PIN DESCRIPTION • High switching speed: max.
DISCRETE SEMICONDUCTORS DATA SHEET 1PS226 High-speed double diode Product specification 1996 Apr 03 Supersedes data of December 1993 File under Discrete Semiconductors, SC01
DISCRETE SEMICONDUCTORS DATA SHEET handbook, halfpage M3D114 1PS226 High-speed double diode Product specification 1996 Apr 03 Supersedes data of December 1993 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION PINNING • Small plastic SMD package The 1PS226 consists of two PIN DESCRIPTION
DISCRETE SEMICONDUCTORS DATA SHEET 1PS193 High-speed diode Product specification 1996 Apr 03 Supersedes data of December 1993 File under Discrete Semiconductors, SC01
DISCRETE SEMICONDUCTORS DATA SHEET handbook, halfpage M3D114 1PS193 High-speed diode Product specification 1996 Apr 03 Supersedes data of December 1993 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION PINNING • Small plastic SMD package The 1PS193 is a high-speed PIN DESCRIPTION • High
DISCRETE SEMICONDUCTORS DATA SHEET 1PS184 High-speed double diode Product specification 1996 Apr 03 Supersedes data of December 1993 File under Discrete Semiconductors, SC01
DISCRETE SEMICONDUCTORS DATA SHEET handbook, halfpage M3D114 1PS184 High-speed double diode Product specification 1996 Apr 03 Supersedes data of December 1993 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION PINNING • Small plastic SMD package The 1PS184 consists of two PIN DESCRIPTION
DISCRETE SEMICONDUCTORS DATA SHEET 1PS181 High-speed double diode Product specification 1996 Apr 03 Supersedes data of December 1993 File under Discrete Semiconductors, SC01
DISCRETE SEMICONDUCTORS DATA SHEET handbook, halfpage M3D114 1PS181 High-speed double diode Product specification 1996 Apr 03 Supersedes data of December 1993 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION PINNING • Small plastic SMD package The 1PS181 consists of two PIN DESCRIPTION
DISCRETE SEMICONDUCTORS DATA SHEET 1N914; 1N916 High-speed diodes Product specification 1996 Apr 10 Supersedes data of April 1992 File under Discrete Semiconductors, SC01
DISCRETE SEMICONDUCTORS DATA SHEET M3D176 1N914; 1N916 High-speed diodes Product specification 1996 Apr 10 Supersedes data of April 1992 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION • Hermetically sealed leaded glass The 1N914; 1N916 are high-speed switching diodes fabricated in pla
DISCRETE SEMICONDUCTORS DATA SHEET
DISCRETE SEMICONDUCTORS DATA SHEET handbook, halfpage M3D119 1N5817; 1N5818; 1N5819 Schottky barrier diodes Product specification 1996 May 03 Supersedes data of April 1992 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION • Low switching losses The 1N5817 to 1N5819 types are Schottky bar
DISCRETE SEMICONDUCTORS DATA SHEET 1N5225B to 1N5267B Voltage regulator diodes Product specification 1996 Apr 26 Supersedes data of April 1992 File under Discrete Semiconductors, SC01
DISCRETE SEMICONDUCTORS DATA SHEET M3D176 1N5225B to 1N5267B Voltage regulator diodes Product specification 1996 Apr 26 Supersedes data of April 1992 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION • Total power dissipation: Low-power voltage regulator diodes in hermetically sealed lea
DISCRETE SEMICONDUCTORS DATA SHEET 1N5059 to 1N5062 Controlled avalanche rectifiers Product specification 1996 Jun 20 Supersedes data of April 1992 File under Discrete Semiconductors, SC01
DISCRETE SEMICONDUCTORS DATA SHEET handbook, 2 columns M3D116 1N5059 to 1N5062 Controlled avalanche rectifiers Product specification 1996 Jun 20 Supersedes data of April 1992 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION This package is hermetically sealed and fatigue free as coeffic
DISCRETE SEMICONDUCTORS DATA SHEET 1N4728A to 1N4749A Voltage regulator diodes Product specification 1996 Apr 26 Supersedes data of April 1992 File under Discrete Semiconductors, SC01
DISCRETE SEMICONDUCTORS DATA SHEET handbook, halfpage M3D130 1N4728A to 1N4749A Voltage regulator diodes Product specification 1996 Apr 26 Supersedes data of April 1992 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION • Total power dissipation: Low voltage regulator diodes in hermetical
DISCRETE SEMICONDUCTORS DATA SHEET 1N4531; 1N4532 High-speed diodes Product specification 1996 Apr 03 Supersedes data of April 1992 File under Discrete Semiconductors, SC01
DISCRETE SEMICONDUCTORS DATA SHEET handbook, halfpage M3D050 1N4531; 1N4532 High-speed diodes Product specification 1996 Apr 03 Supersedes data of April 1992 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION • Hermetically sealed leaded glass The 1N4531, 1N4532 are high-speed switching d
DISCRETE SEMICONDUCTORS DATA SHEET
DISCRETE SEMICONDUCTORS DATA SHEET M3D176 1N4150; 1N4151; 1N4153 High-speed diodes Product specification 1996 Apr 19 Supersedes data of April 1992 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION • Hermetically sealed leaded glass The 1N4150, 1N4151, 1N4153 are high-speed switching diod
DISCRETE SEMICONDUCTORS DATA SHEET
DISCRETE SEMICONDUCTORS DATA SHEET M3D176 1N4148; 1N4446; 1N4448 High-speed diodes Product specification 1996 Apr 15 Supersedes data of April 1992 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION • Hermetically sealed leaded glass The 1N4148, 1N4446, 1N4448 are high-speed switching diod
DATA SHEET
DISCRETE SEMICONDUCTORS DATA SHEET handbook, 2 columns M3D116 1N4001G to 1N4007G Rectifiers Product specification 1996 May 24 Supersedes data of April 1992 File under Discrete Semiconductors, SC01 FEATURES DESCRIPTION This package is hermetically sealed and fatigue free as coefficients of • Glass pa