BODY PANEL REPLACEMENT BP-47

BODY LOWER BACK PANEL (ASSY)

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld

F25743A F25743B

REMOVAL.INSTALLATION

F25743

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
3 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-75

CAUTION LABEL ATTACHMENT POSITION

After using a degreasing agent to clean the surfaces of the body where the caution labels will be attached, attach the
caution labels to the positions shown in the illustration.
HINT:
1) Attach each caution label with its orientation the same as the numbers shown in the illustration.
2) Make sure the caution label is not attached over a spot weld.
3) When attaching the caution label, make sure not to touch the label’s adhesive surface.
4) To prevent the edges of the caution label from peeling, apply extra pressure to the label’s periphery.
5) If the work area’s temperature is 5
C or less, the caution label’s adhesive will deteriorate. It is
recommended that you heat the label to 20 to 40
C.

Loaded Inspection Maintenance Exemption (VSC only)

Emission Control Information
Long Life Coolant Service Label
Engine Vacuume Hose Information
Battery Caution
Cooler Service Caution

F26007
BP-76 BODY PANEL REPLACEMENT

Fuel Label

Certification Reguration Information Label

Tire Pressure
Label Information

Side Air Bag Caution Label

Mercury Information Label

Side Air Bag Caution Label

F26008
BP-24 BODY PANEL REPLACEMENT

CENTER BODY PILLAR (CUT)

Symbol meaning : Cut with disc sander, etc.

: Remove Weld Points : Cut and Join Location : Cut Location for Supply Parts

F25726A F25726B

REMOVAL

Urethane Foam
20
(0.79)
Urethane Foam

90 80
(3.54) (3.15)

60
(2.36)

mm (in.)
F25726

REMOVAL POINT
1 *1: Take care not to damage the internal reinforcement.
 BODY PANEL REPLACEMENT BP-25

Symbol meaning

: MIG Plug Weld : Cut and Join Location

: Tack Weld : Butt Weld

F25727B

INSTALLATION

Center Body Pillar Lower Reinforce

310
(12.20)

Center Body Pillar Upper Reinforce

Center Body Inner Pillar

mm (in.)
F25727

INSTALLATION POINT
1 Before temporarily installing the new parts, weld the center body pillar lower reinforce, center body pillar upper
reinforce and center body inner pillar with the standard number of welding points.
BP-26 BODY PANEL REPLACEMENT

Symbol meaning

: MIG Plug Weld : Cut and Join Location

: Tack Weld : Butt Weld

F25727B

Center Body Pillar

Upper Reinforce
Center Body
Inner Pillar

Roof Side Outer No.2 Rail

Urethane Foam Urethane Foam

12 (0.47)

Center Body Pillar Lower Reinforce

Center Body Outer Pillar

mm (in.)
F25728

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
3 After welding the center body pillar lower reinforce, center body pillar upper reinforce and center body inner
pillar to thevehicle side, install the center body outer pillar and roof side outer No.2 rail.
 BODY PANEL REPLACEMENT BP-27

20
(0.79)

F25808

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
2 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)
3 After welding, apply the polyurethane foam to the corresponding parts. (See the paint.coating)
4 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
5 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-18 BODY PANEL REPLACEMENT

COWL TOP OUTER PANEL (ASSY)

With the cowl top side reinforcement and front body pillar lower gusset removed.

Symbol meaning

REMOVAL : Remove Weld Points : Cut with disc sander, etc.

INSTALLATION : MIG Plug Weld : Tack Weld
F25721A F25721B

REMOVAL.INSTALLATION

7
(0.28)

mm (in.)
F25721

INSTALLATION POINT
1 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)
2 After welding, apply body sealer to the corresponding parts. (See the paint.coating)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-16 BODY PANEL REPLACEMENT

COWL TOP SIDE REINFORCEMENT (ASSY)

Symbol meaning

REMOVAL : Cut with disc sander, etc.

INSTALLATION : Tack Weld

F25720A F25720B

REMOVAL.INSTALLATION

13
(0.51)

15
(0.59) 15
(0.59)

10 25
(0.39) (0.98) mm (in.)
F25720

INSTALLATION POINT
1 After welding, apply body sealer to the corresponding parts. (See the paint.coating)
2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-66 BODY PANEL REPLACEMENT

FIT STANDARD/ADJUSTMENT METHOD/TORQUE SPECIFICATION

HOOD SUB-ASSEMBLY

3.5 (0.138)

3.7 (0.146)
5.1 (0.201)

mm (in.)
F25764

1. ADJUST HOOD SUB-ASSEMBLY

HINT:

Centering bolts are used to mount the hood hinge and hood lock. The hood and hood lock cannot be
adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (with washers)
when making adjustments.
a. Horizontally and vertically adjust the hood.
i. Loosen the 4 hinge bolts of the hood.
ii. Adjust the clearance between the
hood and front fender by moving the
hood.
iii. Tighten the 4 hinge bolts after the
adjustment.
Torque:
13 N.m (133 kgf.cm, 10 ft..lbf) B132829

b. Adjust the height of the front end of the

hood using the cushion rubber.
i. Adjust the cushion rubber so that the
height of the hood and fender are
aligned.

HINT:
Raise or lower the front end of the
hood by turning the cushion rubber.

B132830
 BODY PANEL REPLACEMENT BP-67

c. Adjust the hood lock.

i. Loosen the 3 bolts.
ii. Tighten the bolts after the adjustment.
Torque:
7.5 N.m (77 kgf.cm, 66 in..lbf)
iii. Check that the striker can engage with
the hood lock smoothly.

B132832
BP-68 BODY PANEL REPLACEMENT

FRONT DOOR
4.8 (0.189)

4.8 (0.189)

4.3 (0.169)

4.2 (0.165)
4.2 (0.165)

5.0 (0.197)
mm (in.)
F25765

1. ADJUST FRONT DOOR

HINT:

Before adjusting the door position for vehicles equipped with side airbags and curtain shield
airbags, be sure to disconnect the battery. After adjustment, inspect the SRS warning light, the
side airbag system, and the curtain shield airbag system for normal operation. Then initialize
both airbag systems.

Use the same procedures for the RH side and LH side.

The procedures listed below are for the LH side.

Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot
be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (with
washers) when making adjustment.
a. Using SST, loosen the hinge bolts on the
vehicle body and adjust the door position.
SST
09812-00010
b. Tighten the hinge bolts on the vehicle
body after the adjustment.
Torque:
26 N.m (265 kgf.cm, 19 ft..lbf)
c. Loosen the hinge bolts on the door and
adjust the door position.
d. Tighten the hinge bolts on the door after
the adjustment.
Torque:
26 N.m (265 kgf.cm, 19 ft..lbf)

B136438
 BODY PANEL REPLACEMENT BP-69

e. Adjust the striker position by slightly

loosening the striker mounting screws
with a “TORX” socket wrench (T40) and
hitting the striker with a plastic hammer.
f. Using a “TORX” socket wrench (T40),
tighten the striker mounting screws after
the adjustment.
Torque:
23 N.m (235 kgf.cm 17 ft..lbf)
B136440
BP-70 BODY PANEL REPLACEMENT

REAR DOOR
4.8 (0.189)

4.8 (0.189)

4.3 (0.169)

4.2 (0.165)
4.2 (0.165)

4.2 (0.165)

5.0 (0.197)
mm (in.)
B25766

1. ADJUST REAR DOOR

HINT:

Before adjusting the door position for vehicles equipped with side airbags and curtain shield
airbags, be sure to disconnect the battery. After adjustment, inspect the SRS warning light, the
side airbag system, and the curtain shield airbag system for normal operation. Then initialize
both airbag systems.

Use the same procedures for the RH side and LH side.

The procedures listed below are for the LH side.

Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot
be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (with
washers) when making adjustments.
a. Loosen the hinge bolts on the vehicle
body and adjust the door position.
SST
09812-00010
b. Tighten the hinge bolts on the vehicle
body after the adjustment.
Torque:
26 N.m (265 kgf.cm, 19 ft..lbf)
c. Loosen the hinge bolts on the door and
adjust the door position.
d. Tighten the hinge bolts on the door after
the adjustment.
Torque:
26 N.m (265 kgf.cm, 19 ft..lbf)

B149005
 BODY PANEL REPLACEMENT BP-71

e. Adjust the striker position by slightly

loosening the striker mounting screws
with a “TORX” socket wrench (T40) and
hitting the striker with a plastic hammer.
f. Using a “TORX” socket wrench (T40),
tighten the striker mounting screws after
the adjustment.
Torque:
23 N.m (235 kgf.cm, 17 ft..lbf)
B136489
BP-72 BODY PANEL REPLACEMENT

LUGGAGE COMPARTMENT DOOR

3.5 (0.138)

3.5 (0.138)

5.7 (0.224)

mm (in.)
F25767

1. ADJUST LUGGAGE COMPARTMENT DOOR

HINT:

Centering bolts are used to mount the door hinge to the door. The door cannot be adjusted with
the centering bolts on. Substitute the centering bolts with standard bolts (with washers) when
making adjustments.
a. Loosen the door side hinge bolts to adjust
the door horizontally and vertically.
Torque:
7.5 N.m (77 kgf.cm, 66 in..lbf)

B136494

b. Adjust the striker position by slightly

loosening the striker mounting screws
and hitting the striker with a plastic
hammer.
c. Tighten the striker mounting screws after
the adjustment.
Torque:
5.5 N.m (56 kgf.cm, 49 in..lbf)

B136495
BP-10 BODY PANEL REPLACEMENT

FRONT FENDER APRON (ASSY)

With the radiator support and front body pillar lower gusset removed.

Symbol meaning

REMOVAL : Remove Weld Points : Cut with disc sander, etc.

INSTALLATION : MIG Plug Weld : Tack Weld
F25710A F25710B

REMOVAL.INSTALLATION

CAUTION
Make sure to attach correctry in accordance with the body dimention diagram as this parts affects
the front wheel alignment.

F25710

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
 BODY PANEL REPLACEMENT BP-11

6
(0.24)

15
(0.59)

6
(0.24)

CAUTION mm (in.)

Make sure to attach correctry in accordance with the body dimention diagram as this parts affects
the front wheel alignment.

F25711

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
3 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-12 BODY PANEL REPLACEMENT

FRONT SIDE MEMBER (CUT-P)

With the radiator support removed.

Symbol meaning

: Remove Weld Points : Cut and Join Location

F25712A F25712B

REMOVAL

110
(4.33)

Front Side Member Extension

mm (in.)
F25712

REMOVAL POINT
1 Remove the front side member extension at the same time.
 BODY PANEL REPLACEMENT BP-13

Symbol meaning

: MIG Plug Weld : Butt Weld

F25713B

INSTALLATION

Front Side Member Extension

F25713

INSTALLATION POINT
1 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)
2 After welding, apply undercoating to the corresponding parts. (See the paint.coating)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-19

FRONT BODY PILLAR (CUT)

With the cowl top outer panel removed.

Symbol meaning : Cut with disc sander, etc.

: Cut and Join Location

: Remove Weld Points : Cut Location for Supply Parts

F25722A F25722B

REMOVAL

200
(7.87)

140
Urethane Foam (5.51)

160
(6.30) 60
(2.36)

mm (in.)
F25722
BP-20 BODY PANEL REPLACEMENT

Symbol meaning : Cut with disc sander, etc.

: Cut and Join Location

: Remove Weld Points : Cut Location for Supply Parts

F25722B

F25723
 BODY PANEL REPLACEMENT BP-21

Symbol meaning
: MIG Plug Weld : Cut and Join Location

: Tack Weld : Butt Weld : Body Sealer

F25724B

INSTALLATION

Cowl Side Panel

45
(1.77)

Center Body Pillar Lower Reinforce

310
(12.20)

Front Body Pillar Lower Reinforce

20
(0.79)

mm (in.)
F25724

INSTALLATION POINT
1 Before temporarily installing the new parts, weld the center body pillar lower reinforce, front body pillar lower
reinforce and cowl side panel with the standard number of welding points.
BP-22 BODY PANEL REPLACEMENT

Symbol meaning

: MIG Plug Weld : Cut and Join Location

: Tack Weld : Butt Weld : Body Sealer

F25724B

Front Body Pillar

Lower Reinforce

Cowl Side Panel

Center Body Pillar

Lower Reinforce

10
(0.39)

mm (in.)
F25725

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
2 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)
3 After welding the center body pillar lower reinforce, front body pillar lower reinforce and cowl side panel to the
vehicle side, install the front body upper outer pillar and center body outer pillar.
 BODY PANEL REPLACEMENT BP-23

Front Body Upper Outer Pillar

Urethane Foam

Center Body Outer Pillar

No. 6 Pillar Outer Bracket

Center Body Pillar

Lower Reinforce

F25807

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
2 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)
3 Before installing a new part, apply body sealer.
HINT:
1) Apply sealer in an even, continuous bead.
4 After welding the center body pillar lower reinforce and front body pillar lower reinforce to the vehicle side,
install the front body upper outer pillar, center body outer pillar and No.6 pillar outer bracket.
5 After welding, apply the polyurethane foam to the corresponding parts. (See the paint.coating)
6 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
7 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-8 BODY PANEL REPLACEMENT

FRONT APRON TO COWL SIDE UPPER MEMBER (ASSY)

With the front fender front apron and front body pillar lower gusset removed.

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld
F25709A F25709B

REMOVAL.INSTALLATION

Front Apron To Cowl Side Lower Front Member

F25709

REMOVAL POINT
1 After removing the front apron to cowl side lower front member, remove the front apron to cowl side upper
member.
INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
3 After welding the to the front apron to cowl side upper member vehicle side, install the front apron to cowl side
lower front member.
 BODY PANEL REPLACEMENT BP-9

F25805

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
3 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-17

FRONT BODY PILLAR LOWER GUSSET (ASSY)

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld

F25719A F25719B

REMOVAL.INSTALLATION

F25719

INSTALLATION POINT
1 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-4 BODY PANEL REPLACEMENT

FRONT CROSSMEMBER (ASSY)

Symbol meaning

REMOVAL : Remove Weld Points : Cut with disc sander, etc.

INSTALLATION : MIG Plug Weld : Tack Weld

F25705A F25705B

REMOVAL.INSTALLATION

10
(0.39)

mm (in.)
F25705

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-28 BODY PANEL REPLACEMENT

FRONT DOOR OUTER PANEL (ASSY)

Symbol meaning

: Remove Weld Points

F25757A F25757B

REMOVAL

Positioning Tape

Installation
Position

Hemming Location

Disc Sander

F25757

REMOVAL POINT
1 Before removing the outer panel, mark the installation position with tape.
2 Before removing the outer panel, establish its exact position in relation to the window frame using a reference
marker, etc.
3 After grinding off the hemming location, remove the outer panel.
 BODY PANEL REPLACEMENT BP-29

Symbol meaning

: MIG Plug Weld : Spot MIG Weld : Body Sealer

F25758B

INSTALLATION

Positioning Tape

10
(0.39) Do not close the
drain hole.

Cloth Tape

30

Hemming Tool

mm (in.)
F25758

INSTALLATION 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 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
contact.
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.
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-6 BODY PANEL REPLACEMENT

FRONT FENDER FRONT APRON (ASSY)

With the radiator support removed.

Symbol meaning

REMOVAL : Remove Weld Points : Cut with disc sander, etc.

INSTALLATION : MIG Plug Weld : Tack Weld
F25707A F25707B

REMOVAL.INSTALLATION

F25707

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
 BODY PANEL REPLACEMENT BP-7

Fender Apron Plate

LH:
RH:

6
(0.24)
Front Fender Apron Front Extension

15
(0.59)
6
(0.24)

mm (in.)
F25708

REMOVAL POINT
1 Remove the front fender apron front extension at the same time.
INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
3 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-14 BODY PANEL REPLACEMENT

FRONT SIDE MEMBER (CUT-H)

With the front fender apron removed.

Symbol meaning

: Remove Weld Points

F25714A F25714B

REMOVAL

F25714
 BODY PANEL REPLACEMENT BP-15

Symbol meaning

: MIG Plug Weld

F25715B

INSTALLATION

Front Side Member Extension

CAUTION
Make sure to attach correctry in accordance with the body dimention diagram as this parts affects
the front wheel alignment.

F25715

INSTALLATION POINT
1 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)
2 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-73

NAME PLATE APPLICATION PROCEDURE

(a) Heat the double-sided tape remaining on the body with an infrared lamp or equivalent.
HINT:
Heat the tape to 40 to 60
C for approximately 1 to 2 minutes.
(b) Wipe off the remaining double-sided tape using a clean cloth or equivalent.
HINT:
If a name plate is installed without thoroughly removing the remaining double-sided tape from the body, the
name plate will not adhere properly. Make sure to thoroughly wipe off the double-sided tape.
(c) After cleaning the installation area of the body with degreasing agent, attach the name plate to the position
shown in the illustration.
HINT:
The working environment should be 20
C when installing the name plate. If the working environment is below
20
C, heat the installation area of the body to 20 to 30
C and then install the name plate.

16.0
(0.630)

8.1
(0.319)

5.5
(0.217)

72.7 72.1
(2.862) (2.839)

88.3
(3.476)

159.8
(6.291)

mm (in.)
F26010
BP-74 BODY PANEL REPLACEMENT

130.3 122.0
(5.130) (4.803)

115.4
(4.543)
262.7
(10.342)

121.8 130.2
(4.795) (5.126)

114.1
(4.492)

260.8
(10.268)

mm (in.)
F25810
 BODY PANEL REPLACEMENT BP-63

OUTER PANEL INSTALLATION TORQUE

13 (133, 10)

13 (133, 10)

13 (133, 10)

13 (133, 10)

6.0 (61, 53 in..lbf)

6.0 (61, 53 in..lbf)

8.0 (82, 71 in..lbf)

8.0 (82, 71 in..lbf)

34 (347, 25)

8.0 (82, 71 in..lbf)

N.m (kgf.cm, ft..lbf) : Specified torque

F25761
BP-64 BODY PANEL REPLACEMENT

26 (265, 19)

26 (265, 19)

26 (265, 19)

26 (265, 19)

N.m (kgf.cm, ft..lbf) : Specified torque

F25762
 BODY PANEL REPLACEMENT BP-65

7.5 (77, 66 in..lbf)

7.5 (77, 66 in..lbf)

7.5 (77, 66 in..lbf)

7.5 (77, 66 in..lbf)

68 (694, 50)

68 (693, 50)

N.m (kgf.cm, ft..lbf) : Specified torque

F25763
BP-48 BODY PANEL REPLACEMENT

QUARTER PANEL END HOUSING (ASSY)

Symbol meaning

REMOVAL : Remove Weld Points : Cut with disc sander, etc.

INSTALLATION : MIG Plug Weld

F25744A F25744B

REMOVAL.INSTALLATION

Luggage Compartment
Opening Trough

Luggage Compartment Trim No. 1 Bracket

F25744

REMOVAL POINT
1 Remove the luggage compartment opening trough at the same time.
INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
3 After welding, apply body sealer to the corresponding parts. (See the paint.coating)
4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-36 BODY PANEL REPLACEMENT

QUARTER PANEL (CUT)

Quarter Panel Replacement Using Adhesive

F25735A

Work Procedure Precaution

1 Cut the wheel arch portion.

2 Heat the quarter panel adhesive area and remove (1) Using an industrial dryer or oxygen acetylene
the quarter panel. burner, heat the quarter panel to 110 to 140
C.
Make sure the quarter panel does not warp.

3 Clean off any adhesive that remains on the (1) Using a gas burner, heat the adhesive to 110 to
vehicle. 140
C.

(2) Using a scraper, scrape away the adhesive.

(3) If adhesive remains, the strength of any

subsequently applied adhesive will be weak.

4 Using a disc grinder or belt sander, scuff and sand (1) Scuff at a width of approximately 10 mm over the
any adhesive that remains on the vehicle. previous adhesive coating.

5 Apply adhesive to the exposed metal areas on the

vehicle. Using a spatula, spread the adhesive
evenly.

6 Apply adhesive to the vehicle again.

7 Using #60-240 grit sandpaper, scuff the adhesive

application area on the new quarter panel.

8 Apply adhesive to the new quarter panel. Using a

spatula, spread the adhesive evenly.

9 Using a vise or the palms of your hands, press the

quarter panel so that the thickness of the
adhesive is even.

10 Complete installation the new quarter panel.

11 Dry the adhesive areas of the new quarter panel. (1) Hardening Time Estimation
With dryer or equivalent (60
C)
: 60 minutes (complete hardening: 90 minutes)
Ambient temperature (25
C)
: 12 hours (complete hardening: 24 hours)
 BODY PANEL REPLACEMENT BP-37

Symbol meaning : Cut with disc sander, etc. : Cut Location for Supply Parts
: Remove Weld Points : Cut and Join Location : Braze

F25735B

REMOVAL

Urethane Foam

85
(3.35)

260
(10.24)

mm (in.)
F25735

REMOVAL 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.
BP-38 BODY PANEL REPLACEMENT

Symbol meaning
: Cut with disc sander, etc. : Cut Location for Supply Parts
: Remove Weld Points : Cut and Join Location : Braze

F25735B

F25736
 BODY PANEL REPLACEMENT BP-39

Symbol meaning

: Spot Weld : MIG Plug Weld : Butt Weld : Body Sealer : Braze

F25737B

INSTALLATION

Urethane Foam

Fuel Filler Opening Lid

Water Proof Rivets 3 Spot Tip

(0.12)

5
(0.24)

mm (in.)
F26012

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
3 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.
4 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 in to the narrow flange.
5 Before installing a new part, apply body sealer.
HINT:
1) Apply sealer in ana even, continuous bead.
BP-40 BODY PANEL REPLACEMENT

Symbol meaning

: Spot Weld : MIG Plug Weld : Butt Weld : Body Sealer : Braze

F25737B

F25738

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
3 After welding, apply the polyurethane foam to the corresponding parts. (See the paint.coating)
4 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
5 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-41

QUARTER WHEEL HOUSING OUTER PANEL (ASSY)

With the quarter panel removed.

Symbol meaning : Cut with disc sander, etc.

: Remove Weld Points : Cut and Join Location

REMOVAL
INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld
F25739A F25739B

REMOVAL.INSTALLATION

[LH]

310
(12.20)

Rocker Outer Extension

mm (in.)
F25739

REMOVAL POINT
1 *1: Take care not to damage the internal reinforcement.
2 After removing the rocker outer extension, remove the quarter wheel housing outer panel.
INSTALLATION POINT
1 After welding the quarter wheel housing outer panel to the vehicle side, install the rocker outer extension.
BP-42 BODY PANEL REPLACEMENT

Symbol meaning : Cut with disc sander, etc.

: Remove Weld Points : Cut and Join Location

REMOVAL
INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld
F25739B

[LH]

Roof Side Outer Panel

F25740

REMOVAL POINT
1 After removing the roof side outer panel, remove the quarter wheel housing outer panel.
INSTALLATION POINT
1 After welding the quarter wheel housing outer panel to the vehicle side, install the roof side outer panel.
 BODY PANEL REPLACEMENT BP-43

[LH]

20
(0.79)

mm (in.)
F25742

INSTALLATION POINT
1 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-44 BODY PANEL REPLACEMENT

Symbol meaning : Cut with disc sander, etc.

: Remove Weld Points : Cut and Join Location

REMOVAL
INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld
F25739B

[RH]

310
(12.20)

Rocker Outer Extension

mm (in.)
F25795

REMOVAL POINT
1 *1: Take care not to damage the internal reinforcement.
2 After removing the rocker outer extension, remove the quarter wheel housing outer panel.
INSTALLATION POINT
1 After welding the quarter wheel housing outer panel to the vehicle side, install the rocker outer extension.
 BODY PANEL REPLACEMENT BP-45

[RH]

Roof Side Outer Panel

F25741

REMOVAL POINT
1 After removing the roof side outer panel, remove the quarter wheel housing outer panel.
INSTALLATION POINT
1 After welding the quarter wheel housing outer panel to the vehicle side, install the roof side outer panel.
BP-46 BODY PANEL REPLACEMENT

Symbol meaning : Cut with disc sander, etc.

: Remove Weld Points : Cut and Join Location

REMOVAL
INSTALLATION : MIG Plug Weld : Tack Weld : Butt Weld
F25739B

[RH]

20
(0.79)

mm (in.)
F25796

INSTALLATION POINT
1 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-2 BODY PANEL REPLACEMENT

RADIATOR SUPPORT UPPER BRACE (ASSY)

With the radiator upper support removed.

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld
F25702A F25702B

REMOVAL.INSTALLATION

Front Bumper Upper Arm

Radiator
Support

F25702

REMOVAL POINT
1 Remove the radiator support at the same time.
INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-3

522
(20.55)
1,482
(58.35)

1,218
(47.95) 1,462
(57.56)
872
(34.33) 456
(17.95)

978
(38.50)

mm (in.)
F25704

INSTALLATION POINT
1 Measure the dimensions before installing the headlights.
2 These values are reference values.
 BODY PANEL REPLACEMENT BP-5

RADIATOR SUPPORT (ASSY)

Symbol meaning

REMOVAL : Remove Weld Points : Cut with disc sander, etc.

INSTALLATION : MIG Plug Weld : Tack Weld

F25706A F25706B

REMOVAL.INSTALLATION

10
(0.39)

mm (in.)
F25706

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-1

RADIATOR UPPER SUPPORT (ASSY)

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld

F25701A F25701B

REMOVAL.INSTALLATION

Front Fender Gusset

F25701

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-30 BODY PANEL REPLACEMENT

REAR DOOR OUTER PANEL (ASSY)

Symbol meaning

: Remove Weld Points

F25759A F25759B

REMOVAL

Positioning Tape

Installation
Position

Hemming Location

Disc Sander

F25759

REMOVAL POINT
1 Before removing the outer panel, mark the installation position with tape.
2 Before removing the outer panel, establish its exact position in relation to the window frame using a reference
marker, etc.
3 After grinding off the hemming location, remove the outer panel.
 BODY PANEL REPLACEMENT BP-31

Symbol meaning

: MIG Plug Weld : Spot MIG Weld : Body Sealer

F25760B

INSTALLATION

Positioning Tape

10
(0.39) Do not close the
drain hole.

Cloth Tape

30

Hemming Tool

mm (in.)
F25760

INSTALLATION 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 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
contact.
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.
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-50 BODY PANEL REPLACEMENT

REAR FLOOR PAN (ASSY)

With the rear floor no.3 crossmember removed.

Symbol meaning

: Remove Weld Points

F25747A F25747B

REMOVAL

Rear Floor Pan Reinforcement

F26001

REMOVAL POINT
1 Remove the rear floor pan reinforcement at the same time.
 BODY PANEL REPLACEMENT BP-51

[LH]

[RH]

LH:

F26002
BP-52 BODY PANEL REPLACEMENT

Symbol meaning

: MIG Plug Weld : Tack Weld

F25749B

INSTALLATION

Spare Wheel Carrier Bracket Fuel Tube No.3 Bracket

Rear Floor Mounting No.2 Bracket Rear Floor Pan Reinforcement

Floor Side Front Plate

Rear Floor Pan Reinforcement

F26003

INSTALLATION POINT
1 Before temporarily installing the new parts, weld the spare wheel carrier bracket, fuel tube No.3 bracket, rear
floor mounting No.2 bracket, rear floor pan reinforcement and floor side front plate with the standard number of
welding points.
BODY PANEL REPLACEMENT BP-53

Rear Floor Pan Reinforcement

F26004
BP-54 BODY PANEL REPLACEMENT

Symbol meaning

: MIG Plug Weld : Tack Weld

F25749B

[LH]

[RH]

LH:

F26005

INSTALLATION POINT
1 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-55

REAR FLOOR SIDE PANEL (ASSY)

With the rear floor pan removed.

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld
F25750A F25750B

REMOVAL.INSTALLATION

[LH]

F25750

INSTALLATION POINT
1 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-56 BODY PANEL REPLACEMENT

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld
F25750B

[RH]

F25751

INSTALLATION POINT
1 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
2 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-57

REAR FLOOR SIDE REAR MEMBER (ASSY)

With the rear floor no.3 crossmember removed.

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld
F25752A F25752B

REMOVAL.INSTALLATION

LH:

RH:

F25752

INSTALLATION POINT
1 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)
2 After welding, apply undercoating to the corresponding parts. (See the paint.coating)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-58 BODY PANEL REPLACEMENT

REAR FLOOR NO. 2 CROSSMEMBER (ASSY)

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : MIG Plug Weld

F25753A F25753B

REMOVAL.INSTALLATION

F25753

INSTALLATION POINT
1 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)
2 After welding, apply undercoating to the corresponding parts. (See the paint.coating)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-49

REAR FLOOR NO. 3 CROSSMEMBER (ASSY)

With the body lower back panel removed.

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : Spot Weld : MIG Plug Weld
F25746A F25746B

REMOVAL.INSTALLATION

F25746

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
3 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-34 BODY PANEL REPLACEMENT

ROCKER OUTER EXTENSION (ASSY)

Symbol meaning

: Remove Weld Points : Cut and Join Location : Cut Location for Supply Parts

F25731A F25731B

REMOVAL

Center Body Outer Pillar

280
(11.02)

Quarter Panel

260
(10.24)

70
(2.76)

Center Body Pillar Lower Reinforce

mm (in.)
F25731

REMOVAL POINT
1 *1 in illustration above indicates where the adhesive is.
2 After removing the center body outer pillar and quarter panel, remove the rocker outer extension and center
body pillar lower reinforce.
 BODY PANEL REPLACEMENT BP-35

Symbol meaning

: MIG Plug Weld : Butt Weld : Body Sealer

F25732B

INSTALLATION

Rocker Panel Reinforcement

Center Body Pillar Lower Reinforce

Center Body Outer Pillar

Quarter Panel

F25732

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
3 Before temporarily installing the new parts, weld the rocker panel reinforcement and rocker outer extension
with the standard number of welding points.
4 Before installing a new part, apply body sealer.
HINT:
1) Apply sealer in an even, continuous bead.
5 After welding the center body pillar lower reinforce and rocker outer extension to the vehicle side, install the
center body outer pillar and quarter panel.
6 After welding, apply body sealer and undercoating to the corresponding parts. (See the paint.coating)
7 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-32 BODY PANEL REPLACEMENT

ROCKER OUTER PANEL (CUT-P)

Symbol meaning : Cut and Join Location

: Remove Weld Points : Cut Location for Supply Parts

F25729A F25729B

REMOVAL

800
(31.50)

60 50
(2.36) (1.97)

mm (in.)
F25729

REMOVAL POINT
1 *1: Take care not to damage the internal reinforcement.
 BODY PANEL REPLACEMENT BP-33

Symbol meaning

: MIG Plug Weld : Cut and Join Location : Butt Weld

F25730B

INSTALLATION

Center Body Pillar Lower Reinforce

Center Body Outer Pillar

mm (in.)
F25730

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
3 After welding the center body pillar lower reinforce to the vehicle side, install the center body outer pillar.
4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
 BODY PANEL REPLACEMENT BP-61

ROOF PANEL (ASSY): Moon Roof

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : Spot Weld : MIG Plug Weld : Body Sealer

F25755A F25755B

REMOVAL.INSTALLATION

Cloth Tape

Wooden Hammer

Disc Sander

[Removal]
[Install]

F25755

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish
2 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)
3 After welding, apply body sealer to the corresponding parts. (See the paint.coating)
4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-62 BODY PANEL REPLACEMENT

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : Spot Weld : MIG Plug Weld : Body Sealer
F25755B

F25756

INSTALLATION POINT
1 Before temporarily installing the new parts, apply body sealer to the windshield header panel, roof panel
reinforcement and back door opening frame.
HINT:
1) Apply just enough sealer for the new parts to make contact.
 BODY PANEL REPLACEMENT BP-59

ROOF PANEL (ASSY): Normal Roof

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : Spot Weld : MIG Plug Weld : Body Sealer

F25754A F25754B

REMOVAL.INSTALLATION

F25754

INSTALLATION POINT
1 Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
2 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)
3 After welding, apply body sealer to the corresponding parts. (See the paint.coating)
4 After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural
weld points.
BP-60 BODY PANEL REPLACEMENT

Symbol meaning

REMOVAL : Remove Weld Points

INSTALLATION : Spot Weld : MIG Plug Weld : Body Sealer
F25754B

F25806

INSTALLATION POINT
1 Before temporarily installing the new parts, apply body sealer to the windshield header panel, roof panel
reinforcement and back door opening frame.
HINT:
1) Apply just enough sealer for the new parts to make contact.