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Body Repair Manual

This document provides a body repair manual for the 2006 Hyundai Santa Fe. It contains sections on body construction, dimensions, panel repair procedures, sealing locations, corrosion protection, modification tools, and plastic parts. The manual aims to simplify body repairs to reduce insurance costs and vehicle ownership expenses by specifying approved repair locations and procedures. It is intended to help Hyundai dealers and body shops perform quality repairs on Hyundai vehicles.

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100% found this document useful (1 vote)

1K views121 pages

Body Repair Manual

Uploaded by

Lacatusu Mircea

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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Body Repair Manual

INTRODUCTION
This Body Repair Manual provides detailed repair procedures for repair of commonly dam-
aged structural panels on the Hyundai 2006 SANTAFE(CM). To aid in the information of the
damaged vehicle, body construction, replacement parts, body dimensions, body sealing
locations, corrosion protection, body modification tools, plastic parts and body repair proce-
dures are contained herein.
The repair procedures specify locations where body members may be structurally sectioned.
All of the repair procedures have been performed on Hyundai SANTAFE(CM) body shells
and that is currently available in most auto body repair shops.
The repair procedures illustrated in this manual were developed to simplify body repair in
order to reduce insurance costs, and indirectly, cost of ownership.
The vehicle should not be sectioned in locations other than those illustrated in this repair
manual. Furthermore, these repair procedures DO NOT apply to any other vehicle. The
individuals performing the work must assume full responsibility for the quality of their
workmanship.
We believe this manual to be helpful for Hyundai dealers, and anticipate it to be effectively
used for Hyundai vehicle bodies.
For the services of other than collision-damaged body parts of the Hyundai SANTAFE(CM),
refer to the SANTAFE(CM) shop manual.
The illustrations and descriptive text in this manual were correct at the time of printing.
It is the policy of HYUNDAI MOTOR COMPANY to continuously improve its products.
Specifications and procedures are subject to change at any time without notice.

November 2005, Printed in Korea

All rights reserved. No part of this publication may be reproduced, stored in any
retrieval system or transmitted in any form or by any means without the prior
written permission of Hyundai Motor Company.
CONTENTS
GENERAL INFORMATION
GENERAL GUIDELINES AND PRECAUTIONS ..................................................................................... GI-2
SRS AIR-BAG ....................................................................................................................................... GI-3
ELECTRONIC PARTS ........................................................................................................................... GI-4
CORROSION PROTECTION AND SEALING ........................................................................................ GI-4
SIDE BODY PANELS ............................................................................................................................ GI-4
WELDING .............................................................................................................................................. GI-5

BODY CONSTRUCTION
BODY COMPONENTS ........................................................................................................................ BC-2
ZINC-GALVANIZED STEEL PANELS ................................................................................................. BC-4
HIGH-STRENGTH STEEL PANELS .................................................................................................... BC-6
FRONT BODY ..................................................................................................................................... BC-8
QUARTER PANEL .............................................................................................................................. BC-13
SIDE BODY PANEL ........................................................................................................................... BC-14
SIDE BODY ........................................................................................................................................ BC-16
REAR BODY ...................................................................................................................................... BC-18
ROOF PANEL ..................................................................................................................................... BC-20
CENTER FLOOR PANEL ................................................................................................................... BC-21
REAR FLOOR PANEL ........................................................................................................................ BC-22 GI
REAR FLOOR SIDE MEMBER ........................................................................................................... BC-23

BODY DIMENSIONS BC
GENERAL ........................................................................................................................................... BD-2
MEASUREMENT METHOD ................................................................................................................. BD-2
FRONT BODY ..................................................................................................................................... BD-4 BD
SIDE BODY ......................................................................................................................................... BD-6
INTERIOR ........................................................................................................................................... BD-8
REAR BODY ...................................................................................................................................... BD-11
BP
UNDER BODY (PROJECTED DIMENSTIONS) .................................................................................. BD-13
UNDER BODY .................................................................................................................................... BD-15 BS
BODY PANEL REPAIR PROCEDURE
FENDER APRON INNER FRONT PANEL AND FENDER APRON UPPER MEMBER (PARTIAL) ....... BP-2 CP
FRONT SIDE MEMBER(PARTIAL) ..................................................................................................... BP-7
FRONT PILLAR .................................................................................................................................. BP-15
CENTER PILLAR ................................................................................................................................ BP-20 BT
SIDE SILL(PARTIAL) .......................................................................................................................... BP-26
QUARTER PANEL .............................................................................................................................. BP-29
BACK PANEL AND REAR SIDE MEMBER(PARTIAL) ....................................................................... BP-33 PP
BODY SEALING LOCATION
FLOOR ................................................................................................................................................ BS-2
UPPER AND SIDE BODY ................................................................................................................... BS-5
UNDER BODY ..................................................................................................................................... BS-8

CORROSION PROTECTION
ZINC-GALVANIZED STEEL PANELS ................................................................................................. CP-2
ZINC-PHOSPHATE COATNIC ELECTRODEPOSITION PRIMER ....................................................... CP-4
ANTIVIBRATION PADS-LOCATION & SECTION ............................................................................... CP-5
ATTACHMENT OF ANTIVIBRATION PADS ....................................................................................... CP-8
UNDER BODY COAT .......................................................................................................................... CP-9
SIDE BODY ........................................................................................................................................ CP-10
CAVITY WAX INJECTION .................................................................................................................. CP-11
UNDER BODY ANTI-CORROSION AGENT ........................................................................................ CP-14
BODY MODIFICATION TOOLS
MODIFICATION TOOLS ....................................................................................................................... BT-2
CUT AND DISASSEMBLY TOOLS ....................................................................................................... BT-3
ASSEMBLY TOOLS ............................................................................................................................. BT-4
WELDING MACHINE ............................................................................................................................ BT-5
BUFFING AND GRINDING TOOLS ...................................................................................................... BT-6
HANDHELD TOOLS ............................................................................................................................. BT-8

PLASTIC PARTS
POLYPROPYLENE(PP) BUMPER REPAIRABILITY ........................................................................... PP-2
BUMPER REPAIR PROCEDURE ........................................................................................................ PP-2
REPAIR METHOD FOR PP BUMPER ................................................................................................. PP-3
GENERAL
INFORMATION
GI

PP
GI-2 GENERAL INFORMATION

GENERAL GUIDE LINES AND PRECAUTIONS

The Hyundai SANTAFE is a completely new vehicle design. During its development, close attention has been given to
safety, stability, weight and corrosion protection. Typical of unit body design, the Hyundai SANTAFE is designed so that the
front and rear compartments will absorb much of the collision energy so that the passengers are better protected. During
collisions, these front and rear energy absorbing systems may be severely damaged. During repair, these damaged areas
must be returned to their original strength and geometry. If this is not properly done, the vehicle will not provide the intended
level of protection to its occupants in the event of another collision.

The repairs described in this manual were performed on SANTAFE body shells. In some instances special fixtures were
welded in place to support the structure. During the repair of an actual vehicle, the interior would be fully disassembled and
standard jack screws or portable braces may be used for temporary support.

During the repair of an accident involved vehicle, the vehicle must first be returned to pre-impact dimensions prior to
beginning the sectioning repair procedures. The extent of damage that must be repaired should then be evaluated to
determine the appropriate repair procedures. This manual provides locations and procedures where structural sectioning
may be employed. It is the responsibility of the repair technician, based upon the extent of damage, to determine which
location and procedure is suitable for the particular damaged vehicle.

During the repair of a collision damaged automobile, it is impossible to fully duplicate the methods used in the factory during
the vehicle manufacture. Therefore, auto body repair techniques have been developed to provide a repair that has
strength properties equivalent to those of the original design and manufacture.

Certain guidelines and precaution are noted as follow.

BCMGI6010
GENERAL INFORMATION GI-3

SRS AIR-BAG
SYSTEM COMPONENT

Clock spring
Front impact sensor PAB

Side impact sensor

Buckle pretentioner

BPT When it is deployed

ERKB012A

The Hyundai SANTAFE is equipped with a Supplemental Restraint System AIR-BAG to provide the vehicle's driver and/or
the front passenger with additional protection than that offered by the seat-belt system alone, in case of a frontal impact of
sufficient severity.

When handling airbag components (removal, installation or inspection, etc.), always follow the directions given in the repair
manual for the relevant model to prevent the occurrence of accidents and airbag malfunction.

Also take the following precautions when repairing the body:

1. Work must be started after approximately 30 seconds or longer from the time the ignition switch is turned to the LOCK
position and the negative (-) terminal cable is disconnected from the battery. (The airbag system is equipped with a
back-up power source so that if work is started within 30 seconds of disconnecting the negative (-) terminal cable of the
battery, the airbag may be deployed.)
When the negative(-) terminal cable is disconnected from the battery, memory of the clock and audio systems will be
cancelled. So before starting work, make a record of the contents memorized by the audio memory system. Then when
work is finished, reset the audio system as before and adjust the clock.
2. When using electric welding, first disconnect the air-bag connectors under the steering column near the MULTI-FUNCTION
SWITCH and the passenger's side crash pad before starting work.
3. Store the air-bag modules where the ambient temperature remains below 93 C(200 F), without high humidity and away
from electrical noise.
4. WARNING/CAUTION labels are attached to the periphery of the air-bag components.
Refer to the SANTAFE SHOP MANUAL
GI-4 GENERAL INFORMATION

ELECTRONIC PARTS
Vehicles today include a great many electronic parts and components, and these are in general very susceptible to adverse
effects caused by overcurrent, reverse current, electromagnetic waves, high temperature, high humidity impacts, etc.
In particular such electronic components can be damaged if there is a large current flow during welding from the body side.
Therefore, take the following precautions during body repair to prevent damage to the CONTROL MODULES (ECM, TCM,
ABS CM, SRS CM, etc.)

1. Before removing and inspecting the electrical parts or before starting electric welding operations, disconnect the negative
(-) terminal cable from the battery.
2. Do not expose the CONTROL MODULES to ambient temperatures above 80 C(176 F).

NOTE
If it is possible the ambient temperatures may reach 80 C(176 F) or more, remove the CONTROL MODULES from the
vehicle before starting work.

3. Be careful not to drop the CONTROL MODULES and not to apply physical shocks to them.

CORROSION PROTECTION AND SEALING

Proper corrosion protection and sealing is an important part of any repair. When reviewing these repair procedures, it is
important to recognize the need for corrosion restoration to provide for long term strength of the repaired member.

A two part epoxy primer was applied to the metal surfaces during the latter part of the repair. For closed sections, such as
front and rear rails, rocker panels and pillars, the primer is applied without applying the metal conditioner and the conversion
coating. These steps are omitted to insure that no rinse water is trapped in the closed sections. The primer application in
followed by an application of an oil or wax based rust proofing material.

After the corrosion restoration process for the closed sections are completed, then the process can be applied to all exterior
sections. For exterior surfaces, both metal conditioner and conversion coating treatments are applied to the exterior surface
prior to application of the epoxy primer. The procedure in applying the corrosion restoration process is important order to
insure that moisture, due to the water rinsing of the metal conditioner and conversion coating is not inadvertently trapped
inside any closed section before the epoxy primer and rust proofing materials have been applied.

Appropriate seam sealers are then applied to all joints. Follow manufacturer's recommendations for the appropriate type of
seam sealer to be used at each seam or joint.

SIDE BODY PANELS

The side body panel for SANTAFE is designed and stamped from a single piece of sheet metal in factory as shown in the
figure. While the entire side panel is available for service, the partial panels sectioned by several damaged areas are also
available. Therefore when repairing side body, refer to "Replacement parts section" of this manual to select and use the
appropriate part.

: Service part line

BCMGI6020
GENERAL INFORMATION GI-5

WELDING
All repairs in this manual require the use of a Metal-Inert Gas (MIG) welder, Gas (oxyacetylene) welding must not be used.
Both high strength steel and mild steel can be welded using the MIG welder. The I-CAR recommendations for welding should
be followed. The shielding gas should be 75% Argon and 25% CO2.
The recommended welding wire size is 0.23" and the wire should satisfy the American Welding Society standard code
AWSER70S-6.

During the repair process, plug welds are used to duplicate original factory spot welds. All plug welds should be done with the
MIG welder. An 8 mm (5/16") hole is placed in the top (welding side) sheetmetal.

You then begin welding along the edges and the spiral towards the center (see illustration). This is important so that weld
penetration between the two metal pieces takes place along the circumference of the circle.

Weld around
edges first
working in to
wards the
center
(Top wiew)

PLUG WELDING

8mm or 5/16" dia. hole

Illustration-Welding in collision repair

CON-0040

SAFETY FACTORS
Disconnect the negative(-) battery cable before performing any work on the vehicle.
Protect yourself by wearing goggles, earplugs, respirators, gloves, safety shoes, caps, etc. when working on a vehicle.
Safely support the vehicle before any work is done. Block the front or rear wheels if the vehicle is not lifted off of the ground.
Cap or remove the fuel tank when working on the rear section of the car.
Insure proper ventilation of your working area. Some paint and sealant can generate toxic gases when heated. Use an air
chisel or saw to remove damaged panels instead of a gas torch.
Observe all local and national safety regulations when performing any work.
Cover interior with heat-resistant cover to insure safety when welding.
Take care when using gas or cutting torches so as not to burn body sealer or interior. Extinguish immediately if they should
catch fire.
BODY
CONSTRUCTION
GI

PP
BC-2 BODY CONSTRUCTION

BODY COMPONENTS
Body construction will sometimes differ depending on specifications and country of destination. Therefore, please keep in
mind that the information contained herein is based on vehicles for general destination.

141
132 150
116
125 144 148
133 140

149
131 138

117
126 139 142 84
118 134
129
83
130 143 110 82
121 109
127 108
108 80
136 107 95
79 81 96
128 106
114 119 122
104
135 137 92
120 77 69 93 94
76 78
112
74
123 103 89 91
115 100 90
124 105 71 75 87
72 73 86 88
102 99
111 49 97 85
46
113 101
44
65 68
42 70
41 57 62
48
61 47 66
35 98 56
60 67
43 39
59 52
145 51
40 34 45
37 55
58
36 29 5
30 158
38
25 53
8 54 64
11 32 13 6 50
63
15 28
10 160
21
27 16 7
12 9
20 153
17 4 157
26 14 33
18
19 24 1 156
31 3
23
22 159
2 151

152
146

154

147 155

BCMBC6001
BODY CONSTRUCTION BC-3

1. Radiator support upper member 81. Rear floor center extension

2. Radiator support lower inner member 82. Rear end upper cross member
3. Body mounting bracket reinforcement 83. Outer inner lower extension
4. Dash panel 84. Rear end outer cross member
5. Dash panel reinforcement 85. Rear floor side front member
6. Dash lower member 86. Rear side sill support
7. Foot rest bracket 87. Rear shock absorber cover support
8. Dash lower member reinforcement 88. Rear floor side member reinforcement
9. Dash center support member 89. Rear floor side rear member
10. Dash center upper member 90. Rear spring stopper bracket
11. Fender apron inner lower support extension 91. Spring sheet
12. Front side inner member 92. Rear member rear bracket
13. Front side member inner reinforcement 93. Rear end extension
14. Front side member inner extension 94. Rear end plate
15. Transaxle mounting reinforcement 95. Towing hook mounting reinforcement
16. Battery tray support 96. Pipe nut
17. Sub frame mounting inner gusset 97. 2nd seat mounting member
18. Sub frame mounting front support 98. Cowl inner lower panel
19. Sub frame mounting reinforcement 99. Cowl top outer panel
20. Battery front bracket 100. Cowl inner lower reinforcement
21. Battery tray bracket 101. Cowl side upper inner panel assembly
22. Sub frame mounting bracket 102. Cowl top side extension assembly
23. Sub frame mounting extension 103. Roof panel
24. Sub frame mounting rear reinforcement 104. Sun roof reinforcement ring assembly
25. Front side outer member 105. Roof front rail
26. Sub frame mounting outer gusset 106. Roof center No.1 rail
27. Transaxle mounting outer support 107. Roof center No.2 rail
28. Front side member inner rear reinforcement 108. Roof center No.3 rail
29. Front side rear lower member 109. Roof center No.4 rail
30. Front side member inner rear upper reinforcement 110. Roof rear upper rail
31. Frame mounting bracket 111. Side inner panel
32. Front side member outer reinforcement 112. Cowl cross bar mounting bracket
33. Front side member inner reinforcement 113. Center cross bar mounting front bracket
34. Engine mounting bracket 114. Front pillar upper extension
35. Shock absorber housing extension 115. Front seat belt upper mounting bracket
36. Fender apron inner lower panel assembly 116. Rear combination lamp housing extension
37. Fender apron inner lower support reinforcement 117. Side outer panel
38. Fender apron inner side reinforcement 118. Fuel filler housing assembly
39. Shock absorber housing panel assembly 119. Front pillar outer lower reinforcement
40. Shock absorber housing cover 120. Front door housing upper mounting bracket assembly
41. Shock absorber housing reinforcement 121. Front pillar outer upper reinforcement
42. Fender apron upper inner panel assembly 122. Front door hinge mounting reinforcement
43. Fender apron upper outer panel assembly 123. Front door check mounting bracket assembly
44. Fender apron upper outer rear panel 124. Front door hinge lower mounting bracket assembly
45. Center floor panel 125. Side sill outer reinforcement
46. Center floor upper reinforcement 126. Roof side outer reinforcement
47. Front seat cross member 127. Center pillar outer reinforcement assembly
48. Front seat rear inner bracket 128. Rear door hinge mounting reinforcement
49. Front seat rear outer bracket 129. Rear door hinge upper mounting bracket assembly
50. Center floor rear reinforcement 130. Rear door check mounting bracket assembly
51. Parking brake cable bracket 131. Quarter rear lower extension
52. Center floor upper front reinforcement 132. Quarter rear upper extension
53. Parking shaft mounting A bracket 133. Rear combination lamp housing panel
54. Parking shaft mounting B bracket 134. Gusset mounting bracket assembly
55. Center floor reinforcement 135. Front pillar inner support assembly
56. Center floor side member 136. Rear wheel house inner panel
57. Center floor side reinforcement 137. Rear wheel house inner front extension
58. Center floor side front reinforcement 138. Quarter inner lower extension
59. Center floor side inner reinforcement 139. Quarter inner lower panel
60. Center floor front cross inner member 140. Quarter inner upper panel
61. Center floor front cross outer member 141. Quarter inner upper reinforcement
62. Center floor front cross member 142. D pillar inner lower reinforcement
63. Center floor inner reinforcement 143. C pillar inner lower reinforcement
64. Side sill inner panel 144. Quarter inner upper reinforcement extension
65. Rear cross member bracket 145. Fender panel
66. Rear floor panel 146. Hood outer panel
67. Rear floor upper panel assembly 147. Hood inner panel
68. Rear floor cross No.4 member 148. Tail gate outer panel
69. Spare tire stopper bracket 149. Tail gate inner panel
70. Interm floor reinforcement 150. Tail gate lamp bracket
71. 2nd seat belt mounting member 151. Front door outer panel
72. 2nd seat belt mounting member 152. Front door inner panel
73. Rear floor cross No.5 member 153. Front door frame channel
74. Cross member No.5 support 154. Front door reinforcement beam assembly
75. Cross member No.5 reinforcement 155. Front door member assembly
76. Rear floor cross No.6 member assembly 156. Rear door outer panel
77. Center member No.6 bracket 157. Rear door inner panel
78. Rear floor cross No.1 member 158. Rear door frame channel
79. Rear floor No.7 cross member 159. Rear door reinforcement beam assembly
80. Rear end lower cross member 160. Rear door member assembly
BC-4 BODY CONSTRUCTION

ZINC-GALVANIZED STEEL PANELS

Becavanized steel panel has excellent resistance, it tis used in areas which have a high possibility of painting deficiency
below.

132
116
148

131 138

84
118 134

83
82

80
95
79 81
119
137 92
77 94
76 78
74
89 91
100 90
124 71 75 87
72 88
102 99
97 85
101
44
65 68
41 57 62
61 66
98
60
43
59

34 145
40
37 55
58
36 29
38 30
25 53
11 54 64
32 13 6
63
28
21
27 16
12
20
33 17 4
26 14 18
19 24 1 156
31 3
23
22
2 151

146

BCMBC6002
BODY CONSTRUCTION BC-5

1. Radiator support upper member 81. Rear floor center extension

HIGH STRENGTH STEEL PANELS

Because high strength steel panel has excellent resistance, it is used in areas which have a high posibility of painting
deficiency below.

132

148

83
110 82
121
127
80
95
79 81
128
114 119 122

92
77 94
76 78
74
123 89 91
100 90
75 87
88
102 99
111 49
85
101
44
65 68
42 70
41 57 62
48
61 47 66
35 98
60
43
59 52

34 145
37 55
58
36 5
38 30
53
8 54 64
11 32
6 50
63
28
10 160
21
16
12 9
20
33 4
26 14
156
31

22
151

146

155

BCMBC6003
BODY CONSTRUCTION BC-7

1. Radiator support upper member 81. Rear floor center extension

FRONT BODY

2
1

3 4

BCMBC6004

No. PART NAME

1 Front side member assembly LH/RH

2 Fender apron panel assembly LH/RH
3 Cowl panel assembly
4 Dash panel complete assembly
BODY CONSTRUCTION BC-9

1. FRONT SIDE MEMBER

23
22

1 17

26 24
3

19
12
10
2
11
16

18
27
4 6

25 7
8
15

9
13 14

BCMBC6005

No. PART NAME No. PART NAME

1 Fender apron inner lower support extension 15 Sub frame mounting rear reinforcement
2 Front side inner member 16 Sub frame mounting nut
3 Front side member inner reinforcement 17 Front side outer member
4 Front side member inner extension 18 Sub frame mounting outer gusset
5 Transaxle mounting reinforcement 19 Transaxle mounting outer support
6 Sub frame mounting inner gusset 20 Front side member inner rear reinforcement
7 Sub frame mounting front support 21 Front side rear lower member
8 Sub frame mounting reinforcement 22 Front side rear lower support
9 Sub frame mounting nut 23 Tie down bracket
10 Battery tray support 24 Front side member inner rear upper reinforcement
11 Battery front bracket 25 Front end module mounting bracket
12 Battery tray rear bracket 26 Front side member outer reinforcement
13 Sub frame mounting rear bracket 27 Front side member inner reinforcement
14 Sub frame mounting rear extension
BC-10 BODY CONSTRUCTION

2. FENDER APRON PANEL

13 11

3 19

15 9

12
5
16
4
2
18

1
6 8 7

BCMBC6006

No. PART NAME No. PART NAME

1 Engine mounting bracket 11 Shock absorber housing reinforcement

2 Engine mounting support 12 Shock absorber housing support
3 Shock absorber housing extension 13 Fender apron upper inner panel assembly
4 Fender apron inner lower panel assembly 14 Fender apron inner upper gusset
5 Fender apron inner lower support reinforcement 15 Fender apron upper outer panel assembly
6 Fender apron inner side reinforcement 16 Air cleaner mounting bracket assembly
7 Junction box mounting bracket assembly 17 Fender apron upper outer rear panel
8 Junction box front mounting bracket assembly 18 Fender mounting bracket
9 Shock absorber housing panel assembly 19 Connect dash bracket
10 Shock absorber housing cover
BODY CONSTRUCTION BC-11

3. COWL PANEL

11 8

6
2
10
14

5
9

BCMBC6007

No. PART NAME No. PART NAME

1 Cowl inner lower panel 9 Wiper motor mounting bracket

2 Cowl top outer panel 10 Cowl side upper inner panel assembly
3 Cowl inner lower extension 11 Cowl top side extension assembly
4 Cowl inner lower reinforcement 12 Fender mounting bracket assembly
5 Wiper center mounting bracket assembly 13 Gas lifter mounting bracket
6 Steering column upper support 14 Intercooler mounting bracket assembly
7 Steering column lower support extension assembly 15 Steering column mounting bracket
8 Clutch padal mounting bracket assembly 16 Wiper motor wiring mounting bracket
BC-12 BODY CONSTRUCTION

4. DASH PANEL

3 2

7 10

5 4
6

BCMBC6008

No. PART NAME

1 Dash panel
2 Dash panel reinforcement
3 Blower lower mounting bracket
4 Heater lower mounting bracket
5 Dash lower member
6 Foot rest bracket
7 Dash lower member reinforcement
8 Dash center support blower mounting bracket
9 Dash cross side member
10 Dash center upper member
BODY CONSTRUCTION BC-13

QUARTER PANEL

15
4

16 14
12

3
10

1
2

13 6

BCMBC6010

No. PART NAME No. PART NAME

1 Quarter outer panel 9 2nd seat belt upper mounting bracket

2 Quarter inner lower panel 10 3rd seat belt upper mounting bracket
3 Quarter inner upper panel 11 3rd seat belt reel mounting reinforcement
4 Quarter inner upper reinforcement 12 2nd seat belt reel mounting reinforcement
5 Quarter inner lower extension 13 Luggage trim lower mounting bracket
6 D pillar inner lower reinforcement 14 3rd seat belt upper mounting plate assembly
7 C pillar inner lower reinforcement 15 D pillar inner upper reinforcement
8 Quarter inner upper reinforcement extension 16 C pillar upper plate and pad
BC-14 BODY CONSTRUCTION

SIDE BODY PANEL

33
19 29 32
8

31
37 28

9
20

24 35
11
12 34
36
15
10 23

21
27

16
5
25
22
3
14
26

2 17 39
6 18

1
4

BCMBC6009
BODY CONSTRUCTION BC-15

No. PART NAME

1 Side inner panel

2 Cowl cross bar mounting bracket
3 Front pillar inner support assembly
4 Center cross bar mounting front bracket
5 Front pillar upper extension
6 Front seat belt upper mounting bracket
7 Front seat belt lower mounting bracket
8 Rear combination lamp housing extension
9 Fender upper mounting bracket
10 Side outer panel
11 Fuel filler housing assembly
12 Fender mounting lower bracket
13 Front pillar outer lower reinforcement
14 Front door hinge upper mounting brackrt assembly
15 Front pillar outer upper reinforcement
16 Front door hinge mounting reinforcement
17 Front door check mounting bracket assembly
18 Front door hinge lower mounting bracket assembly
19 Side sill outer reinforcement
20 Roof side outer reinforcement
21 Center pillar outer reinforcement assembly
22 Rear door hinge mounting reinforcement assembly
23 Rear door hinge upper mounting bracket assembly
24 Door lock striker plate assembly
25 Front pillar lower plate and pad
26 Center pillar lower plate and pad
27 Rear door check mounting bracket assembly
28 Quarter rear lower extension
29 Quarter rear upper extension
30 Rear combination lamp housing panel
31 Tail gate damper bracket assembly
32 Rear bumper guide bracket
33 Gas spring bracket assembly
34 Rear gusset A panel
35 Rear gusset B panel
36 Gusset mounting bracket assembly
37 Rear door striker mounting reinforcement assembly
38 Side outer reinforcement assembly
39 Quarter inner upper panel
40 Quarter inner lower panel
BC-16 BODY CONSTRUCTION

SIDE BODY
< Cross-Sectional Views >

K
L
A
H L
H

G G
B B M
A F F
M
N
D
C C E E N

[ SIDE VIEW ]

BCMBC6011

A B Front door panel assembly

Hood panel assembly Fender panel
2.7 mm 4 mm

Fender panel

Front pillar
assembly
12.6 mm

A-A BCMBC6012 B-B BCMBC6013

C Fender panel
D
Front door panel assembly
4 mm
Door panel
12.6 mm assembly
8 mm

Front pillar
assembly
12.6 mm

Side sill assembly

C -C BCMBC6014 D-D BCMBC6015

BODY CONSTRUCTION BC-17

E F
Rear door panel assembly Front door panel assembly
Front door panel assembly Rear door panel assembly
4 mm 4 mm

Center pillar
assembly
Center pillar
assembly
12.6 mm
12.6 mm

12.6 mm

12.6 mm
E-E BCMBC6016 F-F BCMBC6017

G Front door panel assembly

H
Front door panel assembly
Rear door panel assembly
4 mm
Rear door panel assembly
4 mm

Center pillar
assembly
12.6 mm

12.6 mm
12.6 mm

12.6 mm

Center pillar assembly

G-G BCMBC6018 H-H BCMBC6019

K N
Side outer panel
4.
5
m
m

Rear door panel assembly

4
m
m

Door panel
assembly
m
m
6.
12

.6
mm Quarter pillar assembly
12

K-K BCMBC6020 N-N BCMBC6021

M L
Rear door panel assembly Rear door panel assembly
m
4m

4 mm
12.6
mm

Quarter pillar assembly D pillar assembly

mm
12.6

M-M BCMBC6022 L-L BCMBC6023

BC-18 BODY CONSTRUCTION

REAR BODY
< Cross-Sectional Views >

Q Q

P P

[ TOP VIEW ]

T
R

S S

[ REAR VIEW ]

BCMBC6024
BODY CONSTRUCTION BC-19

P Q

Roof panel assembly Roof panel assembly

6 mm Taill gate panel 6 mm

assembly Taill gate panel
assembly

m
3m
12.

P-P BCMBC6025 Q-Q BCMBC6026

R S
Rear gusset a panel
Taill gate panel
assembly

4m
m
Taill gate panel
assembly
12.3 mm

S-S BCMBC6028

mm
12.3
mm
4.5
12.
3m

Back panel
m

assembly

R-R BCMBC6027 T -T BCMBC6029

BC-20 BODY CONSTRUCTION

ROOF PANEL

6
5

4
8
3

BCMBC6030

No. PART NAME

1 Roof panel
2 Roof front rail
3 Roof center No.1 rail
4 Roof center No.1 rail
5 Roof center No.1 rail
6 Roof center No.1 rail
7 Roof rear upper reail
8 Sun roof reinforcement assembly
BODY CONSTRUCTION BC-21

CENTER FLOOR PANEL

7
25
4
33
30
21 37
17
15 27 6 36
16
26
20 5
24
28
23
12
10
29 3
22
19

13
2
11

14
1
9 31 34
32 18
8
35
BCMBC6031

No. PART NAME No. PART NAME

1 Side sill inner front gusset 20 Center floor side member

2 Side sill center reinforcement 21 Center floor side reinforcement
3 Center floor panel 22 Center floor side front reinforcement
4 Center floor upper reinforcement 23 Center floor side inner reinforcement
5 Front seat cross member 24 Center floor front cross inner member
6 Front seat rear inner beacket 25 Parking cable mounting front bracket
7 Front seat rear outer bracket 26 Center floor front cross outer member
8 Amp mounting bracket 27 Center floor front cross member
9 Center floor rear reinforcement 28 Muffler hanger front bar
10 Parking brake cable bracket 29 Pipe
11 Center support bracket 30 Parking cable pipe
12 Center floor upper front reinforcement 31 Tunner rear mounting bar
13 Propeller shaft mounting A bracket 32 Center floor inner reinforcement
14 Propeller shaft mounting B bracket 33 Parking cable mounting bracket
15 Propeller shaft mounting bracket 34 Side sill inner panel
16 Propeller shaft mounting support 35 Side sill inner jack reinforcement
17 Propeller shaft mounting pipe nut 36 Front seat outer mounting reinforcement assembly
18 Fuel tank mounting plate 37 Rear cross member bracket
19 Center floor reinforcement
BC-22 BODY CONSTRUCTION

REAR FLOOR PANEL

17 19
18
16
15
14
13
11
10
27
12
1

7 24

23
26
6 22

2
25
3
4
21

BCMBC6032

No. PART NAME No. PART NAME

1 Rear floor panel 15 Rear gate lock bracket

2 Rear floor upper panel assembly 16 Tail gate striker plate assembly
3 Rear seat mounting side bracket assembly 17 Rear door striker support plate
4 Heater protector mounting bracket assembly 18 Quarter inner lower extension
5 Rear floor cross No. 4 member 19 Rear end outer center member
6 Seat stopper bracket 20 Rear buffer cover mounting center bracket
7 Interm floor reinforcement 21 Cross member No. 7 support
8 Rear end lower center member 22 Spring stopper reinforcement
9 Rear floor center extension 23 Rear suspension front mounting reinforcement
10 Rear spare tire plate assembly 24 Brake hose mounting bracket
11 Muffler hanger mounting rear plate 25 Sub frame mounting bolt
12 Muffler hanger mounting rear bar 26 Rear floor side reinforcement
13 Rear end upper center member 27 Side sill No. 2 support
14 Tail gate striker mounting reinforcement
BODY CONSTRUCTION BC-23

REAR FLOOR SIDE MEMBER

24 25 48
23 46 49
19
45
22
44 1
17 40
39
21 20
18 47
12 38
43
11 13
8 15 42
35
41
7 10 37
9 33
16
3
14 31 36
29 30 32

5 6 28
2 34

4
50
26
27

BCMBC6033

No. PART NAME No. PART NAME

1 Spare tire stopper bracket 26 Rear floor side front member

2 2nd seat belt mounting member 27 Rear side member bulhead
3 2nd seat belt mounting bracket assembly 28 Rear side sill support
4 2nd seat belt mounting member 29 Rear tie down bracket
5 Seat tilt anchor mounting member 30 Rear tie down hock plate
6 Rear seat bar 31 Seat tilt anchor bracket assembly
7 Rear floor cross No. 5 member 32 Rear shock absorber cover support
8 Cross member No. 5 support 33 Shock absorber upper pipe nut
9 Cross member No. 5 reinforcement assembly 34 Rear floor side member reinforcement
10 Seat mounting pipe nut 35 Rear floor side rear member
11 Seat mounting plate 36 Rear spring stopper bracket
12 Seat anchor 2nd rear bracket 37 Spring sheep
13 Rear floor cross No. 6 member assembly 38 Spring sheep bracket
14 Seat belt washer assembly 39 Pipe mounting plate
15 Seat anchor 3rd rear center bracket assembly 40 Muffler hanger mounting front bar
16 Seat anchor 3rd rear bracket 41 2ad rear seat mounting bracket assembly
17 Center member No. 6 bracket 42 Shock absorber upper pipe nut
18 Nut pipe 43 Rear wheel house plate
19 Rear cross member rear mounting support 44 Rear cross member rear mounting bracket
20 Rear floor center No. 1 member 45 Rear and extension
21 Sub frame mounting bolt 46 Trailing hitch pipe
22 Spare tire mounting plate assembly 47 Rear end plate
23 Seat anchor 3rd rear bracket assembly 48 Towing hook mounting reinforcement
24 Rear floor No. 7 cross member 49 Pipe nut
25 3rd seat belt rear bracket assembly 50 2nd seat mounting member
BODY
DIMENSIONS
GI

PP
BD-2 BODY DIMENSIONS

GENERAL MEASUREMENT METHOD

1. Basically, all measurements in this manual are taken PROJECTED DIMENSIONS
with a tracking gauge.
1. These are the dimensions measured when the
2. When a measuring tape is used, check to be sure there measurement points are projected into the reference
is no elongation, twisting or bending. plane, and are the reference dimensions used for body
alterations.
3. For measuring dimensions, both projected dimension
and actual-measurement dimension are used in this 2. If the length of the tracking gauge probes are
manual. adjustable, make the measurement by lengthening one
probe by the amount equivalent to the difference in
height of the two surfaces.

Height

Projected Dimension
BMCBD6001
BODY DIMENSIONS BD-3

ACTUAL-MEASUREMENT DIMENSIONS MEASUREMENT POINT

1. These dimensions indicate the actual linear distance 1. Measurements should be taken at the hole center.
between measurement points, and are the reference
dimensions for use if a tracking gauge is used for
measurement.

2. Measure by first adjusting both probes to the same

length (A=A')

CAUTION
Check the probes and gauge itself to make sure
there is no free play.

Hole Center
BMCBD6003

Ac
tu
al
ly-
M A'
ea
su
re
d
Di
m
en
sio
n
BMCBD6002
BD-4 BODY DIMENSIONS

FRONT BODY

F
F'

B E

A E'
B'

C D

P A'

N C'
M
K
N' P'
H
M'

K'
H'

G'
BCMBD6101

* These dimensions indicated in this figure are actual-measurement dimensions.

Point symbol A-A' A-B A-B' B-B' C-C' D-A D-B D-A'

Length(mm) 1514.2 646 1601.4 1418 1247.5 852.2 756.5 852.2

Point symbol D-B' D-F D-F' E-E' E-F E-F' F-F' G-G'

Length(mm) 756.5 1254.3 1254.3 1511.4 717.9 1505.5 1158.7 888

Point symbol H-H' H-N' H'-N N-N' K-K' M-M' P-P'

Length(mm) 970 1111.3 1126.8 963.3 1328 1001.4 1526.5

BODY DIMENSIONS BD-5

B,B'
A,A'

C'
BCMBD6102 BCMBD6103 BCMBD6104

Fender and carrier mounting hole Hood hinge mounting hole (ø13) Front shock absorber mounting
(ø9) hole (ø11)

E,E'

F,F'

BCMBD6105 BCMBD6110 BCMBD6111

Cowl top cover mounting hole Joint of front pillar and fender Joint of roof panel and front pillar
(ø7)

H,H'

K,K'

G,G'

BCMBD6108 BCMBD6108A BCMBD6106

Front end module carrier Hood stay mounting hole Tooling hole (ø8)
mounting hole (ø7) (s12x16)

N' P,P'
N M'
M BCMBD6107 BCMBD6106A BCMBD6109

M : Tooling hole (ø8) M' : Transaxle mounting hole (ø16) Tooling hole (ø10)
N : Ground terminal stopper hole N' : Transaxle mounting hole (ø16)
(ø5)
BD-6 BODY DIMENSIONS

SIDE BODY

K
N
C

P
G
D
B
M Q

A E H

BCMBD6201

* These dimensions indicated in this figure are actual-measurement dimensions.

Point symbol A-B A-D A-E A-F B-D B-E B-F D-C

Length(mm) 682.7 1334.4 1255 1237.8 774.7 864.4 999.5 589.1

Point symbol D-G D-H D-E E-G E-H E-F F-H C-K

Length(mm) 1065.3 1112.3 390 1162 1046.8 278.2 1100.2 1159.5

Point symbol C-G C-H G-K G-M G-H H-K H-M H-Q

Length(mm) 757.5 1035.9 756.8 937 457.5 1145.3 1046.5 1822.3

Point symbol K-M M-N M-Q N-P

Length(mm) 761.2 640 874.5 311.9

BODY DIMENSIONS BD-7

BCMBD6202 BCMBD6203 BCMBD6204

Ground terminal mounting hole Tooling hole (ø8) Body check point
(ø6.6)

G
D
F

BCMBD6205 BCMBD6206 BCMBD6207

Front door hinge upper mounting E : Front door hinge lower mounting Rear door hinge upper mounting
hole (ø12) hole (ø12) hole (ø12)
F : Fender mounting hole (ø10)

M
H

BCMBD6208 BCMBD6209 BCMBD6210

Rear door hinge lower mounting Body check point (ø6) Rear door switch mounting hole
hole (ø12) (ø10)

N
Q

BCMBD6211 BCMBD6211A BCMBD6212

Fixed glass moulding mounting Fixed glass moulding mounting Rear bumper mounting hole
upper notch (ø8) lower notch (ø6.2) (8.6x8.6)
BD-8 BODY DIMENSIONS

INTERIOR

T
S T'
S'

H
A H'
A' E'
E N N
K'
F K O
O
F'
B L L
B'
C M P P
C' G
M
D
Q G'
Q'

BCMBD6301

* These dimensions indicated in this figure are actual-measurement dimensions.

Point symbol A-A' B-B' C-C' D-D' E-E' F-F' G-G' H-H'

Length(mm) 1149.7 1487.6 1572.4 1424 1264.2 1440.9 1462 1135.6

Point symbol K-K' L-L' M-M' N-N' O-O' P-P' Q-A Q-E

Length(mm) 1343.5 1520 1290.5 1120.5 1180.4 1498 1245 1193.4

Point symbol S-S' S-T S-T' T-T'

Length(mm) 1158.7 2005.5 2005.5 1081.1

BODY DIMENSIONS BD-9

A,A' B,B' C,C'

BCMBD6302 BCMBD6303 BCMBD6304

Air bag mounting hole (ø6.6) Cowl cross bar mounting hole Front door checker mounting hole
(ø9) (ø11.4)

D,D' E,E'

F,F'
BCMBD6305 BCMBD6306 G,G' BCMBD6307

Wiring mounting hole (8x16) E : Center pillar mounting hole (ø9) Seat belt mounting hole (ø14.5)
F : Seat belt mounting hole (ø15)

K,K'
L,L'
H,H'

BCMBD6308 BCMBD6309 BCMBD6310

Assist handle bracket mounting 2ND seat belt upper mounting 3RD seat belt reel mounting hole
hole (ø6.6) hole (ø15) (ø15)

O,O'

N,N'
M,M'
BCMBD6311 BCMBD6312 BCMBD6313

Seat belt mounting hole (ø15) Assist handle mounting hole 3RD seat belt upper mounting
(ø6.6) hole (ø15)
BD-10 BODY DIMENSIONS

Q'
Q

S,S'

P,P' BCMBD6314 BCMBD6315 BCMBD6111A

3RD seat belt reel mounting hole Front seat rear inner mounting Joint of roof panel and front pillar
(ø15) hole (ø11)

T,T'

BCMBD6407A

Joint of roof quarter and roof

panel
BODY DIMENSIONS BD-11

REAR BODY

A' A
F' F

B' B

C' C

D' D

G' G
E' E

BCMBD6401

* These dimensions indicated in this figure are actual-measurement dimensions.

Point symbol A-A' A-C A-E' A-G A'-G' A-C' B-B' C-C'

Length(mm) 1081.1 592.7 1618.3 1166 1166 592.7 1242.1 1508

Point symbol C-E C-E' D-D' E-E' F-F'

Length(mm) 678.2 1482.7 1256 1152.8 670

BD-12 BODY DIMENSIONS

A,A' C,C'

B,B'

BCMBD6402 BCMBD6403 BCMBD6404

Joint of quarter and roof panel Gas lifter ball joint mounting hole Joint of quarter and panel tail
(ø15) gate

F,F'
E,E'
D,D'

BCMBD6405 BCMBD6406 BCMBD6407

Rear bumper mounting hole Rear bumper mounting hole (ø14) Tail gate hinge mounting hole
(ø18.6) (ø14)

G' G

BCMBD6408

Tail gate striker mounting hole

(ø13)
BODY DIMENSIONS BD-13

UNDER BODY ( PROJECTED DIMENSIONS )

Q P F
M K H C B A
N G D
E

E'
G' D'
N' A'
M' H' C' B'
K'
Q' P' F'

BCMBD6501

* These dimensions indicated in this figure are actual-measurement dimensions.

Point symbol A-A' A-F A-F' B-B' B-E' C-C' D-D' E-E'

Length(mm) 1000 1156.3 1627.6 985 924.7 1010.1 1005.5 601

Point symbol F-F' G-G' G-H G-H' H-H' H-N' K-K' K-P'

Length(mm) 1312 980 1320.3 1659.7 1032 1409 1066 1646.4

Point symbol M-M' M-P M-Q' N-N' P-P' Q-Q'

Length(mm) 1020 868.2 1542 880 1284 1313

BD-14 BODY DIMENSIONS

B,B'

B,B' A,A'

D,D' C,C'
BCMBD6502 BCMBD6503 BCMBD6502A

A : Tooling hole (ø20) C : Side cover mounting hole (ø6.6)

B : Front sub frame front mounting D : Side cover mounting hole (ø9)
hole

F,F'

G,G'

E,E' E,E'
BCMBD6504 BCMBD6505 BCMBD6504A

Front sub frame rear mounting F : Tooling hole (ø6)

hole G : Tooling hole (ø16)

K,K' H,H' M,M'

N,N'
BCMBD6506 BCMBD6506A BCMBD6507

H : Tooling hole (ø25) Rear cross member front Rear cross member rear
K : Hanger tooling hole (ø12) mounting hole (ø20) mounting hole (ø19)

Q,Q' P,P'

N,N'
BCMBD6508 BCMBD6507A

P : Tooling hole (ø25)

Q : Trailer hitch mounting hole
(ø16)
BODY DIMENSIONS BD-15

UNDER BODY

F P Q
H K M
A B C D N
G
E

E'
G' N'
A' B' C' D' M'
H' K'
P' Q'
F'

A B C D E F G H K M N P Q
BCMBD6600

* These dimensions indicated in this figure are projected dimensions.

Point symbol A-A' B-B' C-C' D-D' E-E' F-F' G-G' H-H'

Length(mm) 1000 985 1010.1 1005.5 601 1312 980 1032

Point symbol K-K' M-M' N-N' P-P' Q-Q' O-A O-B O-C

Length(mm) 1066 1020 880 1284 1313 84.6 -57.4 139.7

Point symbol O-D O-E O-F O-G O-H O-K O-M O-N

Length(mm) 146.3 -123.6 -56.3 -56.3 -52 -19.2 22 -43

Point symbol O-P O-Q A-B B-C C-D D-E E-F F-G

Length(mm) 106 106 196.6 237.9 256.8 611.3 375.5 174

Point symbol G-H H-K K-M M-N N-P P-Q

Length(mm) 1320.3 278 296.3 476.7 461.3 149

BD-16 BODY DIMENSIONS

B,B'

B,B' A,A'

D,D' C,C'
BCMBD6502 BCMBD6503 BCMBD6502A

A : Tooling hole (ø20) C : Side cover mounting hole (ø6.6)

B : Front sub frame front mounting D : Side cover mounting hole (ø9)
hole

F,F'

G,G'

E,E' E,E'
BCMBD6504 BCMBD6505 BCMBD6504A

Front sub frame rear mounting F : Tooling hole (ø6)

hole G : Tooling hole (ø16)

K,K' H,H' M,M'

N,N'
BCMBD6506 BCMBD6506A BCMBD6507

H : Tooling hole (ø25) Rear cross member front Rear cross member rear
K : Hanger tooling hole (ø12) mounting hole (ø20) mounting hole (ø19)

Q,Q' P,P'

N,N'
BCMBD6508 BCMBD6507A

P : Tooling hole (ø25)

Q : Trailer hitch mounting hole
(ø16)
BODY PANEL
REPAIR
PROCEDURE GI

PP
BP-2 BODY PANEL REPAIR PROCEDURE

FENDER APRON INNER FRONT PANEL AND FENDER APRON UPPER MEMBER

WELDING POINTS

MIG plug welding

MIG butt welding
MIG lap welding
BCMBP6001

130 mm

MIG plug welding

MIG butt welding
MIG lap welding
BCMBP6002
BODY PANEL REPAIR PROCEDURE BP-3

REMOVAL 2. Drill out all the spotwelds to separate the fender apron
upper member, front side member and shock absorber
NOTE housing panel.
Before repairing, remove Engine and Suspension
Components. NOTE
Refer to the body dimension charts and measure the vehicle When spotwelded portions are not apparent, remove
to determine straightening and alignment requirements. The paint with a rotary wire brush.
body must be returned to its original dimension before you
begin the repair procedure.

BCMBP6201A

BCMBP6101A
3. Measure and mark the vertical cutlines on fender apron
upper member hole edge.
1. Before removing the fender apron upper member,
remove fender apron inner front panel assembly
previously.
130 mm

BCMBP6203A

BCMBP6201

150mm

BCMBP6204A
BP-4 BODY PANEL REPAIR PROCEDURE

4. Cut through the front side member inner and outer at INSTALLATION
cutlines.
1. Transcribe the front side member inner and outer cutline
to the new front side member, cut to length and chamfer
butt end to improve weld surface.

BCMBP6203B

5. Prepare all surfaces to be welded.

BCMBP6206

6. After cutting, apply welding primer.

2. Fit and clamp the front side member inner and outer in
place.

3. Measure each measurement point ( Refer to the BODY

DIMENSIONS) and correct the installation position.

BCMBP6205A

BCMBP6108A
BODY PANEL REPAIR PROCEDURE BP-5

4. MIG but weld all seams. 8. Fit and clamp the fender apron inner front panel inner
and outer in place.
5. Prepare all surfaces to be welded.

BCMBP6201B
BCMBP6202A
9. MIG plug weld all holes.
6. Clean MIG welds with a disc grinder.
10. Prepare all surfaces to be welded.

BCMBP6202B
BCMBP6201C
7. Transcribe the fender apron inner front panel cutline to
the new fender apron inner front panel , cut to length 11. Clean MIG welds with a disc grinder.
and chamfer butt end to improve weld surface.

BCMBP6201D
BCMBP6207
BP-6 BODY PANEL REPAIR PROCEDURE

12. Apply an anti-corrosion agent as required.(Refer to the 19. After completing body repairs, carefully apply under
CORROSION PROTECTION) coating to the fender apron complete panel assembly
(Refer to the CORROSION PROTECTION).
13. Prepare the exterior surfaces for priming using wax
and grease remover. 20. In order to improve corrosion resistance, if necessary,
apply an under body anti-corrosion agent to the panel
14. Apply metal conditioner and water rinse. which is repaired or replaced (Refer to the CORROSION
PROTECTION).
15. Apply conversation coating and water rinse.

16. Apply the two-part epoxy primer.

BCMBP6204B

cf) Repeat on the right side, but note that the engine
BCMBP6201E mounting bracket should be additionally removed as
shown in the picture when removing fender apron inner
17. Apply the correct seam sealer to all joints carefully front panel.
(Refer to the BODY SEALING LOCATION).

18. Reprime over the seam sealer to complete the repair.

BCMBP6208

BCMBP6201F
BODY PANEL REPAIR PROCEDURE BP-7

FRONT SIDE MEMBER

WELDING POINTS

10mm
140mm

MIG butt welding

MIG lap welding
BCMBP6005

10mm

40mm

MIG butt welding

MIG lap welding
BCMBP6006
BP-8 BODY PANEL REPAIR PROCEDURE

REMOVAL (LH) 3. Drill out all the spotwelds to separate front side member
outer front extension from front side member.
1. Before cutting the front side member LH, remove the
battery mounting bracket.
NOTE
When spotwelds portion are not apparent, remove paint
with a rotary wire brush.

BCMBP6102

2. Measure mark the vertical cutlines on front side BCMBP6103B

member tooling hole edge.

140mm BCMBP6104B
BCMBP6103A

10mm
BCMBP6105A
BCMBP6104A
BODY PANEL REPAIR PROCEDURE BP-9

4. Cut through the front side member inner and outer at 7. After cutting, apply the welding primer.
culines.

5. Prepare all surfaces to be welded.

NOTE
Take care not to cut through front side member inner
reinforcement.

BCMBP6106B

BCMBP6103C

BCMBP6104C

6. Clean MIG welds with a disc grinder.

BCMBP6106A
BP-10 BODY PANEL REPAIR PROCEDURE

INSTALLATION (LH) 5. MIG plug weld all holes.

1. Transcribe the front side member inner and outer cutline

to the new front side member, cut to length and chamfer
butt end to improve weld surface.

2. Drill 6mm holes in new front side member for MIG plug
welding.

BCMBP6103D

6. Clean MIG welds with a disc grinder.

NOTE
Be careful not to grind welded portion too much.
BCMBP6107
The internal parts will be stronger if the weld traces
are not ground.
3. Temporarily install new parts in place.

4. Measure each measurement point.(Refer to the BODY

DIMENSIONS) and correct the installation position.

BCMBP6103E

7. Temporarily install new battery mounting bracket in

place.

BCMBP6108B
8. MIG plug weld all holes.

BCMBP6102A
BODY PANEL REPAIR PROCEDURE BP-11

9. Clean MIG welds with a disc grinder. 16. Apply the correct seam sealer to all joints carefully
(Refer to the BODY SEALING LOCATION).
10. Prepare all surfaces to be welded.
17. Reprime over the seam sealer to complete the repair.

BCMBP6102B
BCMBP6102D
11. Apply an anti-corrosion agent as required.
(Refer to the CORROSION PROTECTION)

12. Prepare the exterior surfaces for priming using wax

and grease remover.

13. Apply metal conditioner and water rinse.

14. Apply conversation coating and water rinse.

15. Apply the two-part epoxy primer.

BCMBP6102C
BP-12 BODY PANEL REPAIR PROCEDURE

REMOVAL (RH) 3. Cut through the front side member inner and outer at
cutlines.
1. Measure mark the vertical cutlines on front side
member tooling hole edge. 4. Prepare all surfaces to be welded.

40mm
BCMBP6110A
BCMBP6110B

5. Clean MIG welds with a disc grinder.

10mm
BCMBP6112A

2. Drill out all the spotwelds to separate front side member

BCMBP6113A
outer front extension from front side member.

NOTE 6. Apply welding, apply welding primer.

When spotweld portions are not apparent. remove paint
with a rotary wire brush.

BCMBP6113B

BCMBP6112B
BODY PANEL REPAIR PROCEDURE BP-13

INSTALLATION (RH) 5. MIG plug weld all holes and MIG butt weld all seams.

1. Transcribe the front side member inner and outer cutline

to the new front side member, cut to length and chamfer
butt end to improve weld surface.

2. Drill 6mm holes in new front side member for MIG plug
welding.

BCMBP6111A

6. Clean MIG welds with a disc grinder.

BCMBP6114

3. Fit and clamp the front side member inner and outer in
place.

4. Measure each measurement point.(Refer to the BODY

DIMENSIONS) and correct the installation position.

BCMBP6110C

BCMBP6115A
BP-14 BODY PANEL REPAIR PROCEDURE

7. Apply the too-part epoxy primer to the interior of the

front side member.

8. Apply an anti-corrosion agent as required(Refer to the

CORROSION PROTECTION).

9. Prepare the exterior surfaces for priming using wax

and grease remover.

10. Apply metal conditioner and water rinse.

11. Apply conversion coating and water rinse.

12. Apply the two-part epoxy primer.

13. Apply the correct seam sealer to all joints carefully

(Refer to the BODY SEALING LOCATIONS).

14. Reprime over the seam sealer to complete the repair.

BCMBP6110D
BODY PANEL REPAIR PROCEDURE BP-15

FRONT PILLAR

WELDING POINTS

120mm
50mm
50mm

100mm 20mm

MIG plug welding

MIG butt welding
MIG lap welding
BCMBP6007
BP-16 BODY PANEL REPAIR PROCEDURE

REMOVAL 3. Measure and mark the each cutline on the front outer
pillar at 120mm from side outer panel angular point as
1. Drill out all the spotwelds and cut all laser welds to indicated the illustration.
separate cowl side upper outer panel from front pillar
outer lower reinforcement, shock absorber housing
gusset and fender apron upper outer panel.

NOTE
When spotweld portions are not apparent, remove paint
with a rotary wire brush.
120mm

BCMBP6303A

4. Measure and mark he cutline on front side sill outer

panel as shown in the illustration.

BCMBP6301

2. Before cutting front pillar, be sure to support roof panel.

100mm 20mm
BCMBP6305A

5. Remove spotwelds and lap welds attaching cowl cross

member bracket to remove side inner panel.

BCMBP6302A

BCMBP6308
BODY PANEL REPAIR PROCEDURE BP-17

6. Cut front pillar through each cutline, tasking care not 10. Cut the side sill inner panel vertical cutting line end
to damage the other panel the as illustration. remove the front pillar.

7. Before cutting the front side sill outer panel, make a 11. Straighten all flanges as necessary, prepare all
rough cut the side sill outer panel only. surfaces to be welded.

NOTE
When cutting the front side sill outer panel, be careful
not to cut side outer reinforcement.

BCMBP6312A
100mm
12. After removing, apply the welding primer.
Front panel outer
panel section
BCMBP6304A

8. Cut the side outer panel as shown in the illustration.

BCMBP6312B

BCMBP6307A

9. Cut the side outer reinforcement as shown in the

illustration.

BCMBP6309A
BP-18 BODY PANEL REPAIR PROCEDURE

INSTALLATION 6. Fit and clamp the new side inner panel in panel in place
for welding.
1. Transcribe the cutline to the new side inner panel to
length and chamfer butt end o improve weld surface. 7. MIG plug weld all holes and MIG butt weld the seams.

2. Transcribe the cutline to new side outer reinforcement

and new front pillar, adding 30mm overlap to end and
cut to length.

3. Drill 6mm holes outer panel flanges in production

location for attachment to other panal.

BCMBP6309B

8. Temporarily install front pillar outer panel in place.

9. Measure and each measurement point (Refer to the

BODY DIMENSIONS) and correct the installation
position.
BCMBP6315

10. If necessary, make temporary welds, and then check

4. Transcribe the cutline to new side inner panel and new to confirm that the closing and fit for windshield glass,
front, adding 30mm overlap to end and cut to length. door and fender are correct.

5. Drill 6mm holes in the side inner panel in place for 11. MIG butt weld front pillar outer panel and side sill outer
welding.. reinforcement seams.

BCMBP6316 BCMBP6317A
BODY PANEL REPAIR PROCEDURE BP-19

12. Reattach the cut away front pillar outer panel section,
then MIG butt weld.

BCMBP6304B

13. Clean and prepare all welds, remove all residue.

14. Apply body filler to joints and sand as needed.

15. Apply the two-part epoxy primer to the interior of the

front pillar.

BCMBP6308A
BP-20 BODY PANEL REPAIR PROCEDURE

CENTER PILLAR

WELDING POINTS

150mm

100mm

B C

B
C

30mm 100mm 100mm 115mm

MIG plug welding

MIG butt welding
BCMBP6008
BODY PANEL REPAIR PROCEDURE BP-21

REMOVAL 4. Before cutting center pillar, be sure to support roof

panel.
1. Measure and mark the horizontal cutting line on center
pillar outer panel as indicated in the illustration.

150mm

100mm

BCMBP6501A

BCMBP6502A 5. Drill out all spotwelds attaching the center outer pillar
2. Measure and mark the vertical cutline on side sill outer to the body to remove center outer pillar.
panel 30mm from the front door step trim mounting
hole.

BCMBP6503A

30mm 100mm 6. Cut through center outer pillar and side sill outer panel
BCMBP6504A at cutlines.
3. Measure and mark the vertical cutline on side sill outer
panel 115mm from the rear door step trim mounting
NOTE
hole.
When cutting side sill outer panel take care not to cut
through mating flanges or side outer reinforcement.

100mm 115mm
BCMBP6505A
BCMBP6502B
BP-22 BODY PANEL REPAIR PROCEDURE

7. After cutting side outer panel (center pillar outer & side 9. Determine if the side outer reinforcement is damaged
sill), cut the center pillar outer reinforcement and center and needs to be replaced. If replacing is necessary,
pillar inner panel. mark out the damaged portion of the reinforcement.
Cut at cutlines and remove damaged portion.

10. Straighten all flanges as necessary.

11. Prepare all surfaces to be welded.

12. After removing, apply the welding primer.

BCMBP6509A

BCMBP6512A

BCMBP6508A

8. Remove the center pillar.

NOTE
When cutting center inner pillar, be careful not to cut
front seat belt mounting upper bracket.

Center pillar
outer panel

Side outer panel

Side inner panel

BMGBP6411A
BODY PANEL REPAIR PROCEDURE BP-23

INSTALLATION 5. MIG butt weld all seams in center inner pillar and sill
side outer reinforcement as shown in the illustration.
1. In order to install center inner pillar drill out all spotwelds
attaching the roof side outer rail to center inner pillar to
separate them.

BCMBP6507A

BCMBP6513

2. Transcribe the center outer pillar cutlines to the new

center outer pillar, adding 30mm overlap at center lower
pillar ends.

3. Cut and chamfer butt end to improve weld surface.

4. Drill 6mm holes in overlap area and along outer panel

flanges.

BCMBP6502C

BCMBP6514
BP-24 BODY PANEL REPAIR PROCEDURE

6. Transcribe the cutting line dimensions to the new side 10. Screw center pillar in place.
sill outer reinforcement, adding 30mm overlap to each
end and cut to length. 11. Measure and each measurement point (Refer to the
BODY DIMENSIONS) and correct the installation
7. Drill 8mm holes in overlap areas on each end of new position.
side sill outer reinforcement and clamp the new side
sill outer reinforcement in place.

8. MIG plug weld all holes and MIG butt weld seams.

NOTE
The reinforcement will be stronger if the weld traces
are not ground.

BMCBP6074

12. Check the fit of the front and rear doors.

13. Reinstall center outer pillar and screw in place.

14. MIG plug weld all holes and MIG butt weld all seams.

BCMBP6514
15. Clean and prepare all welds, and remove all residue.

9. Temporarily install new center outer panel in place.

BCMBP6509B

BCMBP6501B
16. Apply body filler to the outer center pillar seam. Sand
and finish.

17. Apply the two-part epoxy primer to the interior of the

center pillar.

18. Apply an anti-corrosion agent to the welded parts and

interior of the center pillar (Refer to the CORROSION
PROTECTION).

19. Prepare exterior surfaces for priming, using wax and

grease remover.
BODY PANEL REPAIR PROCEDURE BP-25

20. Apply metal conditioner and water rinse.

21. Apply conversion coating and water rinse.

22. Apply the two-part epoxy primer.

23. Apply the correct seam sealer to all joints carefully

(Refer to the BODY SEALING LOCATIONS).

24. Reprime over the seam sealer to complete the repair.

BCMBP6507B

BCMBP6504B
BP-26 BODY PANEL REPAIR PROCEDURE

SIDE SILL PANEL

WELDING POINTS

MIG plug welding

MIG butt welding
BCMBP6009

REMOVAL
1. Measure and mark vertical cutting line from the rear 2. At the front center pillar, measure and mark horizontal
door step trim mounting hole on the rear side sill outer cutting lines from the door hinge mounting hole on the
panel. side sill outer panel as shown in the illustration.

30mm
BCMBP6012 BCMBP6013 BCMBP6014
BODY PANEL REPAIR PROCEDURE BP-27

3. Cut the side sill outer panel along cutlines, be careful 6. Clean cutting portions with a disc grinder.
not to cut mating flanges.

BCMBP6402A
BCMBP6401A
7. After grinding, apply welding primer.
4. Drill out all spotwelds, attaching the side sill outer panel
to side sill outer reinforcement.

BCMBP6402B

BCMBP6401B

5. Remove the side sill outer panel.

BCMBP6402
BP-28 BODY PANEL REPAIR PROCEDURE

INSTLLATION 5. Before welding the side sill outer panel, apply the two-
part epoxy primer and anti-corrosion agent to the
1. Transcribe cutline dimension to side sill outer panel, welded parts.
adding 30mm overlap to rear end and cut to length.
NOTE
2. Drill 6mm holes in overlap area on rear end and along
front flange.
The reinforcement will be stronger if the weld traces
are notground.

BCMBP6401C
BCMBP6401E

3. Fit and clamp the side sill outer reinforcement in place.

4. MIG plug weld all holes and MIG butt weld seams.

BCMBP6401D
BODY PANEL REPAIR PROCEDURE BP-29

QUARTER PANEL

WELDING POINTS

A B
210mm

250mm

70mm

MIG plug welding

MIG butt welding
BCMBP6010
BP-30 BODY PANEL REPAIR PROCEDURE

REMOVAL 3. Cut the quarter outer panel at cutlines and remove the
quarter outer panel as illustration.
1. Depending on the extend of damage, measure and
mark cutlines on the quarter outer panel as indicated
NOTE
in the illustration.
When cutting the quarter outer panel, be careful not to
cut side inner panel.

BCMBP6134

BCMBP6604
2. Drill out all attaching spotwelds on the quarter outer
panel, including the seam around the door lip opening.
4. Prepare all surfaces to be welded.

5. After removing, apply the welding primer.

BCMBP6602A

BCMBP6604A

BCMBP6603A
BODY PANEL REPAIR PROCEDURE BP-31

INSTALLATION 6. Apply body filler to the welded seam. Sand and finish.
Apply the two-part epoxy primer to the interior of the
1. Transcribe the cutline to the new quarter outer panel, quarter outer panel.
adding 30mm for overlap at the old joint.

2. Drill out 6mm holes in overlap areas and along upper

and lower flanges of the new quarter outer panel for
MIG plug welding.

PRO-1250

7. Apply an anti-corrosion agent to the welded parts and

interior of the quarter outer panel (Refer to the
CORROSION PROTECTION).
BCMBP6605

8. Prepare exterior surfaces for priming, using wax and

3. Fit and clamp the quarter outer panel place. grease remover.

4. MIG plug weld all holes and MIG butt weld seams. At 9. Apply metal conditioner and water rinse.
the wheel well the edge must be crimped over the wheel
housing. This joint may be welded after crimping or 10. Apply conversion coating and water rinse.
applying a bead of adhesive which may be applied to
the joint before or after crimping. 11. Apply the two-part epoxy primer.

5. Clean and prepare all welds, remove all residue.

PRO-1260

BCMBP6601A
BP-32 BODY PANEL REPAIR PROCEDURE

12. Apply the correct seam sealers to all joints.

13. Reprime over the seam sealer to complete the repair.

PRO-1270

14. In order to improve corrosion resistance, if necessary,

apply an under body anti-corrosion agent to the wheel
well (Refer to the CORROSION PROTECTION).

PRO-1490
BODY PANEL REPAIR PROCEDURE BP-33

BACK PANEL AND REAR SIDE MEMBER

WELDING POINTS

MIG plug welding

MIG butt welding
BCMBP6011

REMOVAL
1. Drill out all attaching spotwelds and laser welds on the 2. Remove the back panel.
back panel, including the seam around trunk lid panel.

BCMBP6701A BCMBP6702
BP-34 BODY PANEL REPAIR PROCEDURE

3. Depending on the extent of damage, if the right side 5. Remove the rear floor side member by drilling out all
member is to be replaced it should be measured and attaching spotwelds.
marked 40mm from the rear floor side member tooling
hole center. 6. Prepare all surfaces to be welded.

NOTE
The flowing procedure illustrates a repair for the right
rear floor side member. The procedure may also be
applied the left rear floor side member.

40mm

BCMBP6704A

BCMBP6703A

4. Cut through rear floor side member at cutline being

careful not to cut rear floor side member reinforcement.

BCMBP6705A

BCMBP6703B
BODY PANEL REPAIR PROCEDURE BP-35

INSTALLATION 6. Apply an anti-corrosion to the interior of the rear floor

side member
1. Transcribe the cutline to the new rear floor side member. (Refer to the CORROSION PROTECTION).
Cut at line and drill out the spotwelds attaching the
reinforcement and separate it. 7. Prepare exterior surfaces for priming, using wax and
grease remover.

8. Apply metal conditioner and water rinse.

9. Apply conversion coating and water rinse.

10. Apply the two-part epoxy primer.

BCMBP6707

2. Fit and clamp the new rear floor side member in place
for welding.
Measure to ensure dimensions are accurate as given
in the body dimension charts.

3. MIG plug weld at the holes and MIG butt weld the PRO-1550
seam in the side member.
11. Apply the correct seam sealer to all joints (Refer to
4. Clean and prepare all surfaces to be welded and remove the BODY SEALING LOCATIONS).
all residue.
12. Reprime over the seam sealer to complete the repair.
5. Apply the two-part epoxy primer to the interior of the
rear floor side member.

PRO-1560

BCMBP6703C
BP-36 BODY PANEL REPAIR PROCEDURE

13. After completing body repairs, carefully apply under 16. Fit and clamp the new back panel in place welding.
coating to the under body (Refer to the CORROSION
PROTECTION). 17. Measure to ensure dimensions are accurate as given
in the body dimension charts.
14. In order to improve corrosion resistance, if necessary,
apply an under body anti-corrosion agent to the panel 18. MIG plug weld all holes.
which is repaired or replaced (Refer to the CORROSION
PROTECTION).

BCMBP6701B

PRO-1490 19. Clean and prepare all surfaces to be welded and remove
all residue.
15. Transcribe the cutline to the new back panel.
20. Apply the two-part epoxy primer to the interior of the
rear floor side member.

21. Apply an anti-corrosion to the interior of the rear floor

side member
(Refer to the CORROSION PROTECTION).

22. Prepare exterior surfaces for priming, using wax and

grease remover.

23. Apply metal conditioner and water rinse.

24. Apply the two-part epoxy primer.

BCMBP6708

PRO-1550
BODY SEALING
LOCATIONS
GI

PP
BS-2 BODY SEALING LOCATIONS

FLOOR

A N
D F
K

C H

E M
B G P

Q R

BCMBS6200

A B

BCMBS6202 BCMBS6203

C D

BCMBS6201 BCMBS6205
BODY SEALING LOCATIONS BS-3

E F

BCMBS6204 BCMBS6207

G H

BCMBS6208 BCMBS6206

K M

BCMBS6210 BCMBS6209

N P

BCMBS6211 BCMBS6212
BS-4 BODY SEALING LOCATIONS

Q R

BCMBS6301 BCMBS6303
BODY SEALING LOCATIONS BS-5

UPPER AND SIDE BODY

C
A

B D

H
K
G

BCMBS6100

A B

BCMBS6102 BCMBS6101
BS-6 BODY SEALING LOCATIONS

C D

BCMBS6104 BCMBS6103

E F

BCMBS6105 BCMBS6106

G H

BCMBS6109 BCMBS6110

K M

BCMBS6304 BCMBS6307
BODY SEALING LOCATIONS BS-7

BCMBS6309
BS-8 BODY SEALING LOCATIONS

UNDER BODY

D C B A

BCMBS6400

A B

BCMBS6401 BCMBS6402

C D

BCMBS6403 BCMBS6404
CORROSION
PROTECTION
GI

PP
CP-2 CORROSION PROTECTION

ZINC-GALVANIZED STEEL PANELS

Becavanized steel panel has excellent resistance, it tis used in areas which have a high possibility of painting deficiency
below.

132
116
148

131 138

84
118 134

83
82

80
95
79 81
119
137 92
77 94
76 78
74
89 91
100 90
124 71 75 87
72 88
102 99
97 85
101
44
65 68
41 57 62
61 66
98
60
43
59

34 145
40
37 55
58
36 29
38 30
25 53
11 54 64
32 13 6
63
28
21
27 16
12
20
33 17 4
26 14 18
19 24 1 156
31 3
23
22
2 151

146

BCMBC6002
CORROSION PROTECTION CP-3

1. Radiator support upper member 81. Rear floor center extension

ZINC-PHOSPHATE COAT & CATIONIC ELECTRODEPOSITION PRIMER

In order to improve the adhesion of the paint coat on the steel panel, and also to improve the corrosion resistance, the entire
body is coated with a film of Zinc-phosphate and a cationic electrodeposition primer.

Cationic electrodeposition primer

Zinc-phosphate film

Body steel panel

BMCCP6020
CORROSION PROTECTION CP-5

ANTIVIBRATION PADS-LOCATION & SECTION

B C D

A A F

C
B E

BCMCP6100

Dash panel Dash reinforcement

Center floor No.1 pad

Dash panel plug Dash panel plug

Center floor pad

Dash lower member

Dash lower member reinforcement Center floor reinforcement

A-A BCMCP6101

Center floor panel Center floor panel

Center floor side

Center floor side member
member

Center floor Center floor rear

No.5 pad No.2 pad
Center floor side
reinforcement Center floor
center rear pad
Center upper
reinforcement

Center floor Center floor rear

reinforcement reinforcement

B-B BCMCP6102 C-C BCMCP6103

CP-6 CORROSION PROTECTION

Side outer panel

Rear floor panel

Rear floor side Quarter inner

member Quarter
lower panel
Rear floor outer pad
No.2 pad Rear wheel house plate
Rear wheel
house panel

Rear floor side

member

Rear side No.1 pad

Rear floor side

Rear floor member
Rear floor rear pad
front pad reinforcement
2nd seat mounting
member

Rear floor panel

Rear floor
panel

E-E BCMCP6105

Rear floor side member

Rear side No.3 pad Rear floor panel

Rear floor
No.2 pad

D-D BCMCP6104 F-F BCMCP6106

CORROSION PROTECTION CP-7

120 mm

45 mm
G

60 mm
120 mm 90 mm

15 mm
G
Except for
sunroof

[ ROOF ]

54 mm
143 mm

H
42 mm

[ FENDER ]

BCMCP6200

Roof panel

Fender panel
45 mm

Pad

G-G BCMCP6201 H-H BCMCP6202

CP-8 CORROSION PROTECTION

ATTACHMENT OF ANTIVIBRATION PADS

Antivibration pads are attached to the upper surface of the floor and at the interior side of the dash panel in order to absorb
vibrations and shut out exhaust gas heat. If these antivibration pads are peeled off in the course of replacement or repair of
a welded panel, cut and attach replacement material (in the shape shown in the figure).

BCMCP6100A

1. Heat the "antivibration pad" with a blow drier to soften 2. Align the antivibration pad layer in the position where
it. it is to be installed, and then press it down with a roller
or a block of wood so that it adheres well.

NOTE
An infrared lamp can also be used to heat both the
antivibration pad layer and the body panels(be sure to
wear gloves).

BMCCP6041

BMCCP6042
CORROSION PROTECTION CP-9

UNDER BODY COAT

In order to provide corrosion, stone chipping and vibration resistance, under body coat is applied to the under sides of the
floor and wheel house.
Therefore, when such panel is replaced or repaired, apply under body coat to that part.

FLOOR

B
A A

Under body coating (Thickness : 0.8 mm , :1.0 mm )

BCMCP6300

Dash panel Center floor panel Side sill inner panel

Center floor panel

Front side rear Center floor front cross Center floor rear
lower member outer member cross panel Center floor side member

A-A BCMCP6301 B-B BCMCP6302

CP-10 CORROSION PROTECTION

SIDE BODY

C A B

Under body coating (Thickness : 0.8 mm , :1.0 mm )

BCMCP6400

Front shock absorber

housing cover
Quarter inner
65 mm
lower panel

Wheel house
Front shock absorber inner panel
housing panel

Front side inner

member Front side
outer member Rear floor
side member
A-A BCMCP6401 B-B BCMCP6402

C [LH] BCMCP6403 C [RH] BCMCP6404

CORROSION PROTECTION CP-11

CAVITY WAX INJECTION

In order to provide greater corrosion resistance, cavity wax injection has been performed for the lower areas of the vehicle,
such as the sidemember, the side sill and the inside of other panels which are a hollow construction.
When replacing these parts, be such to apply cavity wax to the appropriate areas of the new parts.

300 mm
250 mm

B B

A
404.5 mm 400 mm

Cavity wax injection (Thickness 40 - 50 )

BCMCP6500

Side outer panel

Side inner panel
Quarter inner panel

Side sill outer

reinforcement Side outer panel
50 mm

25 mm
20 m
Side sill
m
inner panel

A-A BCMCP6501 B-B BCMCP6502

CP-12 CORROSION PROTECTION

Wax injection holes Wax injection holes

100 mm
100 mm

Wax injection Wax injection

holes holes
300 mm

300 mm
[ HOOD ]
300 mm 300 mm

B
150 mm

Wax injection holes

[ TAIL GATE ]

Wax injection must be done through access holess marked.

Cavity wax injection (Thickness 40 - 50 )
BCMCP6600

Tail gate Tail gate

Hood outer panel inner panel outer panel

m
m
50
35 mm

Hood inner panel

A-A BCMCP6601 B-B BCMCP6602

CORROSION PROTECTION CP-13

A A1

130 mm
130 mm

130 mm

A A1

Wax injection holes

Wax injection must be done through access holess marked.

Cavity wax injection (Thickness 40 - 50 )

BCMCP6700

Door outer panel

Door inner panel

60 mm

A - A' / A1 - A1' BCMCP6701

CP-14 CORROSION PROTECTION

UNDER BODY ANTI-CORROSION AGENT

The undersides of the floor and wheel house are undercoated to provide greater corrosion resistance. Therefore, when such
panel is replaced or repaired, apply under body anti-corrosion agent to that part.

NOTE
Do not apply the under body anti-corrosion agent to come in contact with tires, muffler and exhaust pipe.

Under body coating (Thickness : 0.8 mm , :1.0 mm )

BCMCP6800
BODY
MODIFICATION
TOOLS GI

PP
BT-2 BODY MODIFICATION TOOLS

BODY MODIFICATION TOOLS

MODIFICATION TOOLS
Name Used for Figure

A3EB3501

Frame straightener Modify twisted or bent body

A3EB3502

A3EB3503

Port power Push out, stretch, pull in damaged area

A3EB3504

Body puller Stretch damaged area

A3EB3505
BODY MODIFICATION TOOLS BT-3

CUT AND DISASSEMBLY TOOLS

Name Used for Figure

Air saw Cut a panel

A3EB3506

Cut or bend a panel, cut and

Air chisel
disassemble spot welded area

A3EB3507

Rotary cutter Cut a panel

A3EB3508

Hand saw and

Cut a panel
metal scissors

A3EB3509

Fix a spot cutter or drill to cut or

Air drill disassembly spot welding area, to
finish a hole

A3EB3510

Spot cutter Cut and disassemble spot welded area

A3EB3511
BT-4 BODY MODIFICATION TOOLS

ASSEMBLY TOOLS
Name Used for Figure

Vice pliers Fix a panel or area to weld

A3EB3512

Finish contact area of flange and finish

Air bench
a hole for plug welding

A3EB3513

Quick bench Finish a hole for plug welding

A3EB3514

Flanging tool Finish contact area of flange

A3EB3515

MEASUREMENT TOOLS
Name Used for Figure

Centering gauge Measure distortion of body and frame

A3EB3516

Tracking gauge Measure body and frame

A3EB3517
BODY MODIFICATION TOOLS BT-5

WELDING MACHINE
Name Used for Figure

Gas welding machine Cut a panel

A3EB3518

Spot welding machine Weld a panel

A3EB3519

Carbon arc welding

Weld a panel
machine

A3EB3520

Stretch a panel, weld a stud bolt to fix

Stud welding machine
front window mold clip

A3EB3521
BT-6 BODY MODIFICATION TOOLS

BUFFING AND GRINDING TOOLS

Name Used for Figure

Disk grinder Buff

A3EB3522

Disk sander Buff

A3EB3523

Belt sander Buff paints

A3EB3524

Small sized grinder Buff paints or smooth finishing

A3EB3525

Grind rough area of puttee assembled

Double action sander
area

A3EB3526

Grind rough area of puttee assembled

Orbital sander(short)
area

A3EB3527
BODY MODIFICATION TOOLS BT-7

Name Used for Figure

Orbital sander(long) Used for puttee grinding of wide area

A3EB3528

Grind touch up area, uneven area of a

Flexible file
panel

A3EB3529

Surform tool Buff rough area of puttee area

A3EB3506
A3EB3530

Hand file Grind body puttee, pulley, finish puttee

A3EB3531
BT-8 BODY MODIFICATION TOOLS

HANDHELD TOOLS
Name Used for Figure

Body hammer and dolly -

A3EB3532

Punch a hole in the middle of a spot

Center punch
welding area

A3EB3533

Plane chisel Cut and disassemble a panel

A3EB3534

Weight hammer Used when greater force is required

A3EB3535

Bowl pin hammer Used when smaller force is required

A3EB3536

Used for an area where not reached by

Spoon
hand

A3EB3537
BODY MODIFICATION TOOLS BT-9

Name Used for Figure

Bend rough body line damaged or sheet

Body chisel
metal etc.

A3EB3538

Remove paints, rust, slag on welded

Wire brush
area which are hard to recognize

A3EB3539

REPAIR TOOLS SET

Name Used for Figure

Window tool set Repair window collar

A3EB3540

Repair tool set for

Repair plastic parts
plastics

A3EB3541
PLASTIC PARTS

PP
PP-2 PLASTIC PARTS

POLYPROPYLENE(PP) BUMPER
REPAIRABILITY
The three types of damaged bumpers shown below can be
repaired. Because of cost and quality considerations,
bumpers with more damage may be repaired, but replacing
the bumper is encouraged.

1. If a hole on a bumper is less than 2 in.(50 mm).

A3EB3601

2. If a crack on a bumper is less than 4 in.(100 mm).

A3EB3602

3. If a crack on bumper sectionis [A] is less than 4 in.

(100 mm) (less than half of the bumper height).

Bumper height Crack on section [A]

A3EB3603
PLASTIC PARTS PP-3

BUMPER REPAIR PROCEDURE

Surface of Surface of Remove paint.

bumper is not bumper is
visible. visible.
Sand damaged area smooth.

Apply aluminum tape on the rear

side of bumper. Replace damaged bumper with a new
bumper.
Apply primer for polypropylene over
bumper surface.
Weld damaged area.

Sand damaged area with a rough sandpaper.

Clean and degrease damaged area(use TCE de-oil material).

Apply primer for polypropylene over damaged area.

Apply solvent over damaged area.

Spray primer surface over bumper and let dry.

Sand surface of bumper with sandpaper.

Clean and degrease with TCE de-oil material.

Wipe the surface of bumper with a tack cloth.

Paint bumper with a paint of the same color and let dry.
VQPP001
PP-4 PLASTIC PARTS

REPAIR METHOD FOR PP BUMPER

Damage to the bumper that reaches the surface of the polyporpylene cannot be fixed just by painting. Use the repair
methods shown below to repair damage that reaches the surface of the polypropylene.

Hole Crack Scar

B C D
A

A' B' C' D'

Section B-B'
Section A-A' 1 Section D-D'
Section C-C'
2
3

1 Upper layer (coating) 2 Primer surface layer

3 Primer layer 4 Polypropylene layer

VQPP002

1. Rough cut the damaged area 45 using a knife and then sand the angle smooth.

A-A' Section D-D'

Cut with a knife. Section B-B' Cut with knife.
C-C'

Surface of polypropylene

Make an angle with a sander .

Make an angle with a sander

Angle of 45 is required for accumulation of polypropylene welding rod.

VQPP003
PLASTIC PARTS PP-5

2. Welding damaged area

a) To repair cracked area, melt the area using a heat gun and attachment.

Heat gun
Melt the surface using a heat gun.

Apply on surface

Surface of polypropylene Section view after melt

VQPP004

b) To repair a hole, remove oil from the damaged area and apply aluminum tape to the rear side of the damaged area.

Section A-A’
Remove oil.

Apply aluminum tape on the rear side of the damaged area.

VQPP005

3. Melt polypropylene welding rod using a heat gun and fill in the cracked area.

A-A’
Section B-B’ Polypropylene
C-C’ welding rod

Polypropylene
Melt here. welding rod

Melt here
VQPP006

NOTE
• Heat and melt the area indicated.
• Melt the welding rod carefully so that it does not over-melt. If the welding rod over-melts like jelly, the welding
strength will deteriorate.
• Use the heat gun 0.4~0.8 in.(10~20 mm) away from the repair area to be welded.
Welding rod should not move until the welded area is cooled.

Section A-A’
Polypropylene welding rod Polypropylene welding rod

Surface of
polypropylene

Tape Plane view

VQPP007
PP-6 PLASTIC PARTS

4. Grind polypropylene surface carefully. It melts easily due to the heat generated by friction. If melted, remove that area.
Also, grind the area where solvent is to be applied.

Area to apply solvent

Do not grind continuously. Paint

Grind painted area and rough surface.

VQPP008

5. Apply polypropylene primer evenly with a brush over an area wider than the area to be repaired.
Dry it at 20 C (68 F) for more than 10 minutes.

Apply primer wider than the area to repair.

Polypropylene primer
VQPP009

6. Mix main filler material and hardener at a ratio depending on paint specifications. Mix filler material and apply over the
damaged area.

NOTE
• Mix main filler material and hardener so that no bubbles are made.
• Work immediately after mixing filler material because the filler material hardens quickly(in about 5 minutes).
• Dry it at 20 C (68 F) for about 30 minutes before sanding.

Filler material Do not allow bubbles to be created.

Weld Surface of polypropylene

VQPP010

• Filler material consists of two types of epoxy.

When the filler material hardens, you will have a desirable finish with flexibility like polypropylene.
• Use only filler material designed for use on polypropylene bumpers.
PLASTIC PARTS PP-7

7. Sand the damaged area with sandpaper using #180~#240 grit paper.

NOTE
• The surface will not be even if excessive force is applied during sanding.
• If there is fuzz in the damaged area, heat it a little bit with a heater gun and melt it.

8. Degrease the painted surface.

VQPP011

9. Mix polypropylene primer and hardener at a ratio depending on paint specifications.

Spray polypropylene primer on the surface of the damaged area and the bumper.

Polypropylene primer Primer hardener

Use the primer within 16 hours after it is mixed.

VQPP012

10. Apply polypropylene primer.

NOTE
Use only water to clean after applying polypropylene primer. Solvent, if used, will melt the primer.

11. Lightly sand the sprayed area using a primer a sandpaper(#400~#600).

The polypropylene surface should not be exposed.(Either wet sanding or dry sanding is all right.)

12. Use agent(TCE(Tri Chloro Ethane) degreasing material) to remove any grease or oil, and wipe the finished surface of the
bumper quickly with a clean cloth.

NOTE
• The painting method for the polypropylene bumper is the same used to paint the urethane bumper.
• Therefore, use urethane primer only on urethane bumpers and polypropylene primer on polypropylene bumpers.

13. Air dry at 20 C(68 F) for about 8 hours, or dry in 60 C(140 F) for about 2 hours.
(Since drying time varies according to the type of paint used, follow paint manufacturers directions for drying times.)

NOTE
Air dry if possible. Forced drying may create air bubbles on the top layer.

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