Mazda 6 Body Shop

3525-1U-12L(INDEX).
fm 1
2014-present
CONTENTS
Title
Bodyshop
Manual
FOREWORD
This bodyshop manual is intended for
use by technicians of Authorized Mazda
Dealers to help them service and repair
Mazda vehicles. It can also be useful to
owners and operators of Mazda vehicles in
performing limited repair and maintenance
on Mazda vehicles.
For proper repair and maintenance, a
thorough familiarization with this manual is
important, and it should always be kept in a
handy place for quick and easy reference.
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing.
As modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Mazda dealers. This manual
should be kept up-to-date.
Mazda Motor Corporation reserves the
right to alter the specifications and contents
of this manual without obligation or advance notice.
All rights reserved. No part of this book may
be reproduced or used in any form or
by any means, electronic or mechanical
including photocopying and recording and
the use of any kind of information storage
and retrieval system-without permission in
writing.
Mazda Motor Corporation
HIROSHIMA, JAPAN
GENERAL INFORMATION
BODY
STRUCTURE
Section
00
CONSTRUCTION
80A
PANEL REPLACEMENT
80B
WATER-PROOF AND RUST

PREVENTIVE
80C
DIMENSIONS
80D
PLASTIC BODY PARTS
80E
CONSTRUCTION
STANDARD VALVES
80F
APPLICATION:
This manual is applicable to vehicles beginning
with the Vehicle Identification Numbers (VIN),
shown on the following page.
2012 Mazda Motor Corporation
PRINTED IN U.S.A., DECEMBER 2012
Form No. 35251U12L
Part No. 999995099F14
3525-1U-12L(INDEX).fm 2
VEHICLE IDENTIFICATION NUMBERS (VIN)

JM1
JM1
JM1
JM1
JM1
JM1
JM1
JM1
JM1
JM1
JM1
JM1
GJ1S3*E#
GJ1S5*E#
GJ1T3*E#
GJ1T5*E#
GJ1U3*E#
GJ1U5*E#
GJ1V3*E#
GJ1V5*E#
GJ1W3*E#
GJ1W5*E#
GJ1X3*E#
GJ1X5*E#
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
3525-1U-12L(00-00).fm 1
GENERAL INFORMATION
00
SECTION
Toc
of SCT INFORMATION . . . . 00-00
GENERAL
Toc of SCT
00-00
GENERAL INFORMATION
VEHICLE IDENTIFICATION
NUMBER (VIN) CODE . . . . . . . . . . . . . . 00-002
VEHICLE IDENTIFICATION NUMBERS
(VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-002
2014 Model Year . . . . . . . . . . . . . . . . . . 00-002
HOW TO USE THIS MANUAL . . . . . . . . . 00-003
Efficient Replacement of
Body Panels . . . . . . . . . . . . . . . . . . . . 00-003
Symbols of Panel Replacement . . . . . . 00-003
Body Dimensions (Flat-plane
Dimensions) . . . . . . . . . . . . . . . . . . . . 00-004
Body Dimensions (Straight-line
Dimensions) . . . . . . . . . . . . . . . . . . . . 00-006
Symbols of Body Dimensions . . . . . . . . 00-007
AIR BAG SYSTEM
SERVICE WARNINGS . . . . . . . . . . . . . . 00-008
Air Bag Module Inspection . . . . . . . . . . 00-008
Air Bag Module Handling . . . . . . . . . . . 00-008
Side Air Bag Module Handling . . . . . . . 00-008
SAS Control Module Handling . . . . . . . 00-009
Crash Zone Sensor Handling . . . . . . . . 00-009
Side Air Bag Sensor Handling. . . . . . . . 00-009
Pre-tensioner Seat Belt Inspection . . . . 00-0010
SERVICE PRECAUTIONS . . . . . . . . . . . . 00-0010
Arrangement of Workshop . . . . . . . . . . 00-0010
Safety Precautions . . . . . . . . . . . . . . . . 00-0010
Vehicle Protection . . . . . . . . . . . . . . . . . 00-0010
Remove Dangerous Articles . . . . . . . . . 00-0010
Use of Pulling Equipment . . . . . . . . . . . 00-0011
Prevent Short Circuits . . . . . . . . . . . . . . 00-0011
EFFICIENT REMOVAL OF
BODY PANELS. . . . . . . . . . . . . . . . . . . . 00-0012
Body Measurements . . . . . . . . . . . . . . . 00-0012
Prevention of Body Deformation. . . . . . 00-0012

Selection of Cut-and-join Locations . . . 00-0012
Removal of Associated Parts . . . . . . . . 00-0012
Rough Cutting of Damaged Panel . . . . 00-0013
EFFICIENT INSTALLATION OF
BODY PANELS . . . . . . . . . . . . . . . . . . . 00-0013
Checking Preweld Measurements And
Watching . . . . . . . . . . . . . . . . . . . . . . 00-0013
Welding Notes . . . . . . . . . . . . . . . . . . . 00-0013
Spot Welding Notes . . . . . . . . . . . . . . . 00-0014
Checking Weld Strength. . . . . . . . . . . . 00-0015
INSTALLATION PREPARATIONS. . . . . . 00-0016
Rough Cutting of New Parts. . . . . . . . . 00-0016
Determination of Welding Method . . . . 00-0016
Making Holes for Arc Welding . . . . . . . 00-0016
Application of Weld-through Primer . . . 00-0017
ANTICORROSION,
SOUND INSULATION,
AND VIBRATION INSULATION . . . . . . 00-0017
Body Sealing . . . . . . . . . . . . . . . . . . . . 00-0017
Application of Undercoating . . . . . . . . . 00-0017
Application of Rust Inhibitor . . . . . . . . . 00-0018
Application of Dumping Sheet . . . . . . . 00-0018
ABBREVIATION . . . . . . . . . . . . . . . . . . . 00-0018
IDENTIFICATION NUMBER
LOCATIONS . . . . . . . . . . . . . . . . . . . . . 00-0019
Vehicle Identification Number (VIN) . . . 00-0019
Engine Type/Number . . . . . . . . . . . . . . 00-0019
BODY COLORS. . . . . . . . . . . . . . . . . . . . 00-0019
Color Code and Color Name . . . . . . . . 00-0019
Verification of Primary Color Mixture for
Body Color . . . . . . . . . . . . . . . . . . . . . 00-0019
End of Toc
BM: GENERAL INFORMATION
00-001
00-00
3525-1U-12L(00-00).fm 2
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN) CODE
id000000600800
2014 Model Year
JM1GJ1S20E1123456
Serial No.
Plant
0= Hiroshima
1= Hofu
Model year
E= 2014
Check digit
0 to 9, X
Engine
Body style
Restraint system, Axle configuration
Carline, series
World manufacturer identification
3= 2.5 L (SKYACTIV-G 2.5, Mexico)

5= 2.5 L (SKYACTIV-G 2.5, U.S.A., Canada)
S, T, U, V, W, X= Sedan
1= with side airbag, 2WD
GJ= Mazda6
JM1= Mazda/passenger car/USA
am6xuw0000649
End Of Sie
VEHICLE IDENTIFICATION NUMBERS (VIN)

2014 Model Year
JM1 GJ1S3*E# 100001
JM1 GJ1S5*E# 100001
JM1 GJ1T3*E# 100001
JM1 GJ1T5*E# 100001
JM1 GJ1U3*E# 100001
JM1 GJ1U5*E# 100001
JM1 GJ1V3*E# 100001
JM1 GJ1V5*E# 100001
JM1 GJ1W3*E# 100001
JM1 GJ1W5*E# 100001
JM1 GJ1X3*E# 100001
JM1 GJ1X5*E# 100001
End Of Sie
00-002
id000000600100
3525-1U-12L(00-00).fm 3
GENERAL INFORMATION
HOW TO USE THIS MANUAL
id000000600900
Efficient Replacement of Body Panels

This section contains information on the body panels in regard to the welding types, number of spot welds, and
cut-and-join locations that are necessary for panel removal and installation.
The type of weld and position are indicated by symbols.
Some sections have notes concerning the operation being performed. Thoroughly read and understand the
notes before carrying out any procedures.
Example
REAR FENDER PANEL REMOVAL
Shows operation section
Shows procedure, caution and note
Caution
Avoid cutting with a flame as the insulator (shaded) is flammable.
1.The rear fender panel and wheel house are joined with glue at the wheel arch line.
NOTE
Drill the 17 weld locations indicated by (A), from the room side.
Shows a cross location
BRAZE WELDING
Shows a dimensions
A
250mm
{9.84in}
Shows a insulator
CUT-AND-JOINT LOCATION
ROUGH CUT LOCATION
17
(A)17
4
30mm
{1.18in}
5
5
Shows welding region
Shows number of weld
7
A-A
1
Shows a cross
acxuub00000031
Symbols of Panel Replacement

The following 6 symbols are used to indicate the type of weld that is used when replacing body panels.
SYMBOL
MEANING
SYMBOL
MEANING
Spot welding
Continuous arc welding (Cut-and-join location)
Arc welding (plug welding)
Brazing welding (oxyacetylene welding)
Arc welding (spot welding)
Rough cut location

ac5wzb00000204
00-003
00-00
3525-1U-12L(00-00).fm 4
GENERAL INFORMATION
Body Dimensions (Flat-plane Dimensions)
Flat-plane dimensions are the dimensions measured by projecting certain reference points onto a plane
surface.
FRONT FENDER INSTALLATION NUT
810 {31.89}
FLAT-PLANE DIMENSIONS
acxuub00000033
When there are no specific indications, the standard points and dimensions are symmetrical in regard to the
center of the vehicle.
The hypothetical lines may differ according to the vehicle model.
The schematic diagram shows the vehicle as it is projected from the underbody.
00-004
3525-1U-12L(00-00).fm 5
GENERAL INFORMATION
Example
Shows vehicle section
UNDERBODY FLAT-PLANE DIMENSIONS
00-00
478
485
650 {25.59}
1,164 {45.83}
543
484
{21.37}
{19.05}
1,073 {37.91}
Shows outline drawing
650 {25.59}
650 {25.59}
605 {23.82}
469
455
{18.46}
{17.91}
1,106 {43.54}
760 {29.92}
1,016
{40.00}
RH LH
The dimensions on the left

and right in regard to the center
of the vehicle are different.
Shows dimension
420
{16.54}
182
93
144
120
{7.17} {3.66} {5.67} {4.72}
140
1,030
{40.55}
760
{29.92}
{5.51}
68
{2.68}
When there are no specific indications, all of

units are in millimeters (mm).
Point
symbol
A
B
C
D
E
Designation
Crossmember No,1 standard
hole
Front side frame standard hole
Front suspension mounting
block surface hole center
Front suspension mounting
bolt
Front frame rear standard hole
Hole diameter
or bolt or nut
size mm {in}
Point
symbol
16 {0.62}
F
G
16 {0.62}
80 {3.14}
M14 {0.55}
16 {0.62}
Designation
Front frame rear standard hole
Rear side frame standard hole
Link bracket
I
J
K
L
Rear suspension housing

Rear suspension housing
Shows bolt size
666
{26.22}
660
{25.98}
1,043
{41.06}
512
{20.16}
445
{17.52}
436
{17.17}
436
{17.17}
1,084 {42.84}
579
{22.80}
479
{18.86}
654
{25.75}
Shows hypothetical
standard line
687
{27.05}
Shows point
symbol
379
{14.92}
mm {in}
Hole diameter
or bolt or nut
size mm {in}
18 {0.62}
16 {0.62}
17 29.5
{0.661.16}
12 {0.47}
16 {0.62}
31 {1.22}
12 {0.47}
Shows
slot
Shows hole diameter

ac9uub00000034
00-005
3525-1U-12L(00-00).fm 6
GENERAL INFORMATION
Body Dimensions (Straight-line Dimensions)
Straight-line dimensions are the actual dimensions between two standard points.
FRONT FENDER INSTALLATION NUT
817 {32.17}
STRAIGHT-LINE DIMENSIONS
acxuub00000035
When there are no specific indications, the standard points and dimensions are symmetrical in regard to the
center of the vehicle.
00-006
3525-1U-12L(00-00).fm 7
GENERAL INFORMATION
Example
ROOM STRAIGHT-LINE DIMENSIONS (1)

Shows vehicle section
Shows point
symbol
00-00
Shows outline drawing

A
Shows dimension
B
1,128
{44.41}
1,067
{42.01}
No indication are shown

within the outline drawing.
F
1,263
{49.72}
Shows dimension location
H
1,048
{41.26}
1,398
{55.04}
C
1,406
{55.35}
799
{31.46}
G
851
{33.50}
D
When there are no specific indications, all of

units are in millimeters (mm).
mm {in}
Shows details of the standard

point location
Shows point indication

Without apostrophe:RH
With apostrophe:LH
Shows position and shape of the points

C
E,E'
Fr
Fr
Fr
Fr
Fr
Fr
Fr
Fr
Front pillar inner designation
Hole diameter
or bolt or nut
size mm {in}
16 {0.62}
Front pillar inner designation
17 {0.67}
Harness installation hole
31 {1.22}
Front floor pan designation
M14 {0.55}
Adjuster installation hole
16 {0.62}
Point
symbol
Designation
Fr
Point
symbol
Designation
F
G
Trim installation hole

Harness installation hole
Chaker bracket installation hole
Chaker bracket installation hole
Hole diameter
or bolt or nut
size mm {in}
18 {0.71}
16 {0.62}
17 29.5
{0.661.16}
12 {0.47}
Shows hole diameter
Shows
slot
Shows bolt size

am3uub0000007
Symbols of Body Dimensions

The following 8 symbols are used to indicate the standard points.
SYMBOL
MEANING
Center of circular hole
SYMBOL
(arrow only)
MEANING
Bolt tip
Center elliptical hole
Center of rectangular-shaped hole
Notch
Edge of rectangular-shaped hole
Panel seam, bead, etc.

acxuub00000037
End Of Sie
00-007
3525-1U-12L(00-00).fm 8
GENERAL INFORMATION
AIR BAG SYSTEM SERVICE WARNINGS
id000000920000
Air Bag Module Inspection

Inspecting an air bag module using a tester can operate (deploy) the air bag module, which may cause
serious injury. Do not use a tester to inspect an air bag module. Always use the on-board diagnostic
function to diagnose the air bag module for malfunctions.
NO GOOD
am6xuw0000606
Air Bag Module Handling

Before removing the air bag module or disconnecting the air bag module connector, always switch the
ignition off, disconnect the negative battery cable, and then wait for 1 min or more to allow the backup
power supply of the SAS control module to deplete its stored power.
Handling a live (undeployed) air bag module
that is pointed toward your body could result
in serious injury if the air bag module were to
accidentally operate (deploy). When carrying
a live (undeployed) air bag module, point the
deployment surface away from your body to
lessen the chance of injury in case it operates
(deploys).
GOOD
NO GOOD
am6xuw0000606
A live (undeployed) air bag module placed

with its deployment surface to the ground is
dangerous. If the air bag module were to
accidentally operate (deploy), it could cause
serious injury. Always place a live
(undeployed) air bag module with its
deployment surface up.
GOOD
NO GOOD
am6xuw0000606
Side Air Bag Module Handling

Before removing the side air bag module or disconnecting the side air bag module connector, always
switch the ignition off, disconnect the negative battery cable, and then wait for 1 min or more to allow
the backup power supply of the SAS control module to deplete its stored power.
When a side air bag module operates (deploys) due to a collision, the interior of the seat back (pad,
frame, trim) may become damaged. If a side air bag does not operate (deploy) normally from a seat
back that has been reused, a serious accident may result. After a side air bag has operated (deployed),
always replace both the side air bag module and the seat back (pad, frame, trim) with new parts. After
servicing, verify that the seat operates normally and that the wiring harness is not caught.
00-008
3525-1U-12L(00-00).fm 9
GENERAL INFORMATION
SAS Control Module Handling
When connecting or disconnecting the SAS control module connector, a person charged with static
electricity could accidentally operate (deploy) each air bag module. Before connecting or
disconnecting the SAS control module connector, discharge any charged static electricity from your
body.
Removing the SAS control module or disconnecting the SAS control module connector with the
ignition ON can activate the sensor in the SAS control module and operate (deploy) the air bags and
pre-tensioner seat belts, which may cause serious injury. Before removing the SAS control module or
disconnecting the SAS control module connector, always switch the ignition off, disconnect the
negative battery cable, and then wait for 1 min or more to allow the backup power supply of the SAS
control module to deplete its stored power.
Connecting the SAS control module connector with the SAS control module not securely fixed to the
vehicle is dangerous. The sensor in the SAS control module could send an electrical signal to the air
bag modules and pre-tensioner seat belts. This will operate (deploy) the air bags and pre-tensioner
seat belts, which may result in serious injury. Therefore, before connecting the connector, securely fix
the SAS control module to the vehicle.
Because a sensor is built into the SAS control module, once the air bags and pre-tensioner seat belts
have operated (deployed) due to a collision or other causes, the SAS control module must be replaced
with a new one even if the used one does not have any visible external damage or deformation. The
used SAS control module may have been damaged internally, which may cause improper operation. If
the SAS control module is reused, the air bags and pre-tensioner seat belts may not operate (deploy)
normally, which could result in a serious accident. Always replace the SAS control module with a new
one. The SAS control module cannot be bench-checked or self-checked.
Crash Zone Sensor Handling
Removing the crash zone sensor or disconnecting the crash zone sensor connector with the ignition
ON can activate the crash zone sensor and operate (deploy) the air bags and pre-tensioner seat belts,
which may cause serious injury. Before removing the crash zone sensor or disconnecting the crash
zone sensor connector, always switch the ignition off, disconnect the negative battery cable, and then
wait for 1 min or more to allow the backup power supply of the SAS control module to deplete its stored
power.
If the crash zone sensor is subjected to shock or the sensor is disassembled, the air bags and pretensioner seat belts may accidentally operate (deploy) and cause injury, or the system may fail to
operate normally and cause a serious accident. Do not subject the crash zone sensor to shock or
disassemble the sensor.
Because a sensor is built into the crash zone sensor, once the air bags and pre-tensioner seat belts
have operated (deployed) due to a collision or other causes, the crash zone sensor must be replaced
with a new one even if the used one does not have any visible external damage or deformation. If the
crash zone sensor is reused, the air bags and pre-tensioner seat belts may not operate (deploy)
normally, which could result in a serious accident. Always replace the crash zone sensor with a new
one. The crash zone sensor cannot be bench-checked or self-checked.
Side Air Bag Sensor Handling
Removing the side air bag sensor or disconnecting the side air bag sensor connector with the ignition
ON can activate the side air bag sensor and operate (deploy) the side air bag, which may cause serious
injury. Before removing the side air bag sensor or disconnecting the side air bag sensor connector,
always switch the ignition off, disconnect the negative battery cable, and then wait for 1 min or more to
allow the backup power supply of the SAS control module to deplete its stored power.
If the side air bag sensor is subjected to shock or the sensor is disassembled, the side air bag may
accidentally operate (deploy) and cause injury, or the system may fail to operate normally and cause a
serious accident. Do not subject the side air bag sensor to shock or disassemble the sensor.
Because a sensor is built into the side air bag sensor, once the air bag has operated (deployed) due to
a collision or other causes, the side air bag sensor must be replaced with a new one even if the used
one does not have any visible external damage or deformation. If the side air bag sensor is reused, the
side air bag may not operate (deploy) normally, which could result in a serious accident. Always
replace the side air bag sensor with a new one. The side air bag sensor cannot be bench-checked or
self-checked.
00-009
00-00
3525-1U-12L(00-00).fm 10
GENERAL INFORMATION
Pre-tensioner Seat Belt Inspection
Inspecting a pre-tensioner seat belt using a
tester can operate (deploy) the pre-tensioner
seat belt, which may cause serious injury. Do
not use a tester to inspect a pre-tensioner
seat belt. Always use the on-board diagnostic
function to diagnose the pre-tensioner seat
belt for malfunctions.
End Of Sie
NO GOOD
ac5uuw00001455
SERVICE PRECAUTIONS
id000000600200
Arrangement of Workshop
Arrangement of the workshop is important for safe and efficient work.
Safety Precautions
Protective head covering and safety shoes should
always be worn. Depending upon the nature of
the work, gloves, safety glasses, ear protectors,
face shield, etc., should also be used.
WELDING
GLASSES
DUST
MASK
EAR
PROTECTORS
WELDING
GLOVES
COTTON
GLOVES
SAFETY
SHOES
SAFETY
GLASSES
FACE SHIELD
am3uub0000007
Vehicle Protection
Use seat covers and floor covers.
Use heat-resistant protective covers to protect glass areas and seats from heat or sparks during welding.
Protect items such as moldings, garnishes, and
ornaments with tape when welding.
acxuub00000063
Remove Dangerous Articles

Remove the fuel tank before using an open flame
in that area. Plug connection piping to prevent
fuel leakage.
acxuub00000064
00-0010
3525-1U-12L(00-00).fm 11
GENERAL INFORMATION
Use of Pulling Equipment
When using pulling equipment, keep away from
the pulling area and use safety wires to prevent
accidents.
00-00
SAFETY WIRES
am3uub0000007
Prevent Short Circuits

Switch the ignition to off.
Disconnect the battery cables.
Battery cable
acxuub00000042
Securely connect the welding machine ground

near the welding area.
End Of Sie
GROUND
am3uub0000007
00-0011
3525-1U-12L(00-00).fm 12
GENERAL INFORMATION
EFFICIENT REMOVAL OF BODY PANELS
id000000600300
Body Measurements
Before removal or rough-cutting, first measure the
body at and around the damaged area against
the standard reference dimension specifications.
If there is deformation, use frame repair
equipment to make a rough correction.
acxuub00000065
Prevention of Body Deformation

Use a clamp or a jack for removal and reinforce at
and around the rough-cutting location to prevent
deforming of the body.
acxuub00000066
Selection of Cut-and-join Locations

For parts where complete replacement is not
feasible, careful cutting and joining operations
should be followed. If the location to be cut is a
flat area where there is no reinforcement, the
selected cutting location should be where the
welding distortion will be minimal.
acxuub00000067
Removal of Associated Parts

Protect moldings, garnishes, and ornaments with tape when removing associated parts.
00-0012
3525-1U-12L(00-00).fm 13
GENERAL INFORMATION
Rough Cutting of Damaged Panel
Verify that there are no parts (such as pipes, hoses, and wiring harness) nearby or on the opposite side of a
panel which could be damaged by heat.
For cut-and-join areas, allow for an overlap of
3050 mm {1.21.9 in} and then rough-cut the
damaged panel.
End Of Sie
Wiring harness
Rough cut location
Cut-and-join location
acxuub00000047
EFFICIENT INSTALLATION OF BODY PANELS
id000000600500
Checking Preweld Measurements And Watching

Align to the standard reference dimensions,
based upon the body dimensions illustration, so
that new parts are installed in the correct position.
acxuub00000069
Welding Notes
For the number of weld points, welding should be
performed in accordance with the following
reference standards.
SPOT WELDING
ORIGINAL WELD
REPAIR WELD
ORIGINAL NUMBER OF
WELDS x 1.3 OR MORE
CO2 ARC WELDING

ORIGINAL SPOT WELD
IF 3 mm
REPAIR WELD
{0.12 in} OR MORE
ORIGINAL NUMBER OF
WELDS OR MORE
am3uub0000007
00-0013
00-00
3525-1U-12L(00-00).fm 14
GENERAL INFORMATION
Spot Welding Notes
The shape of the spot welder tip is D=(2t)+3. If
the upper panel thickness is different from that of
the under panel, adjust to the thinner one.
70120
ac9uub00000041
Because the weld strength is affected by the

shape of the spot welder tip, the optimum
condition of the tip should always be maintained.
Spot welds should be made at points other than
the originally welded points.
acxuub00000070
Before spot welding, make a trial weld using the

same material as the body panel to check the
weld strength.
TEST PIECE METHOD
NUGGET DIAMETER
:4/5 OF TIP
am3uub0000007
00-0014
3525-1U-12L(00-00).fm 15
GENERAL INFORMATION
Checking Weld Strength
Installation locations of the engine, chassis, and
seat belts are designated as important safety
locations for weld strength. Check weld strength
by driving a chisel between the panels at every
fourth or fifth weld spot, and every tenth regular
weld location.
CHISEL DIMENSIONS
20
25 mm
{0.98 in}
00-00
8 mm {0.31 in}
WELD LOCATION
WITHIN 5 mm
{0.20 in}
WITHIN 5 mm
{0.20 in}
am3uub0000007
Drive the chisel between the panels according to

the number of panels as shown below.
To determine weld strength, drive the chisel
between the panel and check whether the panels
come apart. If the panels come apart, make
another weld near the original weld.
Restore the shape of the checked area.
End Of Sie
TWO PANELS
WELD LOCATION
ONE LOCATION
THREE PANELS
WELD LOCATION
TWO LOCATION
FOUR PANELS
WELD LOCATION
THREE LOCATION
am3uub0000008
00-0015
3525-1U-12L(00-00).fm 16
GENERAL INFORMATION
INSTALLATION PREPARATIONS
id000000600400
Rough Cutting of New Parts

For cut-and-join areas, allow for an overlap of 3050 mm {1.21.9 in} with the remaining area on the body
side and then rough-cut the new parts.
3050 mm{1.21.9 in}

OVER LAP
3050 mm{1.21.9 in}

OVER LAP
BODY SIDE ROUGH CUT LOCATION

NEW PART ROUGH CUT LOCATION
am3uub0000008
Determination of Welding Method

If the total thickness at the area to be welded is 3 mm {0.12 in} or more, use a gas shielded-arc welder to make
the plug welds.
3 mm
{0.1 in} OR MORE
am3uub0000008
Making Holes for Arc Welding

For places that cannot be spot welded, make a hole for arc welding using a punch or drill as follows.
(mm {in})
Panel thickness ()
0.600.90 {0.0240.035}
0.911.20 {0.0360.047}
1.211.80 {0.0477
0.0708}
1.814.50 {0.0720.177}
Hole diameter ()
5.0 {0.20}
6.0 {0.24}
8.0 {0.31}
10.0 {0.394}
Grind the shaded section indicated in the diagram below and create a hole in the part where the 34 plates
are put together. Also, weld the plates together tightly so that gaps do not develop.
10.0 mm {0.394 in}
30
30
OUTER PANEL
MIDDLE PANEL
INNER PANEL
am3uub0000008
00-0016
3525-1U-12L(00-00).fm 17
GENERAL INFORMATION
Application of Weld-through Primer
For treatment against corrosion, remove the paint grease, and other material from the portion of new part and
body to be welded, and apply weld-through primer.
End Of Sie
00-00
acxuub00000068
ANTICORROSION, SOUND INSULATION, AND VIBRATION INSULATION
id000000600600
Body Sealing
Apply body sealer where necessary.
For locations where application of body sealer is difficult after installation, apply it before installation.
acxuub00000059
Application of Undercoating
Apply an undercoat to the required location of the body.
acxuub00000060
00-0017
3525-1U-12L(00-00).fm 18
GENERAL INFORMATION
Application of Rust Inhibitor
Apply rust inhibitor (wax, oil, etc.) to the back of the welded areas.
acxuub00000061
Application of Dumping Sheet

Apply dumping sheet by heating with an infrared ray lamp.
End Of Sie
acxuub00000062
ABBREVIATION
Fr
LH
RH
Rr
Front
Left Hand
Right Hand
Rear
End Of Sie
00-0018
id000000600700
3525-1U-12L(00-00).fm 19
GENERAL INFORMATION
IDENTIFICATION NUMBER LOCATIONS
id000000978900
Vehicle Identification Number (VIN)

The VIN marking position is located on the floor
on the front passenger-side.
00-00
ac5wzw0000118
If the VIN plate is adhered to the dashboard, it is

located in the position shown in the figure.
am6zzw0000387
Engine Type/Number
SKYACTIV-G 2.0, SKYACTIV-G 2.5
FRONT
am6xuw0000622
End Of Sie
BODY COLORS
WM: GENERAL INFORMATION
id000000788800
Color Code and Color Name

Color Code
A4D
25D
34K
35J
38P
41V
41W
42A
42B
Color Name
Arctic white CLE
Snowflake white pearl
Crystal white pearl
Stormy blue MC
Aluminum metallic M
Soul red M
Jet black MC
Meteor gray MC
Blue reflex MC
Verification of Primary Color Mixture for Body Color

Confirm the primary color mixture for the body color at the paint manufacturer URL.
End Of Sie
00-0019
3525-1U-12L(00-00).fm 20
3525-1U-12L(09-80A).fm
BODY & ACCESSORIES
09
SECTION
09-80A
Toc
of SCT
BODY
STRUCTURE
[CONSTRUCTION] . . . . . . . . . 09-80A
BODY STRUCTURE
[PANEL REPLACEMENT] . . . 09-80B
BODY STRUCTURE
[WATER-PROOF AND
RUST PREVENTIVE] . . . . . . . 09-80C
BODY STRUCTURE
[DIMENSIONS] . . . . . . . . . . . 09-80D
BODY STRUCTURE
[PLASTIC BODY PARTS] . . . 09-80E
BODY STRUCTURE
[CONSTRUCTION STANDARD
VALUES] . . . . . . . . . . . . . . . . 09-80F
Toc of SCT
09-80A BODY STRUCTURE [CONSTRUCTION]

BODY COMPONENTS CONSTRUCTION
[CONSTRUCTION] . . . . . . . . . . . . . . . . . 09-80A2
ULTRA HIGH-TENSION STEEL
[CONSTRUCTION] . . . . . . . . . . . . . . . . . 09-80A7
Characteristics of Ultra High-Tensile

Steel Plates . . . . . . . . . . . . . . . . . . . . 09-80A7
Range of Use and
Cautions for Service . . . . . . . . . . . . . . 09-80A7
End of Toc
BM: CONSTRUCTION
09-80A1
3525-1U-12L(09-80A).fm
BODY STRUCTURE [CONSTRUCTION]

BODY COMPONENTS CONSTRUCTION [CONSTRUCTION]
id098007739700
54
55
56
26
46
47
49
48
27
29 30 31
23
53
51 52 2324 25
22
50
28
37
20
35
39
38
21
33
36
32
34
40
9 10 11 12 13 14
41
2
42
15
5 6
43
44
18
66 67
17 16
4 7
8
57
19
58
45
71
77
78
77
72
65
68
59 60 61 64
73 74 75 76
60 61
58
57
62
69
70
63
am6zzb0000032
No.
Part Name
x:Applied
-:Not applied
Ultra hightension steel
Hightension
steel
Rust proof
steel
Hood
Bumper bracket
Suspension mounting reinforcement
Outer frame reinforcement
09-80A2
Thicknes
s (mm)
{in}
0.70
{0.03}
2.60
{0.10}
2.90
{0.11}
2.00
{0.0787}
3525-1U-12L(09-80A).fm

Hightension
steel
Rust proof
steel
Thicknes
s (mm)
{in}
Apron
reinforcement
(lower)
1.00
{0.0394}
Side stay
Shroud side
panel
Front
Rear
Front
Rear
2.30
{0.091}
1.20
{0.0472}
1.40
{0.0551}
1.00
{0.0394}
10 Front wheel apron panel
11 Front fender junction
12 Wiper bracket
13 Cowl plate (upper)
14 Cowl side reinforcement (upper)
Front
Rear
16 Torque box
17 Side member
18 Front frame (rear)
19 Front fender panel
20 Hinge pillar (inner)
21 Front pillar (inner)
22 Front pillar upper reinforcement
23 Nut plate
No.
Part Name
Shroud side member component
Shroud upper reinforcement
Front side frame (inner)
Front side frame (outer)
Wheel apron component
Suspension
housing
(upper)
Apron
reinforcement
Apron
reinforcement
No.3
Cowl side
reinforcement
(inner)
Suspension
housing (lower)
15 Cowl side reinforcement (lower)
1.20
{0.0472}
0.90
{0.035}
0.80
{0.031)
1.40
{0.0551}
1.60
{0.0630}
1.40
{0.0551}
1.60
{0.0630}
1.00
{0.0394}
0.80
{0.031}
0.80
{0.031}
1.40
{0.0551}
1.40
{0.0551}
1.60
{0.0630}
0.80
{0.031}
1.20
{0.0472}
1.80
{0.0709}
1.40
{0.0551}
2.00
{0.0787}
0.70
{0.028}
1.20
{0.0472}
1.60
{0.0630}
0.70
{0.028}
1.20
{0.0472}
09-80A3
09-80A
3525-1U-12L(09-80A).fm

Hightension
steel
Rust proof
steel
24 Roof corner gusset
25 Roof rail (inner)
29 Wheel housing (outer)
30 Rear fender rain rail
31 Corner plate
32 Rear fender panel (lower)
33 Tower anchor reinforcement
34 Side sill reinforcement (rear)
35 Wheel housing (inner)
Upper
Lower
37 Center pillar reinforcement (inner)
38 Center pillar (inner)
39 Roof rail reinforcement
Upper
Lower
41 Hinge reinforcement
42 Side sill reinforcement
43 Cabin side outer frame
Outer panel
Inner panel
No.
Part Name
26 Package gusset component
Package
junction
Package
reinforcement
Package
gusset
Wheel housing
gusset
27 Rear pillar (inner)

C pillar
reinforcement
28 Suspension housing reinforcement component Suspension
housing
reinforcement
36 Center pillar reinforcement
40 Front pillar reinforcement
44 Front door
09-80A4
Thicknes
s (mm)
{in}
1.20
{0.0472}
1.20
{0.0472}
0.90
{0.035}
0.90
{0.035}
1.00
{0.0394}
1.00
{0.0394}
0.65
{0.026}
1.40
{0.0551}
0.65
{0.026}
0.65
{0.026}
0.70
{0.028}
0.70
{0.028}
0.70
{0.028}
1.60
{0.0630}
1.80
{0.0709}
0.70
{0.028}
2.00
{0.0787}
2.00
{0.0787}
2.30
{0.0906}
1.20
{0.0472}
1.40
{0.0551}
1.60
{0.0630}
1.80
{0.0709}
1.40
{0.0551}
1.40
{0.0551}
0.70
{0.028}
0.70
{0.028}
0.65
{0.026}
3525-1U-12L(09-80A).fm

No.
Hightension
steel
Rust proof
steel
Outer panel
Inner panel
Upper panel
Part Name
45 Rear door
Tunnel junction
No.1
Front frame
rear
reinforcement
Tunnel
reinforcement
Cowl panel
Dash upper
panel
48 Front header
49 Roof reinforcement No.1
53 Rear header
54 Roof panel
55 Rear package tray
Outer
Inner
End
Front
Rear
59 Tunnel reinforcement
60 Crossmember No.2
61 Crossmember No.2.5
Front
Rear
46 Dash lower component
47 Dash and cowl component
56 Cabin side outer frame
57 Front floor side panel
58 Floor reinforcement
62 Front B frame
Thicknes
s (mm)
{in}
0.70
{0.028}
0.65
{0.026}
0.80
{0.031}
0.80
{0.031}
1.20
{0.0472}
1.20
{0.0472}
0.60
{0.024}
0.90
{0.035}
0.70
{0.028}
0.55
{0.022}
1.00
{0.0394}
0.55
{0.022}
0.55
{0.022}
0.75
{0.0310}
0.75
{0.0310}
0.60
{0.024}
0.70
{0.028}
0.60
{0.024}
0.60
{0.024}
0.60
{0.024}
1.80
{0.0709}
1.00
{0.0394}
0.90
{0.035}
1.00
{0.0394}
1.60
{0.0630}
1.40
{0.0551}
1.00
{0.0394}
09-80A5
09-80A
3525-1U-12L(09-80A).fm

Hightension
steel
Rust proof
steel
Front
Center
Rear
Center upper
Side upper
Center lower
Side lower
65 Crossmember No.3 (upper)
66 Center floor panel
67 Rear floor front reinforcement
68 Crossmember No.4 (front)
69 Rear frame reinforcement
Front
Center
Rear
71 Trunk floor panel
72 Crossmember No.4 (rear)
73 Rear bumper bracket
74 Floor side panel No.2
Front
Rear (upper)
Rear (lower)
Rear end panel
Rear end
member
77 Rear bumper reinforcement No.1
78 Rear bumper reinforcement No.2
No.
Part Name
63 Side sill (inner)
64 Crossmember No.3 (lower)
70 Rear side frame
75 Floor side panel No.1
76 Rear end panel component
End Of Sie
09-80A6
Thicknes
s (mm)
{in}
1.40
{0.0551}
1.60
{0.0630}
1.20
{0.0472}
1.40
{0.0551}
1.60
{0.0630}
0.80
{0.031}
1.00
{0.0394}
0.60
{0.024}
0.60
{0.024}
0.90
{0.035}
0.90
{0.035}
0.90
{0.035}
1.60
{0.0630}
1.60
{0.0630}
1.40
{0.0551}
0.60
{0.024}
0.90
{0.035}
2.00
{0.0787}
0.70
{0.028}
1.20
{0.0472}
2.00
{0.0787}
1.60
{0.0630}
0.60
{0.024}
0.70
{0.028}
1.00
{0.0394}
1.00
{0.0394}
3525-1U-12L(09-80A).fm

ULTRA HIGH-TENSION STEEL [CONSTRUCTION]
id098007745600
Characteristics of Ultra High-Tensile Steel Plates

Ultra high-tensile steel plates have enhanced tensile strength compared to previous high-tensile steel plates.
Because the strength is maintained even though the plates are thin-walled, the ultra high-tensile steel plates
are used for the frames and the main frame parts which form the cabin, reducing the weight of the vehicle.
Enhanced shock absorption has improved the safety.
Range of Use and Cautions for Service
Because the ultra high-tensile steel is hard and it may be difficult to reform, when extracting the damaged part
using a frame repair machine, perform the work verifying that other parts are not affected.
When drilling welded parts, use a well-ground drill bit.
After welding, inspect the weld strength. If adhesion is poor, perform arc welding (plug welding).
18
19
20 21 22 23 24 25
26 27
28
29
7 8 9 10 11 12
30
13
14
15 16
31
17
aatjjb00000297
NO.
1
2
3
4
5
6
7
8
9
10
11
12
Part Name
Bumper bracket
Front side frame (inner, rear)
Front frame (rear)
Front side frame (outer, rear)
Front frame (rear) reinforcement
Cowl side reinforcement (lower, rear)
Hinge reinforcement
Front pillar reinforcement
Crossmember No.2
Tunnel reinforcement
Crossmember No.2.5
Side sill reinforcement
Strength (MPa) {kgf/cm2,

psi}
590 {6016, 85572}
590 {6016, 85572}
590 {6016, 85572}
590 {6016, 85572}
590 {6016, 85572}
590 {6016, 85572}
590 {6016, 85572}
590 {6016, 85572}
590 {6016, 85572}
590 {6016, 85572}
780 {7954, 113130}
780 {7954, 113130}
09-80A7
09-80A
3525-1U-12L(09-80A).fm

NO.
Part Name
13
Center pillar reinforcement
14
Crossmember No.3 (lower)
15
16
Side sill reinforcement (rear)

Tower anchor reinforcement
17
Rear side frame
18
19
20
21
Apron reinforcement No.3

Hinge pillar (inner)
Front pillar (inner)
Floor reinforcement (front)
22
Side sill (inner)
23
24
25
26
27
28
29
Front B frame
Center pillar reinforcement (inner)
Roof corner gusset
Roof rail reinforcement
Roof rail (inner)
Roof rail reinforcement No.2
C pillar reinforcement (upper)
30
Floor side panel No.1
31
Rear bumper bracket
End Of Sie
09-80A8
Upper
Lower
Center, upper
Side, upper
Front
Center
Rear
Center
Rear
Front
Rear, lower
Strength (MPa) {kgf/cm2,

psi}
780 {7954, 113130}
590 {6016, 85572}
590 {6016, 85572}
590 {6016, 85572}
590 {6016, 85572}
590 {6016, 85572}
590 {6016, 85572}
590 {6016, 85572}
590 {6016, 85572}
590 {6016, 85572}
590 {6016, 85572}
590 {6016, 85572}
780 {7954, 113130}
780 {7954, 113130}
590 {6016, 85572}
590 {6016, 85572}
980 {9993, 142137}
590 {6016, 85572}
780 {7954, 113130}
590 {6016, 85572}
590 {6016, 85572}
780 {7954, 113130}
590 {6016, 85572}
780 {7954, 113130}
590 {6016, 85572}
3525-1U-12L(09-80B).fm
BODY STRUCTURE [PANEL REPLACEMENT]
09-80B BODY STRUCTURE [PANEL REPLACEMENT]

BUMPER BRACKET REMOVAL
[PANEL REPLACEMENT]. . . . . . . . . . . 09-80B3
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B3
Removal Procedure . . . . . . . . . . . . . . . 09-80B3
BUMPER BRACKET INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B5
Installation Procedure . . . . . . . . . . . . . 09-80B5
SHROUD SIDE MEMBER REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B6
SHROUD SIDE MEMBER INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B7
SHROUD UPPER
REINFORCEMENT REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B8
SHROUD UPPER
REINFORCEMENT INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B9
COWL SIDE
REINFORCEMENT REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B10
COWL SIDE
REINFORCEMENT INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B11
WIPER BRACKET REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B12
WIPER BRACKET INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B13
WHEEL APRON
COMPONENT REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B14
WHEEL APRON
COMPONENT INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B16
FRONT FENDER JUNCTION REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B18
FRONT FENDER
JUNCTION INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . 09-80B19
Installation Procedure . . . . . . . . . . . . . . 09-80B19

FRONT SIDE FRAME REMOVAL
[PANEL REPLACEMENT] . . . . . . . . . . . 09-80B20
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B20
Removal Procedure. . . . . . . . . . . . . . . . 09-80B20
FRONT SIDE FRAME INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B21
FRONT SIDE FRAME
(PARTIAL CUTTING) REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B22
FRONT SIDE FRAME
(PARTIAL CUTTING) INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B24
COWL UPPER PLATE REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B30
COWL UPPER PLATE INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B31
TORQUE BOX REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B32
TORQUE BOX INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B34
SIDE MEMBER REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B36
SIDE MEMBER INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B37
FRONT FRAME (REAR) REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B38
FRONT FRAME (REAR) INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B39
FRONT PILLAR REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B40
FRONT PILLAR INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B44
CENTER PILLAR REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B47
09-80B1
09-80B
3525-1U-12L(09-80B).fm

CENTER PILLAR INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B52
SIDE SILL PANEL REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B55
SIDE SILL PANEL INSTALLATION
Symbol Mrak . . . . . . . . . . . . . . . . . . . . . 09-80B58
REAR FENDER PANEL REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B61
REAR FENDER PANEL INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B64
REAR FENDER PANEL
(LOWER) REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B67
REAR FENDER PANEL
(LOWER) INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B68
CORNER PLATE REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B69
CORNER PLATE INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B70
REAR FENDER RAIN RAIL REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . . . 09-80B71
REAR FENDER RAIN RAIL
End of Toc
BM: BUMPER BRACKET
09-80B2
INSTALLATION
[PANEL REPLACEMENT]. . . . . . . . . . .
Symbol Mark . . . . . . . . . . . . . . . . . . . .
Installation Procedure . . . . . . . . . . . . .
REAR END PANEL REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . .
Removal Procedure . . . . . . . . . . . . . . .
REAR END PANEL INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . .
FLOOR SIDE PANEL REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . .
FLOOR SIDE PANEL INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . .
TRUNK FLOOR PANEL REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . .
TRUNK FLOOR PANEL INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . .
REAR SIDE FRAME REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . .
REAR SIDE FRAME INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . .
ROOF PANEL REMOVAL
Symbol Mark . . . . . . . . . . . . . . . . . . . .
ROOF PANEL INSTALLATION
Symbol Mark . . . . . . . . . . . . . . . . . . . .
09-80B72
09-80B72
09-80B72
09-80B73
09-80B73
09-80B73
09-80B74
09-80B74
09-80B74
09-80B75
09-80B75
09-80B75
09-80B77
09-80B77
09-80B77
09-80B79
09-80B79
09-80B79
09-80B80
09-80B80
09-80B80
09-80B82
09-80B82
09-80B82
09-80B84
09-80B84
09-80B84
09-80B86
09-80B86
09-80B86
09-80B88
09-80B88
09-80B88
3525-1U-12L(09-80B).fm

BUMPER BRACKET REMOVAL [PANEL REPLACEMENT]
id098008999500
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
CONTINUOUS CO2 ARC WELDING (CUT-AND-JOIN LOCATION)
09-80B
ROUGH CUT LOCATION

am6zzb0000032
Removal Procedure
1. Rough cut the location indicated by (A) shown in the figure.
(A) ROUGH CUT AREA

20 mm {0.79 in}
am6zzb0000032
2. Grind the 6 locations indicated by (B) shown in the figure.

Caution
When grinding 6 locations indicated by (B) shown in the figure and the front side frame is
damaged, there is a possibility that attachment of a bracket may become difficulty. When grinding
6 locations indicated by (B) shown in the figure, the amount removed will affect the quality of the
installation.
09-80B3
3525-1U-12L(09-80B).fm

(B) 3
(D) 2
(C) 1
(B) 1
(F) 1
(B) 1
(B) 1
(G) 2
(G) 2
(C) 1
BUMPER BRACKET
(E) 3
am6zzb0000032
3. Grind the 2 locations indicated by (C) shown in the figure.

4. Drill the 2 locations indicated by (D) shown in the figure, then remove the half portion above the bumper
bracket.
5. Drill the 3 locations indicated by (E) shown in the figure.
6. Grind the 1 location indicated by (F) shown in the figure.
7. Drill the 4 locations indicated by (G) shown in the figure.
8. Remove the half portion below the bumper bracket.
End Of Sie
09-80B4
3525-1U-12L(09-80B).fm

BUMPER BRACKET INSTALLATION [PANEL REPLACEMENT]
id098008999600
Symbol Mark
SYMBOL MARK
MEANING
PLUG WELDING (ARC WELDING)
CONTINUOUS ARC WELDING (CUT-AND-JOIN LOCATION)
am6zzb0000032
Installation Procedure
1. When installing new parts, measure and adjust the body as necessary to conform with standard dimensions.
2. Drill holes for the plug welding before installing the new parts.
3. After temporarily installing new parts, make sure the related parts fit properly.
4. Plug weld the 6 locations indicated by (A) shown in the figure.
(A) 2
(B) 2
(B) 1
(B) 3
(A) 2
(A) 2
(B) 3
BUMPER BRACKET
(C) 3
am6zzb0000032
5. Continuos weld the 9 locations indicated by (B) shown in the figure from the front wheel housing and engine
room.
Note
A flange part is fixed by a hand vise, and where a welded area is press-fitted, welding is performed so that
a clearance does not open in the part welded.
6. Plug weld the 3 locations indicated by (C) shown in the figure, then install the bumper bracket.
End Of Sie
BM: SHROUD PANEL
09-80B5
09-80B
3525-1U-12L(09-80B).fm

SHROUD SIDE MEMBER REMOVAL [PANEL REPLACEMENT]
id098008919000
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000032
Removal Procedure
1. Drill the 3 locations indicated by (A) shown in the figure.
(B) 7
(A) 3
SHROUD SIDE MEMBER
aatjjb00000172
2. Drill the 7 locations indicated by (B) shown in the figure.

3. Remove the shroud side member.
End Of Sie
09-80B6
3525-1U-12L(09-80B).fm

SHROUD SIDE MEMBER INSTALLATION [PANEL REPLACEMENT]
id098008919100
Symbol Mark
SYMBOL MARK
MEANING
PLUG WELDING (ARC WELDING)
am6zzb0000032
(A) 7
(B) 3
SHROUD SIDE MEMBER
aatjjb00000173
5. Plug weld the 3 locations indicated by (B) shown in the figure, then install the shroud side member.
End Of Sie
09-80B7
09-80B
3525-1U-12L(09-80B).fm

SHROUD UPPER REINFORCEMENT REMOVAL [PANEL REPLACEMENT]
id098008927900
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000033
Removal Procedure
1. Drill the 3 locations shown in the figure.
Note
When drilling the 3 locations shown in the figure, do not drill a hole all the way through or there could be a
problem when installing the new part.
SHROUD UPPER REINFORCEMENT
1
2
am6zzb0000033
2. Remove the shroud upper reinforcement.
End Of Sie
09-80B8
3525-1U-12L(09-80B).fm

SHROUD UPPER REINFORCEMENT INSTALLATION [PANEL REPLACEMENT]
id098008928000
Symbol Mark
SYMBOL MARK
MEANING
PLUG WELDING (CO2 ARC WELDING)
am6zzb0000033
4. Plug weld 3 locations shown in the figure, then install the shroud upper reinforcement.
SHROUD UPPER REINFORCEMENT
am6zzb0000033
End Of Sie
BM: COWL SIDE REINFORCEMENT
09-80B9
09-80B
3525-1U-12L(09-80B).fm
10

COWL SIDE REINFORCEMENT REMOVAL [PANEL REPLACEMENT]
id098008741700
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000032
Removal Procedure
COWL SIDE REINFORCEMENT

(A) 17
(B) 8
(A) 12
am6zzb0000033
2. Drill the 8 locations indicated by (B) shown in the figure, then remove the cowl side reinforcement.
End Of Sie
09-80B10
3525-1U-12L(09-80B).fm
11

COWL SIDE REINFORCEMENT INSTALLATION [PANEL REPLACEMENT]
id098008741800
Symbol Mark
SYMBOL MARK
MEANING
am6zzb0000033
4. Plug weld 8 locations indicated by (A) shown in the figure.
COWL SIDE REINFORCEMENT

(B) 17
(A) 8
(B) 12
am6zzb0000033
5. Plug weld 29 locations indicated by (B) shown in the figure, then install the cowl side reinforcement.
End Of Sie
BM: WIPER BRACKET
09-80B11
09-80B
3525-1U-12L(09-80B).fm
12

WIPER BRACKET REMOVAL [PANEL REPLACEMENT]
id098008968800
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000033
Removal Procedure
1. Drill the 1 location indicated by (A) from the inside shown in the figure.
(B) 3
WIPER BRACKET
(B) 8
am6zzb0000033
2. Drill the 11 locations indicated by (B) shown in the figure, then remove the wiper bracket.
End Of Sie
09-80B12
3525-1U-12L(09-80B).fm
13

WIPER BRACKET INSTALLATION [PANEL REPLACEMENT]
id098008968900
Symbol Mark
SYMBOL MARK
MEANING
am6zzb0000033
(A) 3
WIPER BRACKET
(A) 8
(B) 1
am6zzb0000034
5. Plug weld the 1 location indicated by (B) from the inside shown in the figure, then install the wiper bracket.
End Of Sie
BM: WHEEL APRON PANEL
09-80B13
09-80B
3525-1U-12L(09-80B).fm
14

WHEEL APRON COMPONENT REMOVAL [PANEL REPLACEMENT]
id098008746000
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
ARC WELDING (SPOT WELDING)
am6zzb0000034
Removal Procedure
1. Drill the 16 locations (driver-side), 15 locations (passenger-side) indicated by (A) from the wheel housing
shown in the figure.
DRIVER-SIDE: (B) 12
PASSENGER-SIDE: (B) 11
WHEEL APRON COMPONENT
(C) 6
DRIVER-SIDE: (A) 16
PASSENGER-SIDE: (A) 15
(D) 2
(D) 2
am6zzb0000034
2.
3.
4.
5.
Drill the 12 locations (driver-side), 11 locations (passenger-side) indicated by (B) shown in the figure.
Drill the 6 locations indicated by (C) shown in the figure.
Grind the 4 locations indicated by (D) shown in the figure.
Drill the 11 locations indicated by (E) from the inside shown in the figure.
09-80B14
3525-1U-12L(09-80B).fm
15
09-80B
(E) 11
aatjjb00000181
6. Remove the wheel apron component.
End Of Sie
09-80B15
3525-1U-12L(09-80B).fm
16

WHEEL APRON COMPONENT INSTALLATION [PANEL REPLACEMENT]
id098008746100
Symbol Mark
SYMBOL MARK
MEANING
am6zzb0000034
2. Drill holes 16 locations (driver-side), 15 locations (passenger-side) indicated by (A) for the plug welding before
installing the new parts.
4. Plug weld the 16 locations (driver-side), 15 locations (passenger-side) indicated by (A) from the wheel housing
shown in the figure.
DRIVER-SIDE: (B) 12
WHEEL APRON COMPONENT
(C) 6
DRIVER-SIDE: (A) 16
PASSENGER-SIDE: (A) 15
(D) 2
(D) 2
am6zzb0000034
5.
6.
7.
8.
Plug weld the 12 locations (driver-side), 11 locations (passenger-side) indicated by (B) shown in the figure.
Plug weld the 6 locations indicated by (C) shown in the figure.
Arc weld the 4 locations indicated by (D) shown in the figure.
Plug weld the 11 locations indicated by (E) from the inside shown in the figure, then install the wheel apron
component.
09-80B16
3525-1U-12L(09-80B).fm
17
09-80B
(E) 11
aatjjb00000184
End Of Sie
09-80B17
3525-1U-12L(09-80B).fm
18

FRONT FENDER JUNCTION REMOVAL [PANEL REPLACEMENT]
id098008828300
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000034
Removal Procedure
1. Drill the 3 locations indicated shown in the figure.
FRONT WHEEL APRON REINFORCEMENT
FRONT FENDER JUNCTION
(B) 2
(B) 1
(A) 1
(A) 2
am6zzb0000034
2. Remove the front wheel apron reinforcement.

4. Remova the front fender junction.
End Of Sie
09-80B18
3525-1U-12L(09-80B).fm
19

FRONT FENDER JUNCTION INSTALLATION [PANEL REPLACEMENT]
id098008828400
Symbol Mark
SYMBOL MARK
MEANING
am6zzb0000034
4. Plug weld the 3 locations indicated by (A) shown in the figure, then install the front wheel apron reinforcement.
FRONT WHEEL APRON REINFORCEMENT
FRONT FENDER JUNCTION
(B) 2
(B) 1
(A) 1
(A) 2
am6zzb0000034
5. Plug weld the 3 locations indicated by (B) shown in the figure, then install the front fender junction.
End Of Sie
BM: FRONT SIDE FRAME
09-80B19
09-80B
3525-1U-12L(09-80B).fm
20

FRONT SIDE FRAME REMOVAL [PANEL REPLACEMENT]
id098008605900
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000034
Removal Procedure
Note
When drilling the 4 locations indicated by (B) shown in the figure, do not drill a hole all the way through or
there could be a problem when installing the new part.
(B) 4
(A) 2
(A) 2
(A) 4
(A) 3
(A) 4
FRONT FRAME
(REAR)
FRONT SIDE FRAME
am6zzb0000035
3. Remove the front side frame from the front frame (rear).
End Of Sie
09-80B20
3525-1U-12L(09-80B).fm
21

FRONT SIDE FRAME INSTALLATION [PANEL REPLACEMENT]
id098008606000
Symbol Mark
SYMBOL MARK
MEANING
am6zzb0000035
5. Plug weld the 11 locations indicated by (B) shown in the figure them install the front side frame.
(A)2
(A)4
(A)2
(B)4
(B)3
(B)4
FRONT SIDE FRAME
am6zzb0000035
End Of Sie
09-80B21
09-80B
3525-1U-12L(09-80B).fm
22

FRONT SIDE FRAME (PARTIAL CUTTING) REMOVAL [PANEL REPLACEMENT]
id098008742100
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
ROUGH CUT LOCATION
am6zzb0000035
Removal Procedure
(B) 1
(A) 2
OUTER FRAME REINFORCEMENT
(C) ROUGH CUT AREA

(D) 5
(A) 5
LH:146mm {5.75 in}

FRONT SIDE FRAME (INNER) RH:190 mm {7.48 in}
LH:(D) 1
RH:(D) 2
SUSPENSION MOUNTING
REINFORCEMENT
am6zzb0000035
2. Grind the 1 location indicated by (B) shown in the figure, then remove the suspension mounting reinforcement
and outer frame reinforcement.
3. Rough cut the location indicated by (C) shown in the figure.
4. Drill the 6 locations (LH), 7 locations (RH) indicated by (D) shown in the figure, then remove the front side frame
(inner).
5. Rough cut the location indicated by (E) shown in the figure.
09-80B22
3525-1U-12L(09-80B).fm
23
09-80B
(F) 1 (LH ONLY)

(E) ROUGH CUT AREA
(G) 1
(F) 1 (LH ONLY)
LH:123 mm {4.84 in}

RH:160 mm {6.30 in}
FRONT SIDE FRAME (OUTER)
am6zzb0000035
6. Drill the 2 locations indicated by (F) shown in the figure. (LH only)
7. Drill the 1 location indicated by (G) shown in the figure, then remove the front side frame (outer).
End Of Sie
09-80B23
3525-1U-12L(09-80B).fm
24

FRONT SIDE FRAME (PARTIAL CUTTING) INSTALLATION [PANEL REPLACEMENT]
id098008742200
Symbol Mark
SYMBOL MARK
MEANING
ROUGH CUT LOCATION

am6zzb0000035
Caution
The cut and joint area indicates the maximum size range of the installation position.
3. Cut and join location indicated by (A) shown in the figure.
09-80B24
3525-1U-12L(09-80B).fm
25
09-80B
(B) 1 (LH ONLY)

(A) CUT AND JOIN LOCATION
(B) 1
(B) 1 (LH ONLY)
LH:123 mm {4.84 in}

RH:160 mm {6.30 in}
FRONT SIDE FRAME (OUTER)
am6zzb0000035
4. Plug weld the 3 locations (LH), 1 location (RH) indicated by (B) shown in the figure, then install the front side
frame (outer).
5. To cut and join the new and existing parts, rough cut the new part at the specified location shown in the figure,
and chamfer the joint surfaces of the new and existing parts.
09-80B25
3525-1U-12L(09-80B).fm
26

FRONT SIDE FRAME (INNER)
(NEW PART)
LH:146 mm {5.75 in}

RH:190 mm {7.48 in}
(C) ROUGH CUT AREA

am6zzb0000035
6. Make a reinforcement panel using the material from the front side frame (inner).
7. Plug weld the 4 locations (LH), 6 locations (RH) indicated by (D) shown in the figure, then install the
reinforcement to the new front side frame (inner).
09-80B26
3525-1U-12L(09-80B).fm
27

LH
REINFORCEMENT
75 mm {3.0 in}
100 mm {3.94 in}

30 mm
{1.2 in}
30 mm
{1.2 in}
09-80B
t = 1.4 mm {0.055 in}

FRONT SIDE FRAME (INNER) (NEW PART)
25 mm
{0.98 in}
50 mm
{2.0 in}
(D) 2
REINFORCEMENT
REINFORCEMENT
REINFORCEMENT
50 mm
{2.0 in}
REINFORCEMENT
50 mm
{2.0 in}
(D) 2
am6zzb0000051
09-80B27
3525-1U-12L(09-80B).fm
28

RH
REINFORCEMENT
90 mm {3.5 in}
100 mm {3.94 in}
25 mm
{0.98 in}
30 mm
{1.2 in}
t = 1.4 mm {0.055 in}

FRONT SIDE FRAME (INNER) (NEW PART)
60 mm {2.4 in}
30 mm {1.2 in}
(D) 2
REINFORCEMENT
REINFORCEMENT
(D) 2
50 mm
{2.0 in}
(D) 2
50 mm
{2.0 in}
REINFORCEMENT
REINFORCEMENT
REINFORCEMENT
am6zzb0000036
8. Plug weld 3 locations (LH), 2 locations (RH) indicated by (E) shown in the figure.
Note
Press fit the reinforcement panel and the body side material, and then weld them.
09-80B28
3525-1U-12L(09-80B).fm
29
09-80B
(I) 1
(H) 2
OUTER FRAME REINFORCEMENT
LH:(E) 2 (E) CUT AND JOIN

LOCATION
(G) 5
RH:(E) 1
RH:(E) 1
LH:(E) 1
FRONT SIDE FRAME (INNER)
(H) 5
LH:146 mm {5.75 in}

RH:154 mm {6.06 in}
LH:(G) 1
RH:(G) 2
SUSPENSION MOUNTING
REINFORCEMENT
am6zzb0000036
9. Cut and join location indicated by (F) shown in the figure.

10. Plug weld the 6 locations (LH), 7 locations (RH) indicated by (G) shown in the figure, then install the front side
frame (inner).
11. Plug weld the 7 locations indicated by (H) shown in the figure.
12. Plug weld the 1 location indicated by (I) shown in the figure, then install the suspension mounting reinforcement
and outer frame reinforcement.
End Of Sie
BM: COWL UPPER PLATE
09-80B29
3525-1U-12L(09-80B).fm
30

COWL UPPER PLATE REMOVAL [PANEL REPLACEMENT]
id098008957100
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000036
Removal Procedure
(B) 8
COWL PLATE (UPPER)
(A) 9
am6zzb0000036
2. Drill the 8 locations indicated by (B) shown in the figure, then remove the cowl plate (upper).
End Of Sie
09-80B30
3525-1U-12L(09-80B).fm
31

COWL UPPER PLATE INSTALLATION [PANEL REPLACEMENT]
id098008957200
Symbol Mark
SYMBOL MARK
MEANING
am6zzb0000036
(A) 8
COWL PLATE (UPPER)
(B) 9
am6zzb0000036
5. Plug weld the 8 locations indicated by (B) shown in the figure, then install the cowl plate (upper).
End Of Sie
BM: TORQUE BOX
09-80B31
09-80B
3525-1U-12L(09-80B).fm
32

TORQUE BOX REMOVAL [PANEL REPLACEMENT]
id098008607100
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000036
Removal Procedure
1. Drill the 23 locations (LH), 28 locations (RH) indicated by (A) shown in the figure.
Note
When drilling the 23 locations (LH), 28 locations (RH) indicated by (A) shown in the figure, do not drill a
hole all the way through or there could be a problem when installing the new part.
RH: (A) 11
LH: (A) 16
(A) 3
(A) 3
(A) 6
TOQUE BOX
am6zzb0000036
2. Drill the 7 locations indicated by (B) from the inside shown in the figure.
09-80B32
3525-1U-12L(09-80B).fm
33
09-80B
(B) 7
aatjjb00000198
3. Remove the torque box.
End Of Sie
09-80B33
3525-1U-12L(09-80B).fm
34

TORQUE BOX INSTALLATION [PANEL REPLACEMENT]
id098008607200
Symbol Mark
SYMBOL MARK
MEANING
am6zzb0000036
2. Drill holes 23 locations (LH), 28 locations (RH) indicated by (B) shown in the figure for the plug welding before
installing the new parts.
4. Plug weld the 7 locations indicated by (A) from the room side shown in the figure.
(A) 7
am6zzb0000036
5. Plug weld the 23 locations (LH), 28 locations (RH) by (B) shown in the figure, then install the toque box.
09-80B34
3525-1U-12L(09-80B).fm
35
RH: (B) 11
LH: (B) 16
(B) 3
09-80B
(B) 3
(B) 6
TOQUE BOX
am6zzb0000037
End Of Sie
BM: FRONT FRAME REAR
09-80B35
3525-1U-12L(09-80B).fm
36

SIDE MEMBER REMOVAL [PANEL REPLACEMENT]
id098008928100
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000037
Removal Procedure
1. Drill the 45 locations (driver-side), 44 locations (passenger-side) shown in the figure.
Note
When drilling the 45 locations (driver-side), 44 locations (passenger-side) shown in the figure, do not drill
a hole all the way through or there could be a problem when installing the new part.
DRIVER-SIDE: 6
PASSENGER-SIDE: 5
SIDE MEMBER
5
8
10
11
3
am6zzb0000037
2. Remove the side member.
End Of Sie
09-80B36
3525-1U-12L(09-80B).fm
37

SIDE MEMBER INSTALLATION [PANEL REPLACEMENT]
id098008928200
Symbol Mark
SYMBOL MARK
MEANING
am6zzb0000037
4. Plug weld the 45 locations (driver-side), 44 locations (passenger-side) shown in the figure, then install the side
member.
DRIVER-SIDE: 6
PASSENGER-SIDE: 5
SIDE MEMBER
5
8
10
11
3
am6zzb0000037
End Of Sie
09-80B37
09-80B
3525-1U-12L(09-80B).fm
38

FRONT FRAME (REAR) REMOVAL [PANEL REPLACEMENT]
id098008742500
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000037
Removal Procedure
Note
When drilling the 26 locations shown in the figure, do not drill a hole all the way through or there could be
a problem when installing the new part.
11
11
FRONT FRAME REAR
am6zzb0000037
2. Remove the front frame (rear).
End Of Sie
09-80B38
3525-1U-12L(09-80B).fm
39

FRONT FRAME (REAR) INSTALLATION [PANEL REPLACEMENT]
id098008742600
Symbol Mark
SYMBOL MARK
MEANING
am6zzb0000037
4. Plug weld the 26 locations shown in the figure, then install the front frame (rear).
11
11
FRONT FRAME (REAR)
am6zzb0000037
End Of Sie
BM: FRONT PILLAR
09-80B39
09-80B
3525-1U-12L(09-80B).fm
40

FRONT PILLAR REMOVAL [PANEL REPLACEMENT]
id098008744700
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
ROUGH CUT LOCATION
am6zzb0000037
Removal Procedure
Caution
Remove the curtain air bag module to prevent damage before servicing.
Front-side
CURTAIN AIR BAG MODULE
am6xub0000010
09-80B40
3525-1U-12L(09-80B).fm
41

Rear-side
09-80B
am6xub0000010
Caution
Avoid cutting with a blowtorch or similar tools as the insulator (shaded area) is flammable.
INSULATOR
INSULATOR
am6zzb0000038
1. Rough cut the 2 locations indicated by (A) shown in the figure.
09-80B41
3525-1U-12L(09-80B).fm
42
150 mm
{5.91 in}
(A) ROUGHT CUT AREA
(B) 13
CABIN SIDE FRAME (OUTER)
(FRONT PILLAR (OUTER))
am6zzb0000038
(B) 6
(FRONT PILLAR OUTER)
(B) 1
(B) 30
76 mm {3.0 in}
(B) 22
(B) 2
(A) ROUGH CUT AREA
am6zzb0000038
2. Drill the 74 locations indicated by (B) shown in the figure, then remove the cabin side frame (outer) (front pillar
(outer)).
3. Rough cut the location (C) shown in the figure.
09-80B42
3525-1U-12L(09-80B).fm
43
180 mm
{7.09 in}
(C) ROUGH CUT AREA
FRONT PILLAR REINFORCEMENT
09-80B
(E) 5
HINGE REINFORCEMENT
(D) 18
am6zzb0000038
4. Drill the 18 locations indicated by (D) shown in the figure.

5. Drill the 5 locations indicated by (E) from the room side shown in the figure, then front pillar reinforcement and
hinge reinforcement as a single unit.
6. Rough cut the location indicated by (F) shown in the figure.
210 mm
{8.27 in}
(F) ROUGH CUT AREA

FRONT PILLAR (INNER)
DRIVER-SIDE: (G) 17
PASSENGER-SIDE: (G) 12
HINGE PILLAR (INNER)
am6zzb0000038
09-80B43
3525-1U-12L(09-80B).fm
44

7. Drill the 17 locations (driver-side), 12 locations (passenger-side) indicated (G) shown in the figure, then remove
the front pillar (inner) and hinge pillar (inner) as a single unit.
End Of Sie
FRONT PILLAR INSTALLATION [PANEL REPLACEMENT]
id098008744800
Symbol Mark
SYMBOL MARK
MEANING
ROUGH CUT LOCATION
am6zzb0000038
4. Cut and join location the indicated by (A) shown in the figure, then install the front pillar (inner).
5. Plug weld the 21 locations (LH), 16 locations (RH) indicated by (B) shown in the figure, then install the hinge
pillar (inner).
190 mm
{7.48 in}

FRONT PILLAR (INNER)
(B) 4
DRIVER-SIDE: (B) 17
HINGE PILLAR (INNER)
am6zzb0000038
6. Plug weld the 5 locations indicated by (C) from the room side shown in the figure.
7. Plug weld the 18 locations indicated by (D) shown in the figure, then install the hinge reinforcement.
8. Cut and join the location indicated by (E) shown in the figure.
09-80B44
3525-1U-12L(09-80B).fm
45

9. Plug weld the 10 locations indicated by (F) shown in the figure, then install the front pillar reinforcement.
160 mm
{6.30 in}
(E) CUT AND JOIN LOCATION
FRONT PILLAR REINFORCEMENT
09-80B
(F) 10
(C) 5
HINGE REINFORCEMENT
(D) 18
am6zzb0000038
10. Cut and join the 2 locations indicated by (G) shown in the figure.
120 mm
{4.72 in}
(G) CUT AND JOIN LOCATION
(H) 13
am6zzb0000039
09-80B45
3525-1U-12L(09-80B).fm
46

11. Plug weld the 74 locations indicated by (H) shown in the figure, then install the cabin side frame (outer).
(H) 6
(H) 1
(H) 30
50 mm
{2.0 in}
(H) 22
(H) 2
(G) CUT AND JOIN

LOCATION
am6zzb0000051
End Of Sie
BM: CENTER PILLAR
09-80B46
3525-1U-12L(09-80B).fm
47

CENTER PILLAR REMOVAL [PANEL REPLACEMENT]
id098008743900
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
ROUGH CUT LOCATION
am6zzb0000039
Removal Procedure
Caution
Front-side
am6xub0000010
09-80B47
09-80B
3525-1U-12L(09-80B).fm
48

Rear-side
am6xub0000009
Caution
INSULATOR
am6zzb0000039
09-80B48
3525-1U-12L(09-80B).fm
49

2. Drill the 81 locations indicated by (B) shown in the figure, then remove the cabin side frame (outer) (center pillar
(outer)).
(A) ROUGH CUT AREA
ROOF RAIL REINFORCEMENT

(A) ROUGH CUT AREA
09-80B
(B) 29
(B) 1

(CENTER PILLAR (OUTER))

CENTER PILLAR
REINFORCEMENT
(B) 2
(B) 34
(A) ROUGH CUT AREA
455 mm
{17.9 in}
230 mm {9.06 in}

(A) ROUGH CUT AREA (B) 15
am6xub0000009
3. Drill the 36 locations indicated by (C) shown in the figure, then remove the center pillar reinforcement.
09-80B49
3525-1U-12L(09-80B).fm
50

(C) 9
CENTER PILLAR REINFORCEMENT
(C) 27
am6xub0000009
4. Rough cut the location (D) shown in the figure.

5. Drill the 5 locations indicated by (E) shown in the figure.
6. Drill the 6 locations indicated by (F) from the room side shown in the figure.
09-80B50
3525-1U-12L(09-80B).fm
51

7. Pull the center pillar (inner) in the direction of arrow shown in the figure, then remove it from between the side
sill (inner) and side sill reinforcement.
CENTER PILLAR (INNER)
09-80B
150 mm {5.91 in}

(D) ROUGH CUT AREA
(F) 6
a
(E) 5
SIDE SILL
REINFORCEMENT
sec. aa
SIDE SILL
(INNER)
a
am6zzb0000039
End Of Sie
09-80B51
3525-1U-12L(09-80B).fm
52

CENTER PILLAR INSTALLATION [PANEL REPLACEMENT]
id098008744000
Symbol Mark
SYMBOL MARK
MEANING
am6zzb0000039
4. Insert the end of the center pillar (inner) shown in the figure, between the side sill (inner) and side sill
reinforcement.
5. Cut and join location indicated by (A) shown in the figure.
6. Plug weld the 6 locations indicated by (B) from the room side shown in the figure, then install the center pillar
(inner).

130 mm {5.12 in}
(B) 6
a
SIDE SILL
(INNER)
SIDE SILL
REINFORCEMENT
sec. aa
a
am6zzb0000040
7. Plug weld the 36 locations indicated by (C) shown in the figure, then install the center pillar reinforcement.
09-80B52
3525-1U-12L(09-80B).fm
53

(C) 9
09-80B
CENTER PILLAR REINFORCEMENT
(C) 27
am6xub0000011
8. Cut and join the 3 locations indicated by (D) shown in the figure.
9. Plug weld the 81 locations indicated by (E) shown in the figure, then install the cabin side frame (outer) (center
pillar (outer)).
09-80B53
3525-1U-12L(09-80B).fm
54

(D) CUT AND JOIN LOCATION
(E) 29
(E) 1

(E) 2
(E) 34
(D) CUT AND JOIN
LOCATION
460 mm
{18.1 in}
235 mm {9.25 in}

(D) CUT AND JOIN LOCATION (E) 15
am6xub0000011
End Of Sie
BM: SIDE SILL PANEL
09-80B54
3525-1U-12L(09-80B).fm
55

SIDE SILL PANEL REMOVAL [PANEL REPLACEMENT]
id098008615300
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
ROUGH CUT LOCATION
am6zzb0000040
Removal Procedure
Side Sill (Front-side)

(SIDE SILL (OUTER))
(B) 9
(B) 7
285 mm {11.2 in}
(A) ROUGHT CUT AREA
455 mm {17.9 in}

(A) ROUGHT CUT AREA
am6zzb0000040
3. Remova the cabin side frame (outer) (side sill (outer)).
09-80B55
09-80B
3525-1U-12L(09-80B).fm
56

Side Sill (Component)
2. Drill the 106 locations indicated by (B) shown in the figure, remove the cabin side frame (outer) (side sill
(outer)).
334 mm {13.1 in}

290 mm {11.4 in}
230 mm {9.06 in}

(A) ROUGH CUT AREA
(A) ROUGH CUT AREA
(A) ROUGH CUT AREA

(B) 25
(B) 20
(B) 1
(B) 2
(B) 53
(SIDE SILL (OUTER))
(B) 5
am6xub0000010
3. Drill the 50 locations indicated by (C) shown in the figure.
09-80B56
3525-1U-12L(09-80B).fm
57

4. Pull the side sill reinforcement from the side sill (inner), hinge reinforcement and center pillar reinforcement,
and then remove it.
09-80B
SIDE SILL REINFORCEMENT

(C) 17
(C) 27
(C) 3
(C) 3
am6xub0000010
End Of Sie
09-80B57
3525-1U-12L(09-80B).fm
58

SIDE SILL PANEL INSTALLATION [PANEL REPLACEMENT]
id098008615200
Symbol Mrak
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000040
Side Sill (Front-side)
4. Cut and join the locations indicated by (A) shown in the figure.
5. Plug weld the 16 locations indicated by (B) shown in the figure, then install the cabin side frame (outer) (side sill
(outer)).

(SIDE SILL (OUTER))
(B) 9
(B) 7
280 mm {11.0 in}
460 mm {18.1 in}
am6zzb0000040
09-80B58
3525-1U-12L(09-80B).fm
59

Side Sill (component)
4. Plug weld the 50 locations indication by (A) shown in the figure, then install the side sill reinforcement.
09-80B
SIDE SILL REINFORCEMENT

(A) 17
(A) 27
(A) 3
(A) 3
am6xub0000010
5. Cut and join the 3 locations indicated by (B) shown in the figure.
09-80B59
3525-1U-12L(09-80B).fm
60

6. Plug weld the 106 locations indicated by (C) shown in the figure, then install the cabin side frame (outer) (side
sill (outer)).
324 mm
{12.8 in}
270 mm
{10.6 in}
(B) CUT AND JOIN
LOCATION
215 mm
{8.46}
(B) CUT AND JOIN
LOCATION
(C) 25
(C) 20
(C) 2
(C) 53
(SIDE SILL (OUTER))
(C) 5
am6xub0000010
End Of Sie
BM: REAR FENDER PANEL
09-80B60
3525-1U-12L(09-80B).fm
61

REAR FENDER PANEL REMOVAL [PANEL REPLACEMENT]
id098008744900
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
ROUGH CUT LOCATION
am6zzb0000041
Removal Procedure
Caution
INSULATOR
INSULATOR
am6zzb0000041
09-80B61
09-80B
3525-1U-12L(09-80B).fm
62

80 mm
{3.1 in}
(A) ROUGH CUT

AREA
(B) 5
(B) 31
(A) ROUGH CUT AREA
(B) 16
(B) 12
(REAR FENDER PANEL)
100 mm
{3.94 in}
(B) 2
am6zzb0000041
3. Drill the 27 locations indicated by (C) shown in the figure.
09-80B62
3525-1U-12L(09-80B).fm
63
(C) 19
09-80B

(REAR FENDER PANEL)
(C) 8
am6zzb0000041
4. Remove the cabin side frame (outer) (rear fender panel).
End Of Sie
09-80B63
3525-1U-12L(09-80B).fm
64

REAR FENDER PANEL INSTALLATION [PANEL REPLACEMENT]
id098008745000
Symbol Mark
SYMBOL MARK
MEANING
am6zzb0000041
4. Before installing new parts, apply body sealer to the wheel arch line.
BODY SEALER
am6zzb0000041
5. Cut and join the 2 locations indicated by (A) shown in the figure.
09-80B64
3525-1U-12L(09-80B).fm
65

6. Plug weld the 66 locations indicated by (B) shown in the figure.
60 mm
{2.4 in}
09-80B
(A) CUT AND

JOIN LOCATION
(B) 5
(B) 31
(A) CUT AND
JOIN LOCATION
(B) 16
(B) 12
(REAR FENDER PANEL)
80 mm
{3.1 in}
(B) 2
am6zzb0000042
7. Plug weld the 27 locations indicated by (C) shown in the figure, then install the cabin side frame (rear fender
panel).
09-80B65
3525-1U-12L(09-80B).fm
66
(C) 19

(REAR FENDER PANEL)
(C) 8
am6zzb0000042
End Of Sie
09-80B66
3525-1U-12L(09-80B).fm
67

REAR FENDER PANEL (LOWER) REMOVAL [PANEL REPLACEMENT]
id098008614300
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000042
09-80B
Removal Procedure
REAR FENDER PANEL (LOWER)
11
am6zzb0000042
2. Remove the rear fender panel (lower).
End Of Sie
09-80B67
3525-1U-12L(09-80B).fm
68

REAR FENDER PANEL (LOWER) INSTALLATION [PANEL REPLACEMENT]
id098008614400
Symbol Mark
SYMBOL MARK
MEANING
am6zzb0000042
3. Plug weld the 24 locations shown in the figure, then install the rear fender panel (lower).
REAR FENDER PANEL (LOWER)
11
am6zzb0000042
End Of Sie
BM: REAR FENDER RAIN RAIL
09-80B68
3525-1U-12L(09-80B).fm
69

CORNER PLATE REMOVAL [PANEL REPLACEMENT]
id098008610400
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000043
09-80B
Removal Procedure
CORNER PLATE
11
am6zzb0000043
2. Remove the corner plate.
End Of Sie
09-80B69
3525-1U-12L(09-80B).fm
70

CORNER PLATE INSTALLATION [PANEL REPLACEMENT]
id098008610500
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000043
5. Spot weld the 3 locations indicated by (B) shown in the figure, then install the corner plate.
(A) 3
(B) 1
CORNER PLATE
(B) 2
(A) 9
am6zzb0000043
End Of Sie
09-80B70
3525-1U-12L(09-80B).fm
71

REAR FENDER RAIN RAIL REMOVAL [PANEL REPLACEMENT]
id098008902200
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000044
09-80B
Removal Procedure
1
4
am6zzb0000044
2. Remove the rear fender rain rail.
End Of Sie
09-80B71
3525-1U-12L(09-80B).fm
72

REAR FENDER RAIN RAIL INSTALLATION [PANEL REPLACEMENT]
id098008902300
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000044
5. Spot weld the 2 locations indicated by (B) shown in the figure, then install the rear fender rain rail.
(A) 1
(A) 3
(B) 1
(B) 1
(A) 3
am6zzb0000044
End Of Sie
BM: REAR END PANEL
09-80B72
3525-1U-12L(09-80B).fm
73

REAR END PANEL REMOVAL [PANEL REPLACEMENT]
id098008744500
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000044
09-80B
Removal Procedure
2. Drill the 4 locations indicated by (B) from the room side shown in the figure.
(B) 2
(B) 2
REAR END PANEL
(A) 16
(A) 16
(A) 12
(A) 15
(A) 12
am6zzb0000044
3. Remove the rear end panel.
End Of Sie
09-80B73
3525-1U-12L(09-80B).fm
74

REAR END PANEL INSTALLATION [PANEL REPLACEMENT]
id098008744600
Symbol Mark
SYMBOL MARK
MEANING
am6zzb0000044
5. Plug weld the 4 locations indicated by (B) from the room side shown in the figure, then install the rear end
panel.
(B) 2
(B) 2
REAR END PANEL

(A) 16
(A) 16
(A) 12
(A) 15
(A) 12
am6zzb0000044
End Of Sie
BM: FLOOR SIDE PANEL
09-80B74
3525-1U-12L(09-80B).fm
75

FLOOR SIDE PANEL REMOVAL [PANEL REPLACEMENT]
id098008618700
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000045
09-80B
Removal Procedure
1. Drill the 40 locations indicated by (A) shown in the figure, then remove the floor side panel No.1.
FLOOR SIDE PANEL No.1
(A) 16
(A) 17
(A) 7
am6zzb0000046
09-80B75
3525-1U-12L(09-80B).fm
76

3. Drill the 7 locations indicated by (C) from the rear wheel housing side shown in the figure.
(C) 7
(B) 11
am6zzb0000046
4. Remove the floor side panel No.2.
End Of Sie
09-80B76
3525-1U-12L(09-80B).fm
77

FLOOR SIDE PANEL INSTALLATION [PANEL REPLACEMENT]
id098008618800
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000046
4. Spot weld the 11 locations indicated by (A) shown in the figure.
5. Plug weld the 7 locations indicated by (B) shown in the figure, then install the floor side panel No.2.
(B) 7
(A) 11
am6zzb0000046
6. Plug weld the 40 locations indicated by (C) shown in the figure, then install the floor side panel No.1.
09-80B77
09-80B
3525-1U-12L(09-80B).fm
78
(C) 16
(C) 17
(C) 7
am6zzb0000046
End Of Sie
BM: TRUNK FLOOR PAN
09-80B78
3525-1U-12L(09-80B).fm
79

TRUNK FLOOR PANEL REMOVAL [PANEL REPLACEMENT]
id098008829500
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000046
09-80B
Removal Procedure
Caution
When drilling the 94 locations shown in the figure, do not drill a hole all the way through or there
could be a problem when installing the new part.
19
16
21
21
11
3
TRUNK FLOOR PANEL
am6zzb0000046
2. Remove the trunk floor panel.
End Of Sie
09-80B79
3525-1U-12L(09-80B).fm
80

TRUNK FLOOR PANEL INSTALLATION [PANEL REPLACEMENT]
id098008829600
Symbol Mark
SYMBOL MARK
MEANING
am6zzb0000046
4. Slide the end of trunk floor panel in the direction of arrow shown in the figure, and then insert it.
END OF TRUNK
FLOOR PANEL
END OF TRUNK
FLOOR PANEL
END OF TRUNK
FLOOR PANEL
END OF TRUNK FLOOR
am6zzb0000047
5. Plug weld the 94 locations shown in the figure, then install the trunk floor panel.
09-80B80
3525-1U-12L(09-80B).fm
81
19
09-80B
16
21
21
11
3
TRUNK FLOOR PANEL
am6zzb0000047
End Of Sie
BM: REAR SIDE FRAME
09-80B81
3525-1U-12L(09-80B).fm
82

REAR SIDE FRAME REMOVAL [PANEL REPLACEMENT]
id098008801200
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
ROUGH CUT LOCATION
am6zzb0000047
Removal Procedure
1. Drill the 40 locations indicated by (A) shown in the figure, then remove the floor side panel No.1.
(A) 16
(A) 17
(A) 7
am6zzb0000047
2. Rough cut the location indicated by (B) shown in the figure.
09-80B82
3525-1U-12L(09-80B).fm
83

3. Drill the 3 locations indicated by (C) shown in the figure, then remove the part of trunk floor panel (shaded
arear).
09-80B
(C) 3
(B) ROUGH CUT AREA
TRUNK FLOOR PANEL
am6zzb0000047
4. Drill the 13 locations indicated by (D) shown in the figure.
(D) 2
(D) 2
(D) 3
REAR SIDE FRAME
(D) 6
am6zzb0000047
5. Remove the rear side frame.
End Of Sie
09-80B83
3525-1U-12L(09-80B).fm
84

REAR SIDE FRAME INSTALLATION [PANEL REPLACEMENT]
id098008801300
Symbol Mark
SYMBOL MARK
MEANING
am6zzb0000047
4. Plug weld the 13 locations indicated by (A) shown in the figure, then install the rear side frame.
(A) 2
(A) 2
(A) 3
REAR SIDE FRAME
(A) 6
am6zzb0000047
5. Cut and join location indicated by (B) shown in the figure.
09-80B84
3525-1U-12L(09-80B).fm
85

6. Plug weld the 3 locations indicated by (C) shown in the figure, then install the part of trunk floor panel.
09-80B
(C) 3
(B) CUT AND JOIN
LOCATION
TRUNK FLOOR PANEL
am6zzb0000047
7. Plug weld the 40 locations indicated by (D) shown in the figure, then install the floor side panel No.1.
(D) 16
(D) 17
(D) 7
am6zzb0000047
End Of Sie
BM: ROOF PANEL
09-80B85
3525-1U-12L(09-80B).fm
86

ROOF PANEL REMOVAL [PANEL REPLACEMENT]
id098008744300
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000048
Removal Procedure
Caution
Front-side
am6xub0000011
Rear-side
am6xub0000011
09-80B86
3525-1U-12L(09-80B).fm
87

22
ROOF PANEL
09-80B
19
19
22
am6zzb0000048
2. Remove the roof panel.
End Of Sie
09-80B87
3525-1U-12L(09-80B).fm
88

ROOF PANEL INSTALLATION [PANEL REPLACEMENT]
id098008744400
Symbol Mark
SYMBOL MARK
MEANING
SPOT WELDING
am6zzb0000048
4. Apply the body sealer to the position shown in the figure.
: BODY SEALER
am6zzb0000048
09-80B88
3525-1U-12L(09-80B).fm
89

6. Spot weld the 38 locations indicated by (B) shown in the figure, then install the roof panel.
(A) 22
ROOF PANEL
(B) 19
(B) 19
(A) 22
am6zzb0000048
End Of Sie
09-80B89
3525-1U-12L(09-80C).fm
BODY STRUCTURE [WATER-PROOF AND RUST PREVENTIVE]
09-80C BODY STRUCTURE [WATER-PROOF AND RUST

PREVENTIVE]
BODY SEALING
[WATER-PROOF AND
RUST PREVENTIVE] . . . . . . . . . . . . . . 09-80C1
UNDER COATING
[WATER-PROOF AND
RUST PREVENTIVE] . . . . . . . . . . . . . . 09-80C5
CHIPPING-RESISTANT COATING
[WATER-PROOF AND
RUST PREVENTIVE] . . . . . . . . . . . . . . . 09-80C5
RUST PREVENTIVE TREATMENT
[WATER-PROOF AND
DUMPING SHEET REPLACEMENT
[WATER-PROOF AND
End of Toc
BODY SEALING [WATER-PROOF AND RUST PREVENTIVE]
BM: WATER-PROOF AND RUST PREVENTIVE
id098009739800
Sealant is applied to the parts where the panels meet and to the hemmed parts of the door panel and hood
panel to provide water proofing and rust proofing.
FRONT BODY
am6zzb0000049
09-80C1
09-80C
3525-1U-12L(09-80C).fm

ROOM
am6zzb0000049
REAR BODY
am6zzb0000049
09-80C2
3525-1U-12L(09-80C).fm

UNDER BODY
09-80C
am6zzb0000049
09-80C3
3525-1U-12L(09-80C).fm

HOOD
DOOR
TRUNK LID
am6xub0000011
End Of Sie
09-80C4
3525-1U-12L(09-80C).fm

UNDER COATING [WATER-PROOF AND RUST PREVENTIVE]
id098009739900
RH
LH
The shaded areas indicated under body locations that are undercoated to prevent noise and rusting.
09-80C
aatjjb00000333
End Of Sie
CHIPPING-RESISTANT COATING [WATER-PROOF AND RUST PREVENTIVE]
id098009740000
The coating locations are indicated by the shaded areas.
aatjjb00000335
End Of Sie
09-80C5
3525-1U-12L(09-80C).fm

RUST PREVENTIVE TREATMENT [WATER-PROOF AND RUST PREVENTIVE]
id098009740100
HOOD
DOOR
TRUNK LID
am6xub0000011
End Of Sie
09-80C6
3525-1U-12L(09-80C).fm

DUMPING SHEET REPLACEMENT [WATER-PROOF AND RUST PREVENTIVE]
id098009745700
After repairing the body, attach the dumping sheet to the location shown in the figure for noise insulation.
09-80C
:ATTACH THE DUMPING SHEET LOCATION
am6zzb0000050
End Of Sie
09-80C7
3525-1U-12L(09-80C).fm
3525-1U-12L(09-80D).fm
BODY STRUCTURE [DIMENSIONS]
09-80D BODY STRUCTURE [DIMENSIONS]

UNDERBODY DIMENSIONS
[DIMENSIONS] . . . . . . . . . . . . . . . . . . .
FRONT WHEEL ALIGNMENT
[DIMENSIONS] . . . . . . . . . . . . . . . . . . .
Steering Angle Adjustment . . . . . . . . .
Total Toe-in Adjustment . . . . . . . . . . . .
REAR WHEEL ALIGNMENT
[DIMENSIONS] . . . . . . . . . . . . . . . . . . .
Total Toe-in Adjustment . . . . . . . . . . . .
FRONT BODY DIMENSIONS (1)
[DIMENSIONS] . . . . . . . . . . . . . . . . . . .
09-80D2
09-80D3
09-80D4
09-80D4
09-80D5
09-80D5
09-80D6
FRONT BODY DIMENSIONS (2)

[DIMENSIONS] . . . . . . . . . . . . . . . . . . . . 09-80D7
CABIN SIDE FRAME DIMENSIONS
[DIMENSIONS] . . . . . . . . . . . . . . . . . . . . 09-80D9
ROOM DIMENSIONS (1)
[DIMENSIONS] . . . . . . . . . . . . . . . . . . . . 09-80D11
ROOM DIMENSIONS (2)
[DIMENSIONS] . . . . . . . . . . . . . . . . . . . . 09-80D13
ROOM DIMENSIONS (3)
[DIMENSIONS] . . . . . . . . . . . . . . . . . . . . 09-80D14
REAR BODY DIMENSIONS
[DIMENSIONS] . . . . . . . . . . . . . . . . . . . . 09-80D15
09-80D
End of Toc
BM: UNDERBODY
09-80D1
3525-1U-12L(09-80D).fm

UNDERBODY DIMENSIONS [DIMENSIONS]
id098010990000
The following figures are bottom and side views.

STRAIGHT-LINE DIMENSIONS
A'
B'
C'
D'
468
{18.4}
1,030
{40.55}
994
{39.4}
RH
LH
403
{15.9}
E'
884
939 {34.8}
{37.0}
1,125
{44.29}
677
{26.7}
1,544
{60.79}
F'
G'
H'
I'
1,428
{56.22}
2,187
{86.10}
469
{18.5}
1,831
{72.09}
1,071
{42.17}
1,121
{44.13}
1,322
{52.05}
1,448
{57.01}
J'
1,672
{65.83}
527
{20.7}
206
{8.11}
403
{15.9}
437
{17.2}
985
{38.8}
756
{29.8}
960 {37.8}
J
522
{20.6}
692
{27.2}
590
{23.2}
528
{20.8}
966 {38.0}
1,014 {39.92}
1,148 {45.20}
922 {36.3}
F
437
{17.2}
437
{17.2}
610
{24.0}
D
497
{19.6}
844 {33.2}
698
{27.5}
529
{20.8}
617
{24.3}
712
{28.0}
937 {36.9}
958 {37.5}
988 {38.9}
RH
LH
FLAT-PLANE DIMENSIONS
458
{18.0}
mm {in}
182
{7.17}
112
246
{9.69} {4.41}
am6zzb0000050
09-80D2
3525-1U-12L(09-80D).fm

A
09-80D
aatjjb00000284
.
Point
symbol
A
B
C
D
E
Designation
Front crossmember
installation hole
Front side frame datum hole
Front crossmember
installation hole
Front crossmember
installation hole
Front crossmember
installation hole
Hole diameter
or bolt or nut
size (mm {in})
Point
symbol
20 {0.79}
F
G
16 {0.63}
22.5 {0.886}
Front B frame datum hole

Front B frame datum hole
Rear crossmember installation
bolt
Rear crossmember installation
bolt
Rear side frame datum hole
H
I
19 {0.75}
Designation
Hole diameter
or bolt or nut
size (mm {in})
16 {0.63}
25 {0.98}
M12
M12
16 {0.63}
22 {0.87}
End Of Sie
FRONT WHEEL ALIGNMENT [DIMENSIONS]

BM: WHEEL ALIGNMENT
id098010898900
Front wheel alignment (Unloaded)*1

Item
Maximum steering angle
[Tolerance 3]
Total toe-in
Tire
[Tolerance 4 {0.2}]
Rim inner
[Tolerance 3 {0.1}]
Empty
1/4
Inner
Outer
Fuel gauge indication

1/2
3/4
3836
3154
Full
2 {0.08}
(mm {in})
1.0 {0.04}
(degree)
Caster angle*2 (Reference value)

[Tolerance 1]
Camber angle*2 (Reference value)
[Tolerance 1]
Steering axis inclination (Reference value)
010020
608
611
613
615
617
-017
-017
-018
-018
-019
1507
1508
1509
1509
1510
*1 : Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated
position.
*2 : Difference between left and right must not exceed 130.
09-80D3
3525-1U-12L(09-80D).fm

Steering Angle Adjustment
1. Loosen the tie-rod end locknuts.
2. Remove the steering gear boot clamp.
3. Turn the tie rods.
Standard length L
17.730.7 mm {0.701.20 in}
4. Turn the tie rods equally to provide the correct
maximum steering angle.
5. Tighten the tie-rod end locknuts.
SCREW END
Tightening torque
6998 Nm {7.19.9 kgfm, 5172 ftlbf}
6. Verify that the boot is not twisted, and install the
boot clamp.
7. Adjust the toe-in after adjusting the steering angle.
am6zzw0000945
Total Toe-in Adjustment

1. Loosen the locknut of the tie-rod end.
2. Remove the rack boot clamp.
3. Adjust the total toe-in by rotating each tie rod (left and right) in the opposite directions by the same amount
respectively.
Note
If toe-in is measured at the tires, the change on one wheel is approx. 7 mm {0.3 in} per one rotation of
the tie rod.
Each tie rod has a right-hand thread. When increasing the toe-in angle, rotate the right tie rod toward the
front of the vehicle and rotate the left tie rod toward the rear of the vehicle by the same amount.
4. Tighten the locknut of the tie-rod end.
Tightening torque
6998 Nm {7.19.9 kgfm, 5172 ftlbf}
5. Verify that the rack boot does not have any twisting and install the rack boot clamp.
End Of Sie
09-80D4
3525-1U-12L(09-80D).fm

REAR WHEEL ALIGNMENT [DIMENSIONS]
id098010899000
Rear wheel alignment (Unloaded)*1

Item
Total toe-in
Tire
[Tolerance 4 {0.2}]
Rim inner
[Tolerance 3 {0.1}]
Empty
1/4
Fuel gauge indication

1/2
3/4
Full
2 {0.08}
(mm {in})
1.0 {0.04}
(degree)
*2 (Reference
value)
Camber angle
[Tolerance 1]
Thrust angle (Reference value) [Tolerance 048]
010020
-053
-056
-058
-100
-103
000
*1 : Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated
position.
*2 : Difference between left and right must not exceed 130.
Total Toe-in Adjustment
1. Loosen the installation nut of the adjusting cam bolt.
2. Rotate the adjusting cam bolt in either direction to
adjust the toe-in.
Toe-out direction
Toe-in direction
Left wheel
Clockwise
Counterclockwise
LEFT SIDE
Right wheel
Counterclockwise
Clockwise
3. Tighten the nut.

Tightening torque
84101 Nm {8.610 kgfm, 6274 ftlbf}
End Of Sie
BM: FRONT BODY
ADJUSTING CAM BOLT

ac5wzw0000245
09-80D5
09-80D
3525-1U-12L(09-80D).fm

FRONT BODY DIMENSIONS (1) [DIMENSIONS]
id098010990100
RH:361 {14.2}
LH:391 {15.4}
C
B
A
D
440 {17.3}
RH:462 {18.2}
LH:488 {19.2}
1,568 {61.73}
1,068 {42.05}
A'
C'
B'
RH:628
LH:657
D'
1,136 {44.72}
RH:841 {33.1}
LH:862 {33.9}
RH:855 {33.7}
LH:871 {34.3}
421 {16.6}
E'
1,499 {59.02}
1,200 {47.24}
F'
mm {in}
am6zzb0000050
A'
aatjjb00000296
.
09-80D6
3525-1U-12L(09-80D).fm

Point
symbol
A
B
C
D
Hole diameter
or bolt or nut
size (mm {in})
M8
M8
M8
Designation
Cowl panel installation nut
Hood hinge installation nut
Suspension housing (upper)
datum hole
Point
symbol
Hole diameter
or bolt or nut
size (mm {in})
Designation
Front fender panel installation
nut
nut
E
F
10.2 {0.402}
M6
M6
End Of Sie
FRONT BODY DIMENSIONS (2) [DIMENSIONS]
id098010990200
09-80D
730 {28.7}
1,190 {46.85}
A'
1,563 {61.54}
C
280 {11.0}
1,606 {63.23}
910 {35.8}
E
1,405 {55.31}
B'
1,435 {56.50}
G
1,275 {50.20}
C'
H
RH:221 {8.70} I
LH:206 {8.11}
E'
1,371 {53.98}
RH:950 {37.4}
LH:951 {37.4}
D'
677 {26.7}
F'
J
1,100 {43.31}
1,014
{39.92}
992 {39.1}
G'
I'
875 {34.4}
J'
H'
mm {in}
am6zzb0000050
09-80D7
3525-1U-12L(09-80D).fm

A
I'
J'
H'
ac5wzb00000168
.
Point
symbol
A
B
C
D
E
Designation
Roof projection location
Cabin side outer frame (front
pillar outer) projection location
Hood hinge installation nut
Suspension housing (upper)
datum hole
Hole diameter
or bolt or nut
size (mm {in})
M8
M8
10.2 {0.402}
Point
symbol
F
G
H
I
J
End Of Sie
BM: CABIN SIDE FRAME
09-80D8
Designation
nut
Shroud upper member
installation nut
Shroud side stay datum hole
Front bumper reinforcement
installation nut
Front bumper reinforcement
installation nut
Hole diameter
or bolt or nut
size (mm {in})
M6
M6
10 {0.39}
M10
M10
3525-1U-12L(09-80D).fm

CABIN SIDE FRAME DIMENSIONS [DIMENSIONS]
id098010990400
F
I
507 {20.0}
1,051 {41.38}
B
1,103 {43.43}
1,348 {53.07}
1,311 {51.61}
1,136 {44.72}
C
546 {21.5}
1,115 {43.90}
1,094 {43.07}
994 {39.1}
D
1,128 {44.41}
1,125
{44.29}
622 {24.5}
J
09-80D
F
I
1,139 {44.84}
836 {32.9}
800 {31.5}
G
1,792 {70.55}
1,112 {43.78}
C
2,124 {83.62}
A
745 {29.3}
1,863 {73.35}
1,211 {47.68}
1,309 {51.54}
2,054 {80.87}
D
H
E
J
mm {in}
am6zzb0000050
09-80D9
3525-1U-12L(09-80D).fm
10

A
aatjjb00000294
.
Point
symbol
A
B
C
D
E
F
Designation
Front side frame (outer) datum
hole
Front fender installation nut
Front door hinge installation
hole
Front door hinge installation
nut
Cabin side frame (outer) notch
Cabin side frame (outer) notch
End Of Sie
BM: ROOM
09-80D10
Hole diameter
or bolt or nut
size (mm {in})
Point
symbol
12 {0.47}
M6
12 {0.47}
M8
H
I
J
K
Designation
Rear door hinge installation
nut
Rear door hinge installation
hole
Rear pillar garnish installation
hole
Hole cover installation hole
Cabin side frame (outer)
datum hole
Hole diameter
or bolt or nut
size (mm {in})
M8
12 {0.47}
8 {0.3}
37 {1.5}
12 (0.47)
3525-1U-12L(09-80D).fm
11

ROOM DIMENSIONS (1) [DIMENSIONS]
id098010990500
B
C
1,080 {42.52}
D
990 {39.0}
1,375 {54.13}
09-80D
968 {38.1}
H
894 {35.2}
J-J'
E
1,194 {47.01}
1,591 {62.64}
821 {32.3}
I
1,042 {41.02}
mm {in}
am6zzb0000050
09-80D11
3525-1U-12L(09-80D).fm
12

A
aatjjb00000301
.
Point
symbol
A
B
C
D
E
Designation
A pillar trim installation square
hole
A pillar trim installation square
hole
Front pillar datum hole
Dashboard installation stud
pin
Side sill (inner) datum nut
Hole diameter
or bolt or nut
size (mm {in})
11 X 13
{0.43 X 0.51}
20 X 8
{0.79 X 0.3}
12 {0.47}
M8
Point
symbol
F
G
H
I
J
End Of Sie
09-80D12
Designation
Tunnel reinforcement datum
hole
Front seat belt upper anchor
installation nut
Center pillar (inner) datum
square hole
Pre-tensioner seat belt
installation nut
Front door checker installation
hole
Hole diameter
or bolt or nut
size (mm {in})
20 {0.79}
M10
7X7
{0.3 X 0.3}
M10
4 {0.2}
3525-1U-12L(09-80D).fm
13

id098010990600
RH:1,194 {47.01}
LH:1,099 {43.27}
E
09-80D
F
B
H-H'
RH:1,102 {43.39}
LH:995 {39.2}
RH:1,036
{40.79}
LH:912
{35.9}
1,598
{62.91}
RH:1,077 {42.40}
LH:953 {37.5}
G
C
RH:1,022 {40.20}
LH:886 {34.88}
RH:880 {34.6}
LH:716 {28.2}
mm {in}
am6zzb0000051
aatjjb00000302
.
09-80D13
3525-1U-12L(09-80D).fm
14

Point
symbol
A
B
C
D
Designation
Front seat belt upper anchor
installation nut
Center pillar (inner) datum
square hole
Pre-tensioner seat belt
installation nut
Center floor panel datum hole
Hole diameter
or bolt or nut
size (mm {in})
M10
77
{0.3 X 0.3}
M6
6 {0.2}
Point
symbol
E
F
G
H
Designation
RH: Keyless receiver
installation nut
LH: Condenser installation nut
Tire house trim installation
hole
Rear pillar (inner) datum hole
Rear door checker installation
hole
Hole diameter
or bolt or nut
size (mm {in})
M6
8.6 {0.34}
8.6 {0.34}
4 {0.2}
End Of Sie
id098010990700
RH:1,171 {46.10}
LH:1,079 {42.28}
C
E-E'
1,538 {60.55}
D
RH:1,668 {65.67}
LH:1,612 {63.46}
RH:1,599 {62.95}
LH:1,597 {62.87}
A
mm {in}
am6zzb0000051
09-80D14
3525-1U-12L(09-80D).fm
15

A
D'
aatjjb00000304
.
Point
symbol
A
B
C
Designation
Center floor panel datum hole
C pillar trim installation square
hole
Trunk side trim installation
hole
Hole diameter
or bolt or nut
size (mm {in})
6 {0.2}
11X13
{0.43 X 0.51}
Point
symbol
D
E
Designation
Trunk lid striker installation nut
Rear door striker installation
hole
Hole diameter
or bolt or nut
size (mm {in})
M6
13 {0.51}
6 {0.2}
End Of Sie
REAR BODY DIMENSIONS [DIMENSIONS]

BM: REAR BODY
id098010990800
1,216 {47.87}
A'
430
249
{16.93} {9.80}
1,285 {50.59}
B'
1,206 {47.48}
C'
1,445 {56.89}
706
{27.80}
H'
1,341 {52.80}
1,439 {56.65}
1,404 {55.28}
1,170 {46.06}
D'
360 {14.2}
G'
E'
154 {6.06}
F'
864 {34.0}
972 {38.3}
1,067 {42.01}
377 {14.8}
E
F
mm {in}
am6zzb0000051
09-80D15
09-80D
3525-1U-12L(09-80D).fm
16

A
G'
aatjjb00000407
.
Point
symbol
A
B
C
Designation
Cabin side frame (outer) (rear
fender panel) projection
location
Cabin side frame (outer) (rear
fender panel) projection
location
Corner plate datum hole
End Of Sie
09-80D16
Hole diameter
or bolt or nut
size (mm {in})
Point
symbol
D
E
10 {0.39}
F
G
H
Designation
Rear combination light wiring
harness through hole
Rear bumper reinforcement
installation bolt
Rear bumper reinforcement
installation bolt
Trunk lid striker installation nut
Brace bracket datum hole
Hole diameter
or bolt or nut
size (mm {in})
35 {1.4}
M10
M10
M6
10 {0.39}
3525-1U-12L(09-80E).fm
BODY STRUCTURE [PLASTIC BODY PARTS]
09-80E BODY STRUCTURE [PLASTIC BODY PARTS]

PLASTIC PARTS HEAT
RESISTING TEMPERATURE
[PLASTIC BODY PARTS] . . . . . . . . . . . 09-80E1
REPAIRABLE RANGE OF
POLYPROPYLENE BUMPERS
[PLASTIC BODY PARTS] . . . . . . . . . . . 09-80E2
Repairable Bumpers . . . . . . . . . . . . . . . 09-80E2

POLYPROPYLENE BUMPER REPAIR
[PLASTIC BODY PARTS]. . . . . . . . . . . . 09-80E3
PROCEDURE
[PLASTIC BODY PARTS]. . . . . . . . . . . . 09-80E4
End of Toc
PLASTIC PARTS HEAT RESISTING TEMPERATURE [PLASTIC BODY PARTS]
BM: PLASTIC BODY PARTS
Part Name
Front bumper
Cowl grille
Front combination light
Power outer mirror
Rear combination light
Lens
Housing
Panel
Visor
Under panel
Lens
Housing
Rear bumper
Reflector
Lens
Housing
Outer handle lever

Trunk lid light
Liftgate light
High-mount brake light
Sail outer garnish
Front door garnish
Rear door garnish
Trunk lid garnish
Liftgate garnish
Lens
Housing
Lens
Housing
Lens
Housing
Code
PP
PP
PC
PP
ABS
AAS
AAS
PMMA
AAS
PP
ABS
PMMA
PC-PBT
PMMA
AAS
PMMA
AAS
PMMA
PC
PVC
AAS
AAS
ABS
PC-ABS
Material Name
POLYPROPYLENE
POLYPROPYLENE
POLYCARBONATE
POLYPROPYLENE
ABS
AAS
AAS
ACRYLIC
AAS
POLYPROPYLENE
ABS
ACRYLIC
POLYCARBONATE-PBT
ACRYLIC
AAS
ACRYLIC
AAS
ACRYLIC
POLYCARBONATE
POLYVINYLCHLORIDE
AAS
AAS
ABS
POLYCARBONATE-ABS
id098011740200
Heat resisting
TemperatureC{F}
120 {216}
120 {216}
125 {225}
120 {216}
90 {162}
100 {180}
100 {180}
96 {173}
100 {180}
120 {216}
90 {162}
96 {173}
125 {212}
96 {180}
100 {158}
96 {180}
100 {158}
96 {180}
125 {225}
95 {203}
100 {180}
100 {180}
90 {162}
100 {180}
Note
The application of temperatures higher than heat resisting temperatures may result in part deformation.
End Of Sie
BM: BUMPER
09-80E1
09-80E
3525-1U-12L(09-80E).fm

REPAIRABLE RANGE OF POLYPROPYLENE BUMPERS [PLASTIC BODY PARTS]
id098011600100
The three types of damaged bumpers shown below are considered repairable. Although a bumper which has been
damaged greater than this could also be repaired, it should be replaced with a new one because such repair would
detract from the looks and quality of the bumper. In addition, such repair is not considered reasonable in terms of
work time.
Repairable Bumpers
1. A bumper with a hole less than 50 mm {1.97 in} in
diameter.
am8rrb00000046
2. A bumper with a crack less than 100 mm {3.94 in}

in length.
am8rrb00000047
3. A bumper with a crack less than 100 mm {3.94 in}

in length that is less than half of the width of the
bumper.
(A)
End Of Sie
LESS THAN HALF OF (A)

am8rrb00000048
09-80E2
3525-1U-12L(09-80E).fm

POLYPROPYLENE BUMPER REPAIR [PLASTIC BODY PARTS]
Scratch on paint only
Bumper
surface
not visible
Hole or crack through surface
Bumper
surface
visible
id098011600200
Crack more than 100 mm

{3.94 in} long or completely
broken
Remove paint
Smooth damaged area
09-80E
Apply aluminium tape to
reverse side of bumper
Plastic weld damaged area
Rough sand damage area
Replace damaged
Bumper
Spray entire bumper
surface with
polypropylene primer
Degrease damaged area
Apply polypropylene primer

to damaged area
Apply repair agent to

damaged area and let dry
Sand damaged
area
Sand damaged area

smooth
Apply polypropylene primer to damaged

area and let dry
Spray primer surfacer on damaged area

and let dry
Sand partial or complete surface of bumper
Spray primer surfacer on

bumper and let dry
Sand surface of bumper
Degrease bumper
Spray matching body color paint on bumper and let dry

am2uub0000000
End Of Sie
09-80E3
3525-1U-12L(09-80E).fm

PROCEDURE [PLASTIC BODY PARTS]
id098011600300
Repair of polypropylene bumpers having damage that has reached the surface of the polypropylene and are too
serious to be restored by painting only.
Hole
Flaw
Crack
SEC. A-A
SEC. D-D
SEC. B-B,
SEC. C-C
3
4
1 Top coat layer

3 Primer layer
2 Primer surface layer

4 Polypropylene layer
am2uub0000001
1. Cut the rough edges around the damage with a knife to make it smooth. Sand the area with a sander to make
an angle of about 45.
SEC. D-D
SEC. A-A, SEC. B-B, SEC. C-C
Cut with knife
Cut with knife

Polypropylene surface
Sand
Sand
45
Angle necessary for deposit of polypropylene welding rog

am2uub0000001
09-80E4
3525-1U-12L(09-80E).fm

2. Weld the damaged area.
For repair of a cracked area, melt the crack together with a heat gun and a melting attachment.
Heat gun
Melt together
SEC. B-B, SEC. C-C
painted surface
Attachment for
melting
Section after melting
am2uub0000001
For repair of a hole, degrease the area on

both sides of the bumper and apply aluminium
tape on the reverse side of the damage area.
SEC. A-A
Degrease
09-80E
Aluminium tape
am2uub0000001
3. Melt the polypropylene welding rod with a heat gun and deposit it the cracked area.
Polypropylene welding rod
SEC. B-B, SEC. C-C, SEC. D-D
Melt this area
Melted area
am2uub0000001
Note
Heat the shaded area to melt it.
Take care not to overly melt welding rod. If the part is welded with the welding rod melted like jelly, the
welding strength will be reduced.
Hold the heat gun 1020 mm {0.390.79 in} from the part being welded.
Do not move the welding rod until the welded parts cool.
Polypropylene welding
SEC. A-A
Paint
Surface
Top view
Aluminium tape
am2uub0000001
09-80E5
3525-1U-12L(09-80E).fm

4. Sand the surface of the polypropylene gradually as it is easily melted by the abrasion heat. Sand the area to
which repair agent will be applied.
Sand gradually
Sand repair area
Paint
am2uub0000001
5. Uniformly apply polypropylene primer with a brush to an area larger than the repaired area. Allow to dry about
10 minutes at 20 C {68 F}.
Larger than repaired area
Polypropylene primer
am2uub0000001
6. Mix the main agent and the stiffening agent in a ratio of one to one. Apply the mixed repair agent to the
damaged area.
Note
When mixing the main and stiffening agents, take care not to allow bubbles to form.
The repair agent hardens quickly (about 5 minutes); proceed with the work immediately after mixing the
agents.
Allow about 30 minutes to dry (20 C {68 F}) before sanding.
Repair agent
Do not mix air
Weld
am2uub0000001
The repair agent is a two part epoxy adhesive.

When the repair agent hardens, it will provide a good finish with the same flexibility as the polypropylens.
The repair agent for a urethane bumper is also a two part adhesive compound. However, this is different from
that for a polypropylene bumper. If the incorrect repair agent is used, the repair will be faulty.
09-80E6
3525-1U-12L(09-80E).fm

7. Sand the area with #180240 sandpaper.
Note
If excessive force is applied to the area when sanding, the surface will be damaged.
If fuzz remains around the repaired area, melt it with a heat gun.
09-80E
am2uub0000001
8. Degrease the painted surface.

9. Mix the primer and the hardener at a ratio of one to one. Apply the primer to the repaired area and the surface
of the bumper with a brush or spray.
polypropylene primer
Primer hardener
1
am2uub0000002
Use the primer within 16 hours after it is mixed.

Note
Polypropylene primer will dissolve even after drying if it is wiped with solvent. Use only water to clean
around the primer.
10. Allow the part to dry.
09-80E7
3525-1U-12L(09-80E).fm

11. Add the softener to the urethane primer surfacer and spray it on the repaired area.
a. Mixing method
Urethane primer surfacer + Softener ..... Mixture A
Mixture A + hardener ..... Mixture B
Dilute mixture B with thinner to spray on bumper
b. Viscosity
1416 seconds/viscosimeter 20 C {68 F}
Urethane primer surfacer
Note
Mix the solutions at the specified ratio.
12.
13.
14.
15.
c. Spray pressure
300400 kPa {34 kg/cm2, 4357 psi}
d. Standard film thickness
3040
e. Spray method
Spot-spray primer surfacer on bumper three
Mixture A 100
or four times
Air drying 20 C {68 F} 8 hours minimum.
Forced drying 60 C {140 F} 1 hour
Lightly sand the complete surface of the bumper
with #400#600 sandpaper. Do not expose the
Mixture B
surface of the polypropylene. (Wet or dry sanding
is acceptable.)
Wipe the complete surface of the bumper with
degreasing agent. Quickly wipe the surface with a
clean rag to degrease it.
Apply a matching coat of body color to the polypropylene bumper.
Hardner
Softener
30
1
am2uub0000002
Note
Be sure to use only urethane primer for a urethane bumper and polypropylene primer for a polypropylene
bumper. Other paints for repairing a polypropylene bumper are the same as those for the urethane
bumper.
16. Air drying 20 C {68 F} 8 hours minimum.
Forced drying 60 C {140 F} 1 hour
Note
Let the part air dry when possible as forced drying could cause bubbles in the top coat.
End Of Sie
09-80E8
3525-1U-12L(09-80F).fm
BODY STRUCTURE [CONSTRUCTION STANDARD VALUES]
09-80F BODY STRUCTURE [CONSTRUCTION STANDARD

VALUES]
Front View . . . . . . . . . . . . . . . . . . . . . . . 09-80F1
Rear View . . . . . . . . . . . . . . . . . . . . . . . 09-80F2
CONSTRUCTION STANDARD VALUES

[CONSTRUCTION
STANDARD VALUES] . . . . . . . . . . . . . . 09-80F1
End of Toc
CONSTRUCTION STANDARD VALUES [CONSTRUCTION STANDARD VALUES]
BM: CONSTRUCTION STANDARD VALUES
id0980c0740300
Front View
H
G
A
A
09-80F
B
E
C
aatjjb00000330
C
3
E
5
6
7
2
I
11
16
17
15
13
14
12
10
K
18
19
20
21
am6xub0000011
.
No.
Measure Standard Maximum Minimum Side by

values
values
values difference
ment
(mm {in}) (mm {in}) (mm {in}) (mm {in})
part
4.2
6.0
2.4
2.0
1
{0.17}
{0.24}
{0.094}
{0.079}
2.0
-2.0
2
0
{0.079}
{-0.079}
No.
B
C

ment
values
values
values difference
part
6.4
8.3
3.5
2.5
3
{0.25}
{0.33}
{0.14}
{0.098}
1.8
3.3
0.3
1.5
4
{0.078}
{0.13}
{0.01}
{0.059}
09-80F1
3525-1U-12L(09-80F).fm

No.
D

ment
values
values
values difference
part
1.8
3.1
0.5
1.3
5
{0.071}
{0.12}
{0.02}
{0.051}
0.5
1.8
6
{0.051}
{0.071}
0.5
1.2
-0.2
7
{0.051}
{0.047}
{-0.008}
1.5
-1.5
8
0
{0.059}
{-0.059}
3.5
4.5
2.5
1.0
9
{0.14}
{0.18}
{0.098}
{0.039}
1.0
-1.0
10
0
{0.039}
{-0.039}
1.0
-1.0
11
0
{0.039}
{-0.039}
1.0
-1.0
12
0
{0.039}
{-0.039}
1.2
-1.2
13
0
{0.047}
{-0.047}
1.5
-1.5
14
0
{0.059}
{-0.059}
2.0
3.2
0.8
1.2
15
{0.079}
{0.13}
{0.03}
{0.047}
No.

values
values
values difference
ment
part
3.5
4.5
2.5
1.0
16
{0.14}
{0.18}
{0.098}
{0.039}
1.0
-1.0
17
0
{0.039}
{-0.039}
3.5
4.5
2.5
1.0
18
{0.14}
{0.18}
{0.098}
{0.039}
1.0
-1.0
19
0
{0.039}
{-0.039}
5.0
6.9
3.1
1.9
20
{0.20}
{0.27}
{0.12}
{0.075}
2.0
-2.0
21
0
{0.079}
{-0.079}
Rear View
A
A
B
C
I
F
F
D
E
G
G
H
aatjjb00000331
09-80F2
3525-1U-12L(09-80F).fm

A
E
9
3
4
8
H
I
14
11
13
10
12
15
am6xub0000011
.
Standar Maximu Minimu Side by

Measure
d values m values m values differenc
No.
ment
(mm
(mm
(mm
e (mm
part
{in})
{in})
{in})
{in})
4.0
5.7
2.3
1
{0.16}
{0.22}
{0.091}
0.5
A
2
0
{0.02}
2.0
3.8
0.2
3
{0.079}
{0.15}
{0.008}
4.0
6.2
1.8
4
{0.16}
{0.24}
{0.071}
B
0.5
5
0
{0.02}
3.5
4.5
2.5
1.0
6
{0.14}
{0.18}
{0.098}
{0.039}
C
0.5
1.5
-0.5
1.2
7
{0.02}
{0.059}
{-0.059}
{0.047}
1.8
3.3
0.3
D
8
{0.071}
{0.13}
{0.01}
Standar Maximu Minimu Side by

Measure
d values m values m values differenc
No.
ment
(mm
(mm
(mm
e (mm
part
{in})
{in})
{in})
{in})
6.0
8.0
4.0
2.0
E
9
{0.24}
{0.31}
{0.16}
{0.079}
1.8
3.0
0.6
F
10
{0.071}
{0.12}
{0.02}
0.5
1.8
11
{0.02}
{0.071}
G
0.5
1.2
-0.2
12
{0.02}
{0.047}
{-0.008}
2.0
-2.0
H
13
0
{0.079}
{-0.079}
3.5
4.5
2.5
1.0
14
{0.14}
{0.18}
{0.098}
{0.039}
I
1.0
-1.0
15
0
{0.039}
{-0.039}
End Of Sie
09-80F3
09-80F
3525-1U-12L(09-80F).fm

Mazda 6 Body Shop

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3525-1U-12L(INDEX).

WATER-PROOF AND RUST

PLASTIC BODY PARTS

VEHICLE IDENTIFICATION NUMBERS (VIN)

Prevention of Body Deformation. . . . . . 00-0012

2014 Model Year

3= 2.5 L (SKYACTIV-G 2.5, Mexico)

VEHICLE IDENTIFICATION NUMBERS (VIN)

Efficient Replacement of Body Panels

Shows operation section

Shows procedure, caution and note

Symbols of Panel Replacement

Continuous arc welding (Cut-and-join location)

Arc welding (plug welding)

Brazing welding (oxyacetylene welding)

Arc welding (spot welding)

Rough cut location

UNDERBODY FLAT-PLANE DIMENSIONS

Shows outline drawing

The dimensions on the left

{7.17} {3.66} {5.67} {4.72}

When there are no specific indications, all of

Rear suspension housing

Shows bolt size

Shows hole diameter

ROOM STRAIGHT-LINE DIMENSIONS (1)

Shows outline drawing

No indication are shown

Shows dimension location

When there are no specific indications, all of

Shows details of the standard

Shows point indication

Shows position and shape of the points

Front pillar inner designation

Front pillar inner designation

Harness installation hole

Front floor pan designation

Adjuster installation hole

Trim installation hole

Chaker bracket installation hole

Chaker bracket installation hole

Shows hole diameter

Shows bolt size

Symbols of Body Dimensions

Center elliptical hole

Center of rectangular-shaped hole

Edge of rectangular-shaped hole

Panel seam, bead, etc.

Air Bag Module Inspection

Air Bag Module Handling

A live (undeployed) air bag module placed

Side Air Bag Module Handling

Remove Dangerous Articles

Prevent Short Circuits

Securely connect the welding machine ground

Prevention of Body Deformation

Selection of Cut-and-join Locations

Removal of Associated Parts

Rough cut location

EFFICIENT INSTALLATION OF BODY PANELS

Checking Preweld Measurements And Watching

CO2 ARC WELDING

Because the weld strength is affected by the

Before spot welding, make a trial weld using the