Mitsubishi Mirage 2014 Body Repair Manual

2014 GROUP INDEX
MITSUBISHI BODY CONSTRUCTION . . . . . . . . . 1

MIRAGE BODY DIMENSIONS . . . . . . . . . . . . . 2
BODY
REPAIR MANUAL WELDED PANEL REPLACEMENT. . 3
FOREWORD CORROSION PROTECTION . . . . . . 4
This manual has been prepared for the use of all
service mechanics engaged in the body repair service. SYNTHETIC-RESIN PARTS . . . . . . . 5
Body dimensions, welded panel replacement
procedures, body sealing application instructions, and BODY COLOR . . . . . . . . . . . . . . . . . . 6
all the other information required to provide quick and
accurate body repair service are contained herein. BASE OF BODY REPAIR . . . . . . . . . 9
One especially important point is the welding method.
All of the vehicle’s original strength and durability can
be maintained by following the welding procedures
contained in this manual.
Now that, in order to maximize the efficiency of the
repair work, first, both the extent of the damage and
the replacement parts that are needed must be
calculated accurately, and then the actual work must
be performed accurately and efficiently.
The publications shown on the following page are also
available, and should be used in conjunction with this
manual.
SERVICE MANUAL MSCD-016B-2015
Mitsubishi Motors Corporation reserves the right to make changes in

design or to make additions to or improvements in its products without
imposing any obligations upon itself to install them on its products
previously manufactured.
2014 Mitsubishi Motors Corporation

All Rights, Reserved
Printed in USA
MSSP-416B-2015
MANUAL DESCRIPTION
CONTENTS
The first page of this manual contains a table of contents which lists the name of vehicle models and groups
within each model.
TEXT
The vehicles to which the information in the text pertains are generally designated according to their body
classification. In some cases, other limiting designations such as model name, type of drive system, etc., are
given. If there are no such limiting designations, the information can be assumed to cover all models.
PAGE NUMBERS
Al pages are numbered consecutively within each model. The page number can be found on the upper left or
right of each page.
SECTION TITLES
The group titles and section titles can be found at the upper center of each page.
Page number Group title

Group number Section title
1-8 BODY CONSTRUCTION

BODY CONSTRUCTION CHARACTERISTICS
DASH PANEL
12
42 ± 16 N·m
(31 ± 11 ft-lb)
13
7 11
14
12
8 9
15
6 10
42 ± 16 N·m
11 (31 ± 11 ft-lb)
5 3
4
2 1
ABB00012AB
1. Harness 2-way bracket 9. Ground bracket

2. Flare nut holder 10. EPS -ECU bracket
3. Harness bracket 11. Dash crossmember lower bracket
4. Battery holder bracket 12. Dash crossmember upper bracket
5. Air intake bracket 13. Accelerator pedal bracket
6. Dash panel 14. J/B lower bracket
7. HVAC bracket 15. Pipe
8. Dash panel reinforcement
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MANUAL DESCRIPTION
CONTENTS
The first page of this manual contains a table of contents which lists the name of vehicle models and groups
within each model.
TEXT
The vehicles to which the information in the text pertains are generally designated according to their body
classification. In some cases, other limiting designations such as model name, type of drive system, etc., are
given. If there are no such limiting designations, the information can be assumed to cover all models.
PAGE NUMBERS
Al pages are numbered consecutively within each model. The page number can be found on the upper left or
right of each page.
SECTION TITLES
The group titles and section titles can be found at the upper center of each page.
Page number Group title

Group number Section title

DASH PANEL
12
42 ± 16 N·m
(31 ± 11 ft-lb)
13
7 11
14
12
8 9
15
6 10
42 ± 16 N·m
11 (31 ± 11 ft-lb)
5 3
4
2 1
ABB00012AB
1. Harness 2-way bracket 9. Ground bracket

2. Flare nut holder 10. EPS -ECU bracket
3. Harness bracket 11. Dash crossmember lower bracket
4. Battery holder bracket 12. Dash crossmember upper bracket
5. Air intake bracket 13. Accelerator pedal bracket
6. Dash panel 14. J/B lower bracket
7. HVAC bracket 15. Pipe
8. Dash panel reinforcement
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1-1
GROUP 1
BODY
CONSTRUCTION
CONTENTS
BODY COMPONENTS. . . . . . . . . . . . 1-2 SIDE BODY . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 1-15
BODY MAIN CROSS-SECTIONAL ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
VIEWS . . . . . . . . . . . . . . . . . . . . . . . . 1-4 UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 1-16
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
MAINTENANCE,
SERVICEABILITY . . . . . . . . . . . . . . . 1-6 SILENCER APPLICATION
LOCATIONS . . . . . . . . . . . . . . . . . . . . 1-21
BODY CONSTRUCTION
CHARACTERISTICS . . . . . . . . . . . . . 1-8 URETHANE FOAM USAGE
FRONT BODY. . . . . . . . . . . . . . . . . . . . . . . 1-8 LOCATIONS . . . . . . . . . . . . . . . . . . . . 1-23
BODY COMPONENTS
BODY COMPONENTS
M4010001002238
24 28
22
20 59* 26
27
19 21 25*
23 29
17 61
58* 60*
18 66*
88*
30
68
57*
62
16 76*
56* 69 31
67
65* 32
15
80
81 33
14 34
82
55 53* 35
13 54 36
77* 63
79* 37
12 87
10 75* 78* 38
74* 52* 72* 39
11 64**
45 44 83
9 51
49
86* 41
8* 43
40*
6 42
7*
70* 84
4 5 85*
71*
3 47
4 73**
3 50
2 46*
48*
1
NOTE:
: Anti-corrosion steel panels
: High-tensile steel panels (*: Indicates 590MPa-high-tensile steel panels.)
(**: Indicates 980MPa-ultra-high-tensile steel panels.) ABC00328AB
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BODY CONSTRUCTION 1-3
BODY COMPONENTS
1. Front panel crossmember lower 45. Rear floor rear seat under crossmember
2. Front bumper reinforcement 46. Front floor side sill inner
3. Headlight support panel 47. Front floor sidemember
4. Headlight support bracket 48. Front sidemember reinforcement rear
5. Headlight support panel upper 49. Front floor
6. Front sidemember plate 50. Front fender
7. Front inner sidemember 51. Front floor sidemember
8. Front outer sidemember 52. Front floor sidemember rear
9. Engine mounting gusset 53. Front pillar reinforcement lower inner
10. Fender shield frame upper inner 54. Front deck frame upper outer
11. Front inner wheel house 55. Front fender bracket
12. Dash panel crossmember 56. Front pillar reinforcement upper
13. Dash panel 57. Front lower inner pillar
14. Cowl top panel 58. Front upper inner pillar
15. Front deck crossmember 59. Roof side rail inner
16. Hood inner panel 60. Center inner pillar
17. Hood outer panel 61. Rear pillar reinforcement
18. Front door panel inner 62. Rear pillar brace
19. Front door side door beam 63. Front fender bracket
20. Front door panel outer 64. Side sill reinforcement
21. Rear door panel inner 65. Center pillar reinforcement
22. Rear door panel outer 66. Roof side rail reinforcement center
23. Roof rail front 67. Side sill rear end plate
24. Roof panel 68. Rear wheel house inner panel
25. Roof bow 69. Quarter panel lower inner
26. Roof rail rear 70. Side inner sill rear
27. Liftgate inner panel 71. Rear seat crossmember reinforcement
28. Liftgate outer panel 72. Rear floor crossmember reinforcement
29. Gate pillar reinforcement 73. Front floor front crossmember
30. Rear inner pillar 74. Front sidemember reinforcement rear lower
31. Quarter panel extension upper outer 75. Dash side brace
32. Quarter panel extension lower outer 76. Rear door hinge reinforcement
33. Fuel filler lid 77. Side sill bulkhead
34. Side outer panel 78. Side sill reinforcement outer support
35. Rear end panel outer 79. Side sill reinforcement support front
36. Rear end panel inner 80. Center pillar reinforcement lower
37. Spare tire bracket 81. Side sill reinforcement support rear
38. Rear towing hook bracket 82. Side sill support rear
39. Rear floor stay 83. Canister bracket
40. Rear floor sidemember reinforcement 84. Side sill reinforcement inner
41. Rear floor sidemember extension 85. Side sill inner reinforcement
42. Rear floor sidemember 86. Rear floor sidemember reinforcement upper
43. Rear floor 87. Rear seat pan reinforcement
44. Rear floor crossmember 88. Rail roof side support
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BODY MAIN CROSS-SECTIONAL VIEWS

M4010002001380
B
D
E
A
C
F
ABB00524AB
A D
Cowl top
outer panel Roof panel
Roof side rail
Cowl top stay reinforcement
center
Rail roof side
Cowl top support
inner panel
Dash panel Roof side rail
ABB00614AB inner Side outer panel ABC00323AB
B Roof panel E Center pillar seat belt

reinforcement
Center inner Center pillar
pillar upper reinforcement
Side outer
panel
Front roof
reinforcement rail
Roof front rail inner
ABC00322AB ABB00618AB
C Front pillar F Side sill Side outer panel

reinforcement lower
reinforcement
Front inner support front
pillar lower
Side sill
Side outer reinforcement
panel
Front floor
side sill inner
Side sill
reinforcement
ABB00616AB outer support ABC00324AB
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K
G
L
ABB00525 AB
G Front pillar reinforcement upper J
Front inner pillar

upper
Rear wheel house
inner panel
Quarter panel
lower inner
Side outer panel Side outer
panel
ABB00620AB ABB00623AB
H Center pillar Rear door hinge K

reinforcement reinforcement
Center inner
pillar upper
Roof panel
Side outer
panel
Roof rear rail inner
ABC00129 AB ABB00624AB
Gate pillar inner L

I upper extension
Rear pillar Gate pillar Quarter outer
reinforcement reinforcement upper A extension Rear end
outer panel
Side outer Gate pillar
panel inner panel
Rear end
inner panel
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MAINTENANCE, SERVICEABILITY
M4010003001145
FENDER SHIELD
A positioning hole and cut-out have been added on
the front sidemember inner and the dash crossmem-
ber to improve assembling workability when replac-
ing the panel.
ABB00389AB
SIDE STRUCTURE
A panel positioning notch has been added on the
door opening to improve assembling workability
when replacing the panel.
Panel positioning notch AB201388AB
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ABB00467AB
SIDE OUTER PANEL

The extra parts are supplied in 4 different cut forms
as a result of employing the integrated side-frame
side outer panel.
Center outer pillar
Front outer pillar
Quarter panel outer
Front floor side sill outer
ABB00600AB
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FRONT BODY
M4010010001750
HEADLIGHT SUPPORT • The bolt-on headlight support panel is used to

• The crush box structure has been adopted to the improve maintainability.
front end of the front sidemember to improve the
maintainability at a minor collision and the char-
acteristics at a minor frontal collision.
ABB00350
7.0 ± 3.0 N·m
62 ± 26 in-lb
10 ± 4 N·m
5
89 ± 35 in-lb
3
7.0 ± 3.0 N·m
62 ± 26 in-lb 4
26 ± 6 N·m 3
19 ± 4ft-lb
2
26 ± 6 N·m
19 ± 4ft-lb A 7.0 ± 3.0 N·m
62 ± 26 in-lb
1
ABC00325AB
1. Front panel crossmember lower

A
2. Front bumper reinforcement
3. Headlight support bracket
4. Headlight support panel
5. Headlight support panel upper
Crush box
ABD00021AB
A crash box has been established in order to effi-

ciently absorb energy upon impact.
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FENDER SHIELD
(Right side)
4
3
2
5
1
23 ± 9 N·m
17 ± 6 ft-lb
ABB00351AB
(Left side)
3 2
23 ± 9 N·m
4 17 ± 6 ft-lb
7
5
23 ± 9 N·m
17 ± 6 ft-lb
ABB00352 AB
1. Engine mounting gusset FRONT SIDEMEMBER REINFORCEMENT

2. Fender shield frame upper inner The 590-MPa class high tensile strength steel panels
3. Front spring house gusset have been adopted for the front sidemember outer,
4. Spring house bracket front sidemember reinforcement rear lower, front
5. Front spring house panel floor sidemember rear and front sidemember inner to
6. Front sidemember
improve the crash safety.
7. Transmission mounting gusset
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(Right side) 7
9*
4
8*
5
6
3*
10
2
12 11
13
1
14*
NOTE: *: Indicates 590MPa-high-tensile steel panels. ABB00353 AB
2
5
14 6 8
10
13
12
ABB00418AB
1. Front sidemember plate 8. Front sidemember reinforcement rear lower

2. Engine mounting bulkhead 9. Front floor sidemember rear
3. Front sidemember outer 10. Front sidemember rear A
4. Brake hose bracket 11. Dash crossmember lower
5. Front sidemember bulkhead front 12. Front suspension crossmember plate rear
6. Front sidemember reinforcement front 13. Front suspension crossmember bracket rear
7. Front sidemember brace lower 14. Front sidemember inner
A 14 B 8
10
2
13
3
ABB00419 AB 12 ABB00420AB
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(Left side)
4
3*
7* 8
6
2* 5
14 1
9
12
13
NOTE: *: Indicates 590MPa-high-tensile steel panels.

11* 10
ABB00354 AB
6 9 11
5
B
1 3
13
12
ABB00421AB
1. Front sidemember rear A 8. Brake hose bracket

2. Front floor sidemember rear 9. Transmission mounting bulkhead
3. Front sidemember reinforcement rear lower 10. Front sidemember plate
4. Front sidemember brace lower 11. Front sidemember inner
5. Front sidemember reinforcement front 12. Front suspension crossmember plate rear
6. Front sidemember bulkhead front 13. Front suspension crossmember bracket rear
7. Front sidemember outer 14. Dash crossmember lower
A B 3
11
1
9
13
7
ABB00422 AB 12 ABB00423AB
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FRONT DECK
The padding structure of the cowl top is designed to
have a crushable structure in order to efficiently
absorb energy upon impact, thus improving the
pedestrian protection capability.
ABB00355
4
5
1
6
7
8 ABC00181AB
1. Cowl top inner panel 5. Wiper center bracket

2. Heater B bracket 6. Wiper A bracket
3. Cowl top outer panel 7. Heater A bracket
4. Cowl top stay 8. Harness bracket
DASH PANEL
The 590-MPa class high tensile strength steel panels
has been adopted for the dash side brace to improve
the crash safety.
ABB00356
8* 9 4 5
6
7
2 9
8*
3
1
10
NOTE: *: Indicates 590MPa-high-tensile steel panels. ABC00182AB
1. Dash panel crossmember 6. Brake reinforcement

2. Canister bracket 7. Clutch pedal reinforcement <M/T>
3. Dash panel 8. Dash side brace
4. Accelerator pedal bracket 9. Heater bracket lower
5. Deck crossmember stay bracket 10. Flare nut holder
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SIDE BODY
M4010011001708
SIDE STRUCTURE
or 980-MPa class ultra high tensile strength steel
panels have been adopted for the front pillar, center
pillar, side sill, and roof side rail to improve the body
rigidity.
9*
13
6
12
16
5 14
11
10 ± 4 N·m 4*
89 ± 35 in-lb 17
8*
23 15
10 18 19 24
22 25
3 7*
21
50*
44*
2
1* 27
26 28
43*
45*
20 29
46* 51*
52* 30
42
41 53 32
38* 37**
40 47*
49*
39
33
36 48* 31
35
NOTE:
34 23 ± 9 N·m
*: Indicates 590MPa-high-tensile steel panels.
17 ± 6 ft-lb
**: Indicates 980MPa-ultra-high-tensile steel panels. ABC00326AB
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1. Front inner pillar lower 28. Rear light housing

2. Instrument panel side bracket 29. Quarter outer lower A extension
3. Wiper side bracket 30. Quarter outer lower B extension
4. Front inner pillar upper 31. Side outer panel
5. Sunvisor bracket 32. Rear door striker reinforcement
6. Front roof rail brace 33. Front fender bracket
7. Center inner pillar lower 34. Upper outer frame
8. Center inner pillar upper 35. Front fender bracket
9. Roof side rail inner 36. Hood hinge reinforcement
10. Seat belt retractor bracket 37. Side sill reinforcement
11. Center pillar seat belt lower reinforcement 38. Front pillar reinforcement lower
12. Center pillar seat belt reinforcement 39. Front pillar bulkhead hinge lower
13. Rear pillar reinforcement 40. Checker bracket front pillar
14. Gate pillar inner upper extension 41. Front pillar bulkhead hinge upper
15. Gate pillar inner panel 42. Deck crossmember bracket
16. Gate pillar reinforcement 43. Front pillar reinforcement upper
17. Seat belt reinforcement 44. Roof side rail reinforcement center
18. Rear seat striker reinforcement 45. Center pillar reinforcement
19. Gate pillar brace 46. Rear door hinge reinforcement
20. Side sill rear end plate 47. Side sill bulkhead
21. Rear wheel house inner panel 48. Side sill reinforcement outer support
22. Rear wheel house inner extension 49. Side sill reinforcement support front
23. Absorber reinforcement 50. Rail roof side support
24. Quarter panel lower inner 51. Center pillar reinforcement lower
25. Filler neck bracket (Left side) 52. Side sill reinforcement support rear
26. Quarter outer upper B extension 53. Side sill support rear
27. Quarter outer upper A extension
SIDE STRUCTURE REINFORCEMENT

The ring structure of the side structure reinforcement
has been adopted to improve the collision character-
istics and the rigidity of the whole vehicle.
Gate pillar
Roof side rail reinforcement
reinforcement center
Front pillar Gate pillar brace

reinforcement upper
Center pillar reinforcement
Front pillar Side sill reinforcement

reinforcement lower ABC00334AB
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REAR BODY
M4010012000991
REAR END PANEL

5 7
6
8
3
2
ABB00357 AB
1. Rear end inner panel 5. Rear end outer panel

2. Bumper bracket lower 6. Rear bumper reinforcement
3. Liftgate lock reinforcement 7. Rear license light bracket
4. Nut plate 8. Garage Jack reinforcement
ROOF
M4010013001834
has been adopted for the roof bow to improve the
body strength.
7 4
5
8
6* 4
2
1
NOTE: *: Indicates 590MPa-high-tensile steel panels. 2 ABC00327AB
1. Roof front rail inner 5. Roof rear rail inner

2. Holder bracket 6. Roof bow
3. Roof panel 7. Roof bow center reinforcement
4. Liftgate hinge reinforcement 8. Front roof reinforcement rail
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UNDER BODY
M4010014001718
FRONT FLOOR
have been adopted for the front sidemember rein-
forcement rear and front floor side sill inner and the
980-MPa class ultra high tensile strength steel pan-
els for the front floor front crossmember to improve
the body strength.
2
5
6
4 5
4
7
3
10
11
14**
8
9
15* 18
8
16
17
13*
12
NOTE:
*: Indicates 590MPa-high-tensile steel panels.
**: Indicates 980MPa-ultra-high-tensile steel panels. ABC00313AB
1. Backbone panel 10. Front seat side bracket rear

2. Parking lever reinforcement 11. Jack bracket
3. ECU bracket 12. Front floor sidemember
4. Nut plate 13. Front floor side sill inner
5. Front seat center bracket rear 14. Front floor front crossmember
6. Parking cable bracket 15. Front sidemember reinforcement rear
7. Backbone reinforcement 16. Backbone crossmember
8. Front floor side pan 17. Backbone crossmember front
9. Fuel reinforcement tank support 18. Front floor crossmember front reinforcement
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REAR FLOOR
have been adopted for the rear seat crossmember
reinforcement and rear floor crossmember reinforce-
ment to improve the body strength.
ABB00360
11
18 10
9
19
8
12
7 13
6*
3 14 15
7
5
2
4*
1 17
16
3
1
NOTE: *: Indicates 590MPa-high-tensile steel panels. ABC00314 AB
1. Fuel tank protector 11. Spare tire bracket

2. Rear seat crossmember 12. Rear seat reinforcement center
3. Tie down reinforcement 13. Rear seat plate center
4. Rear seat crossmember reinforcement 14. Rear seat back reinforcement side
5. Rear floor crossmember 15. Rear floor sidemember
6. Rear floor crossmember reinforcement 16. Side sill reinforcement inner
7. Rear seat bracket 17. Side sill reinforcement inner support
8. Rear floor pan 18. Rear seat pan reinforcement
9. Rear floor stay 19. Canister bracket
10. Rear towing hook bracket
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REAR FLOOR SIDEMEMBER

REINFORCEMENT
has been adopted for the side inner sill rear to
improve the body strength.
3
2
3
1 9*
8* 4
1
5
NOTE: *: Indicates 590MPa-high-tensile steel panels. 7* 6* ABC00315AB
B
A 1 3
9
8
ABC00331AB
1. Rear floor sidemember 6. Side sill inner rear reinforcement

2. Muffler hanger A bracket (Right side) 7. Side inner sill rear
3. Rear floor sidemember extension 8. Rear floor sidemember reinforcement
4. Spring seat 9. Rear floor sidemember reinforcement upper
5. Torsion arm support bracket
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A B
8
1
1 7
9
6 ABC00332 AB 8 ABC00333AB
DOOR
M4010015001119
(Front door)
12 6
2
1 4
11
3
9
10
7
8 ABB00362 AB
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(Rear door)
17
14
16 18
13 24
15 23
22
21
20
19 ABB00363 AB
1. Front door panel outer 13. Rear door panel outer

2. Front door window front sash 14. Rear door window front sash
3. Front door hinge reinforcement 15. Rear door hinge reinforcement
4. Front door beltline outer reinforcement 16. Rear door beltline outer reinforcement
5. Front door glass guide 17. Rear door glass rear guide
6. Glass stopper 18. Glass stopper
7. Front door panel inner 19. Rear door panel inner
8. Nut plate 20. Nut plate
9. Front door side door beam 21. Rear door outer lower stiffener
10. Front door outer front stiffener 22. Rear door outer upper front stiffener
11. Front door outer rear stiffener 23. Rear door outer upper rear stiffener
12. Front door latch reinforcement 24. Rear door latch reinforcement
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BODY CONSTRUCTION
SILENCER APPLICATION LOCATIONS
1-21
M4010005002627
• In order to suppress noise, a silencer (melting • A silencer (melting sheet) has been affixed on the
sheet) has been adhered on the cowl top outer upper surface of the floor for vibration dampening.
panel.
• In order to suppress noise, a front pillar silencer
(damping sheet) has been adhered on the front
inner pillar lower.
Silencer
(Left side) (Right side)
Front pillar
silencer Front pillar
silencer
NOTE:
: 1.5 mm (0.06 in) thick melting sheet (Place a melting sheet.)
: 2.0 mm (0.08 in) thick damp sheet (Place two melting sheet one on top of another.)
( ) indicates the number of 1.6 mm (0.06 in) melting sheets that are used for repair.
ABC00126AB
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BODY CONSTRUCTION
1-22
NOTE:
: 1.6 mm (0.06 in) thick melting sheet (Place a melting sheet.)
: 3.2 mm (0.13 in) thick damp sheet (Place two melting sheet one on top of another.)
( ) indicates the number of 1.6 mm (0.06 in) melting sheets that are used for repair.
ABD00276AB
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BODY CONSTRUCTION
URETHANE FOAM USAGE LOCATIONS
1-23
URETHANE FOAM USAGE LOCATIONS

M4010007000661
• A front door inner panel pad (urethane foam) is • In order to suppress noise, a center pillar pad
inserted in the front door sash to reduce the (urethane foam) has been filled in the bottom of
transfer of noises to the interior. the center pillar.
Front door inner

panel pad
ABB00801AB
Center pillar pad
ABC00223AB
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2-1
GROUP 2
BODY DIMENSIONS
CONTENTS
BODY DIMENSIONS AND TYPE B (ACTUAL-MEASUREMENT

MEASUREMENT METHODS. . . . . . . 2-2 DIMENSIONS). . . . . . . . . . . . . . . . . . . 2-7
UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 2-7
TYPE A FRONT BODY . . . . . . . . . . . . . . . . . . . . . . . 2-9
(PROJECTED DIMENSIONS) . . . . . . 2-4 SIDE BODY . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
UNDER BODY . . . . . . . . . . . . . . . . . . . . . . 2-4 REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 2-13
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
HEADLIGHT SUPPORT PANEL . . . . . . . . . 2-19
2-2 BODY DIMENSIONS
BODY DIMENSIONS AND MEASUREMENT METHODS

M4020001000619
Projected dimension • Type A (projected dimensions) is the dimension when a

measurement location is projected onto the plane.
NOTE: The height indicates a distance from the assumed
Height standard line established 100 mm (3.9 in) below the lowest
Probe measurement point.
AB302138AE
• Type B (actual-measurement dimensions) is the actual dis-

Ac
dim tual tance between the measurement points. Measure using a
en -me tracking gauge or a measuring tape, etc.
sio as
n ure
d NOTE: .
A
• Make the lengths of the tracking gauge probes the same
A'
(A=A’).
• Do not bend or twist the measuring tape.
AB302139AE
• Insert the tracking gauge probes securely into the measure-

ment holes.
Center of hole • When the standard dimensions in the illustration are
enclosed by rectangle, this indicates that the symmetrical
left and right positions have the same dimensions.
AB302140AF
• When using a notch for dimension measurement, set the

measuring point at the center of the outer panel notch.
AB302141AD
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BODY DIMENSIONS 2-3
Bolt • When measuring the suspension mounting arm, or link

mounting position, use the suspension mounting bolt, etc.
(Type B only)
• The body center points are shown for the purpose of check-
ing the position of the left and right symmetry location.
Measurement point AB302142 AB
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2-4 BODY DIMENSIONS
TYPE A (PROJECTED DIMENSIONS)

UNDER BODY
M4020005002576
mm (in)
657
814 (25.9)
616 660 (32.0)
(24.3) (26.0)
1,109 840 814 814 814 1,078 934

(43.7) (33.1) (32.0) (32.0) (32.0) (42.4) (36.8)
885 814 814 1,086 974 1,108

(34.8) (32.0) (32.0) (42.8) (38.3) (43.6)
350 487 450

1 (13.8) (19.2) (17.7) 378 362 328
3 4 5 6 (14.9) 296 (14.3) (12.9) 10
(11.7) 9
266 173
11 (10.5) 7 8 12
Center line (6.8)
of the vehicle
439 937
(17.3) (36.9) 663
(26.1) 690
(27.2)
ABB00189AB
mm (in)
936 930
(36.9) (36.6)
1,009
(39.7)
1,049 1,221 1,218
(41.3) 1,048 1,147 (48.1) (48.0)
(41.3) (45.2)
832 1,241 1,244 1,122 1,087

931 (32.8) (48.9) (49.0) (44.2) (42.8)
(36.7) 1,013
(39.9)
2
3 4 5 6
1 9 10
7 8
Center line
of the vehicle
869 949
(34.2) (37.4) ABB00190AB
No. Standard measurement point Hole shape Size mm (in)

1* Center of front sidemember inner positioning hole Round 25.0 (0.98)
2* Center of front suspension crossmember mounting hole Round 16.0 (0.63)
3* Center of front suspension crossmember mounting hole Round 16.0 (0.63)
4* Center of front sidemember rear A positioning hole Round 15.0 (0.59)
5* Center of front floor sidemember rear positioning hole Round 25.0 (0.98)
TSB Revision
BODY DIMENSIONS 2-5

6* Center of front floor sidemember positioning hole Round 20.0 (0.79)
7* Center of tie down mounting hole Oblong 22.0×40.0
(0.87×1.57)
8 Center of torsion axle arm assembly mounting position − −
9* Center of spring seat positioning hole Round 10.0 (0.39)
10* Center of trailer hitch mounting hole Round 13.0 (0.51)
11 Center of front shock absorber mounting hole Round 76.0 (2.99)
12 Center of rear shock absorber mounting hole Round 21.0 (0.83)
NOTE: The * mark indicates the mounting position for the frame centering gauge.
A Vehicle center B Vehicle center
4˚20´
2˚29´
ABB00573 ABB00113
919 1,198 mm (in)

(36.2) (47.2)
4˚34´
A B
11 8˚41´
12
1 2 10
9
710 7 8 616
(28.0) 3 4 5 6 (24.3)
340
(13.4) 306 295 315
(12.0) 136 102 100 101 146 171 (11.6) (12.4)
(5.4) (4.0) (3.9) (4.0) (5.7) (6.7)
487 450 353

(19.2) (17.7) (13.9)
660 649
Standard line (26.0) (25.6)
926 1,008
(36.5) (39.7)
1,275 1,335
(50.2) (52.6)
NOTE: The assumed standard line is established 100 mm (3.9 in) below the measurement point No.5. ABB00465AB
TSB Revision
2-6 BODY DIMENSIONS
1 2, 11 3, 4
11
3
2
4
ABB00522 AB ABB00489AB ABB00483 AB
5 6 7
ABB00484 AB ABB00523 AB ABB00486 AB
8 9, 10, 12
12
10
ABB00487 AB ABB00490 AB
TSB Revision
BODY DIMENSIONS 2-7
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

UNDER BODY
M4020005002587
mm (in)
674
816 (26.5)
649 661 (32.1)
(25.6) (26.0)
885 840 814 814 814 814 1,086 1,078 974 934
(34.8) (33.1) (32.0) (32.0) (32.0) (32.0) (42.8) (42.4) (38.3) (36.8)
316 3 487 450

352 (19.2) (17.7)
1 (13.9) (12.4) 381 383 328 10
2 4 5 6 (15.0) 297 (15.1) (12.9)
(11.7) 9
177 7 8
(7.0)
486 937
(19.1) (36.9) 666 704
(26.2) (27.7)
ABB00191AB
mm (in)
959 930
(37.8) (36.6)
1,009
(39.7)
1,069 1,230 1,226
(42.1) 1,049 1,150 (48.4) (48.3)
(41.3) (45.3)
833 1,241 1,245 1,122 1,094

931 (32.8) (48.9) (49.0) (44.2) (43.1)
(36.7) 1,014
(39.9)
2
3 4 5 6
1 9 10
7 8
885 949
(34.8) (37.4) ABB00192AB

1 Center of front sidemember inner positioning hole Round 25.0 (0.98)
2 Center of front suspension crossmember mounting hole Round 16.0 (0.63)
3 Center of front suspension crossmember mounting hole Round 16.0 (0.63)
4 Center of front sidemember rear A positioning hole Round 15.0 (0.59)
5 Center of front floor sidemember rear positioning hole Round 25.0 (0.98)
TSB Revision
2-8 BODY DIMENSIONS

6 Center of front floor sidemember positioning hole Round 20.0 (0.79)
7 Center of tie down mounting hole Oblong 22.0×40.0
(0.87×1.57)
8 Center of torsion axle arm assembly mounting position − −
9 Center of spring seat positioning hole Round 10.0 (0.39)
10 Center of trailer hitch mounting hole Round 13.0 (0.51)
1 2 3, 4
4
5 6 7
8 9, 10
10
ABB00487 AB ABB00488AB
TSB Revision
BODY DIMENSIONS 2-9
FRONT BODY
M4020006001640
mm (in)
1,087
(42.8) 21
880 1,507
(34.6) (59.3)
19 Body center point
1,376
286 (54.2)
(11.3)
1,407 20
1,370 (55.4)
(53.9) 306
(12.0)
1,197 18 17
533 (47.1)
(21.0)
1,223 781 500

(48.1) (30.7) (19.7)
16
958 15
(37.7)
958 14
(37.7)
13
514 723 20
(20.2) (28.5)
690
1,002 (27.2)
846 (39.4)
(33.3)
17
18
700 1,426 656
(27.6) (56.1) (25.8)
243
(9.6)
16
877
127 (34.5)
(5.0) 15
966
(38.0) 14
13
ABB00170 AB
TSB Revision
2-10 BODY DIMENSIONS

13 Center of headlight support panel mounting hole Round 9.0 (0.35)
14 Center of headlight support panel mounting hole Round 9.0 (0.35)
15 Center of battery tray stay mounting hole Round 10.0 (0.39)
16 Center of harness mounting hole Oblong 12.0×7.0
(0.47×0.28)
17 Center of front fender mounting hole Round 6.6 (0.26)
18 Center of front strut mounting hole Round 11.0 (0.43)
19 Center of front deck garnish mounting hole (Body center point) Round 6.0 (0.24)
20 Center of hood hinge mounting hole Round 11.0 (0.43)
21 Corner of roof panel − −
13, 14, 15 16 17, 18

15
18
14
17
13
ABB00491AB ABB00492 AB ABB00493AB
19 20 21
TSB Revision
BODY DIMENSIONS 2-11
SIDE BODY
M4020007001386
mm (in)
24 28
22
699 26
(27.5) 812
785
443 (30.9) (32.0) 30
(17.4) 869
995 465 (34.2) 978
(39.2) (18.3) (38.5)
23 857 536
(33.7) 1,012 (21.1)
(39.8)
1,127 27 746
(44.4) (29.4)
31
25 29
ABB00193AB
mm (in)
24 28
1,119
(44.1) 754
34 (29.7)
1,097
32 (43.2) 1,166 746
1,086 (45.9) (29.4)
(42.8) 395
347 (15.6) 36
(13.7) 782
(30.8)
1,032
33 (40.6)
35
ABB00194 AB

22 Front pillar positioning notch − −
24 Roof side rail positioning notch − −
25 Side sill positioning notch − −
26 Center pillar positioning notch − −
30 Quarter panel positioning notch − −
TSB Revision

32 Center of front door upper hinge mounting hole Round 12.0 (0.47)
33 Center of front door lower hinge mounting hole Round 12.0 (0.47)
34 Center of rear door upper hinge mounting hole Round 12.0 (0.47)
35 Center of rear door lower hinge mounting hole Round 12.0 (0.47)
36 Center of rear door switch mounting hole Round 5.0 (0.20)
22 23, 32 24
23
32
ABB00497 AB ABB00507AB ABB00499AB
25 26 27, 34
34
27
ABB00500 AB ABB00501 AB ABB00509AB
28 29 30
31, 36 33 35
36
31
ABB00511AB ABB00508 AB ABB00510AB
TSB Revision
REAR BODY
M4020008001356
mm (in)
37 817
(32.2)
894
38 (35.2)
1,229
555 (48.4) 882
(34.7) 1,071
(21.9) (42.2) 990
(39.0)
39
844
(33.2)
40 41
42
1,056
(41.6)
43
600
(23.6)
37 268
(10.6)
994
(39.1)
38
1,040
795 1,309 (40.9)
(31.3) (51.5)
1,465
(57.7)
1,312
40 (51.7)
417
(16.4)
43
ABB00184AB
TSB Revision

37 Center of liftgate hinge mounting hole Round 10.0 (0.39)
38 Center of liftgate gas spring mounting hole Round 8.0 (0.31)
39 Center of rear combination light mounting hole Square 8.5×8.5
(0.33×0.33)
40 Center of rear bumper mounting hole Square 9.0×9.0
(0.35×0.35)
41 Center of rear bumper mounting hole Round 6.6 (0.26)
42 Center of liftgate striker mounting hole Round 14.0 (0.55)
43 Center of rear bumper reinforcement plate mounting hole Round 12.0 (0.47)
37, 38 37 39, 40 41
39
38 40
ABB00512AB ABB00513 AB ABB00514 AB
42 43
ABB00515 AB ABB00516AB
TSB Revision
INTERIOR
M4020009001713
mm (in)
1,146 1,106
(45.1) (43.5)
24 28
1,265 1,309
(49.8) (51.5) 1,277
(50.3)
22 26 30
1,339 1,340 1,340

(52.7) 23 (52.8) (52.8)
27 31
1,340
(52.8)
1,340
(52.8) 29
25
ABB00478 AB
mm (in)
24 28
22 26
1,165 30
(45.9)
1,119 1,087 1,033
(44.1) 1,082 (42.8) (40.7)
23 (42.6)
27 753
1,027 787 (29.6) 31
(40.4) (31.0) 675
(26.6)
723 29
(28.5)
25
44 Body center point 45 Body center point ABB00479 AB
mm (in)
656
(25.8)
1,036
(40.8) 798
1,070 (31.4)
46 (42.1)
491
(19.3)
47
ABB00480AB
TSB Revision

44 Center of backbone reinforcement positioning hole (Body center point) Round 16.0 (0.63)
45 Center of floor carpet mounting hole (Body center point) Round 8.5 (0.33)
46 Center of rear seat belt anchor mounting hole Round 14.0 (0.55)
47 Center of trunk room rear end trim mounting hole Round 8.5 (0.33)
22 23 24
ABB00497 AB ABB00498 AB ABB00499AB
25 26 27
TSB Revision
28 29 30
31 44 45
46 47
TSB Revision
mm (in)
48 1,294
(50.9)
130 1,301
(5.1) (51.2)
1,294
49 (50.9)
ABB00212 AB

48 Center of front deck crossmember mounting hole Round 12.5 (0.49)
49 Center of front deck crossmember mounting hole Round 12.5 (0.49)
48, 49
48
49
ABB00521AB
TSB Revision
HEADLIGHT SUPPORT PANEL

M4020017000027
mm (in)
816
(32.1)
50
939
(37.0)
404
(15.9)
880
(34.6)
51
ABC00342 AB

50 Center of front end upper bar bracket positioning hole Round 8.0 (0.31)
51 Center of headlight support panel positioning hole Round 20.0 (0.79)
50 51
TSB Revision
NOTES
3-1
GROUP 3
WELDED PANEL
REPLACEMENT
CONTENTS
ULTRA HIGH STRENGTH REAR FLOOR. . . . . . . . . . . . . . . . . . . 3-22

STEEL PLATE . . . . . . . . . . . . . . . . . . 3-2
ROOF . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
FENDER SHIELD. . . . . . . . . . . . . . . . 3-3
QUARTER INNER. . . . . . . . . . . . . . . . 3-26
FRONT SIDEMEMBER
(PARTIAL REPLACEMENT) . . . . . . . 3-6 QUARTER INNER LOWER . . . . . . . . 3-28
FRONT PILLAR . . . . . . . . . . . . . . . . . 3-7 FRONT DOOR OUTER PANEL

(WELDED TYPE) . . . . . . . . . . . . . . . . 3-29
FRONT PILLAR
(PARTIAL REPLACEMENT) . . . . . . . 3-10 FRONT DOOR OUTER PANEL
(ADHESION TYPE). . . . . . . . . . . . . . . 3-30
CENTER PILLAR . . . . . . . . . . . . . . . . 3-13
REAR DOOR OUTER PANEL
SIDE SILL. . . . . . . . . . . . . . . . . . . . . . 3-16 (WELDED TYPE) . . . . . . . . . . . . . . . . 3-31
QUARTER OUTER . . . . . . . . . . . . . . 3-19 REAR DOOR OUTER PANEL

(ADHESION TYPE). . . . . . . . . . . . . . . 3-32
REAR END PANEL . . . . . . . . . . . . . . 3-21
FRONT END CROSSMEMBER . . . . . 3-33
3-2 WELDED PANEL REPLACEMENT
ULTRA HIGH STRENGTH STEEL PLATE
ULTRA HIGH STRENGTH STEEL PLATE

M4030002800073
ADVANTAGES OF ULTRA HIGH • For the part in which the ultra high strength steel
STRENGTH STEEL PLATE plate is used, do not repair it by cutting and bond-
ing to avoid the reduction in strength by heat.
The ultra high strength steel plate has the following
Instead, replace the whole assembly including
advantages as compared with conventional high
the part.
strength steel plate.
• Be careful with rough extending work, because
• It has tensile strength approximately 1.7 times
the ultra high strength steel plate has higher ten-
higher than the conventional high strength steel
sile strength and a higher yielding point than high
sheet.
strength steel plate and general steel plate. Care-
• It has a higher yielding point and yielding ratio
less work will cause symptom such as over-pull-
(yielding point/tensile strength).
ing and springback. Do not extend it completely
These advantages allow thinner and lighter plates
at a time. Do it gradually while removing the dis-
and better fuel efficiency than the high strength steel
tortion by sheet metal processing with a hammer.
plate.
• Plug welding of φ 8 mm (0.31 inch) diameter plug
for repair ensures the strength equivalent to spot
PRECAUTION UPON MAINTENANCE OF
welding for 2 steel sheets. For 3 sheets, weld 2
ULTRA HIGH STRENGTH STEEL PLATE sheets each time instead of welding from one
• Use a spot cutter for ultra high strength steel side to give sufficient welding strength.
plate to ensure that the spot-welded area is cut
off.
TSB Revision
WELDED PANEL REPLACEMENT 3-3
FENDER SHIELD
FENDER SHIELD
M4030004001720
Symbol Operation description

Spot welding
MIG plug welding : indicates two panels to be welded
( : indicates three panels to be welded )
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
ABB00450AB
(Use access holes to apply liberally to butt-welded joints.)
REPAIR WELDS
23 ± 9 N·m
17 ± 6 ft-lb
ABB00553AB
TSB Revision
FENDER SHIELD
23 ± 9 N·m
17 ± 6 ft-lb
D
C 23 ± 9 N·m
17 ± 6 ft-lb
23 ± 9 N·m
17 ± 6 ft-lb
E
C
ABB00554AB
TSB Revision
FENDER SHIELD
;
; ; ; ;; ; ; ;;
;
;; ;; ;;;;; ;; ;;;;;
;;;
;;; ;;;
;;;;
;;;
;;;;
;
; ;; ;; ;; ; ;
;; ;;;
;;;;;;;
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;;;;;;;;;
;;; ;;
;;; ;;;;
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;;;;
;;;;;
;;;;;;
; ; ;
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;; ;
;;
; ; ; ;;;;;;
;; ;
; ;; ;;;;; ; ;;;;;;;;;;;;;;;;;;;;
;
;;
;; ;;
; ; ;;; ;;;;
;; ; ; ;;;;;;;;
; ; ;;;;;;;
; ;;
;;;;;;; ;
;;;;;;;;;
;;;;;;;;;;
;
;;; ;; ;; ; ; ;;; ;
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; ;;;;;
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;;
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; ;;
; ;;;;; ;;;;;;; ;;;;;;;
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;
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;
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; ;;;;;;;;;
;;; ;;;; ;;
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;
;; ; ; ; ;;
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;;; ;;;; ;;; ; ; ;; ;;; ;
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; ;; ;;;;; ;
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; ;;;; ; ;;
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; ;;;;;;;;;;;; ;; ;; ;
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; ; ;
;;;
;;; ;; ; ; ;;; ;;;;; ; ;;;;; ;;;
;;;
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;; ; ; ;;; ;;;;
;; ;;
; ;; ;;;;
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; ;;;;; ;;
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;
;
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; ;
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; ;
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; ; ;;; ;;;;
; ;;
; ; ;; ;
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; ;;; ;;;
; ;; ;;;;;;;
; ;;;;
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;;
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;;;; ;;; ; ;;;; ; ;;;;;
;; ;;;; ;;;
; ;;
;;
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;;;;;
; ;;;
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;;
;;; ;;
;;; ;; ;;;
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;
;; ;;;
;
; ;;
;;;
;;;
;
;; ; ; ;;;
;;;;
; ;; ;;;;;;;;;;;;;;;;;;; ;;;;;;
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;; ; ;;;;
;;;;;; ;; ;; ; ;; ;;;;;; ;;;;
;;;;;;;;;;;;;;;;;;; ;;;;;;;
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;;;; ;;
;; ; ; ;
;;; ; ; ;;; ; ;;
; ;;
;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;; ;; ;;;;;;;;;;;; ;;;
;;;; ;;;;;;;
;;;
;;
;;;;; ;;;;
; ;;; ;; ;;;;
;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;; ;;; ;;;; ;;;;
;;;;;;;;;
;
;;; ; ;;
;
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;;
;; ;;; ;; ; ;;
;;;;
; ;;;
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;; ;;
;;;;
; ;;;;;;;;;;;;;;;;;;;;; ;
;; ;;; ; ;
; ;; ;
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;;; ;;;;;;;;;;;;;;;;;;;
;; ;; ;;;;
; ;;
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;
;;;;;;;;;;;;;;;;;;;;; ;; ;
;;;;;;;
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;; ;;;;
; ;; ;;
; ;
;;; ;;; ;;
; ;;;;;
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; ;;;;;;;;;;;;;;;;;;;;;
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;
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;;;;;
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;;;
;;;
;;;; ; ;; ;;;; ;
;;;;;;;;;;;;;;;;;;;;;;;;;;
; ;;;
;; ; ; ;;
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;
;;; ;;;;;; ;;;;; ;;;;;;; ;
;;;;;;;;;;;;;;;;;;;;;
;;;;;
;;;;;
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;;;;
; ; ;; ;;;
;; ;;
;;; ; ; ;; ; ;
;; ;
;; ;;;
; ;;;;;;;
; ;
;; ;;
;
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;;;
;;; ;;
;;;
;;; ; ;;
; ;;;
;; ;;;; ; ; ;; ; ;;;
; ;;;
;;;
; ;
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;
;;;;;;;;;;; ;; ;
;;;
;;;;; ; ; ;; ;;
; ;;;;; ;;
;
; ; ; ;;;; ;;
;; ;;
;; ; ;
;
;;
;;;;;;; ;;; ; ; ;;; ;;; ;; ;
;; ;
;; ; ;;;;; ;;
;
;;;;;; ;;
;; ; ;;
; ; ; ; ;;
;;
; ; ;;
; ; ; ; ; ;;;
; ;;;; ;; ;
;;; ;;;
;;;;;;; ;
;;;;;;;;
;;;; ;; ;;; ;;;
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; ;;
;;;;;
; ; ;;;
;;;
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; ;;;
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;;; ;;;;;;
;; ;; ;;
;; ;; ;
; ;;
;;
;
; ;;;
;;;; ;;
;;
;
;
; ;;;;
; ;
;
;D ;
;;;; ;
E
(With the upper outer frame removed)

F
ABB00555 AB
TSB Revision
FRONT SIDEMEMBER (PARTIAL REPLACEMENT)
FRONT SIDEMEMBER (PARTIAL REPLACEMENT)

M4030000100926

Spot welding
MIG spot welding
Braze welding
ABB00451AB
REPAIR WELDS
(Right side) (Left side)
115 mm 180 mm
(4.5 in) (7.1 in)
Center of engine mounting Center of transmission mounting

insulator mounting hole insulator mounting hole
A B
Center of splash front Center of splash front
shield mounting hole shield mounting hole
70 mm 60 mm
(2.76 in) (2.36 in)
A B
ABB00640AB
TSB Revision
FRONT PILLAR
FRONT PILLAR
M4030005002102

Spot welding
MIG spot welding
Braze welding
ABB00452AB
Cutting
REPAIR WELDS position
C
B
;;;;;
;;
;;;
;;;
; ;;
A ; ;
Notch
150 mm (5.9 in)
;;
;
;;
;;;
;;;
;
F
H
50 mm (1.97 in)
Notch
; ;;
;;;
;;;
;;
G (With the side outer panel removed)

D B
(With the side outer panel removed)
C D E ABB00557AB
TSB Revision
FRONT PILLAR
;;
;;;
;;;;;
;;
;;;;;;;; ;;
;
;;;;
;;;;;;;;; ;;;
;;;;; ;;; 10 ± 4 N·m
;;
;;
;;;;;;;;;
;;;;;;;;;
; ;;;
;;;;
;;;;
; ;;;
;;
;;;;;;; ; ;;;;
;;;;;;;;;;;
;
;;; ;;
;;;;;
;;;
;;;
;;;
;;;;
; 89 ± 35 in-lb
;
;;;;;;;
;;;
;;;;;;;;;
;;
;;;;;;;
;;;;;;;
; ;;;
;;;
;;;
;;; ;;;;;
;
;; ;
;;;;;;;;;
; ;; ;
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;
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; ;;;; ; ;;
;;; ;
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;
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; ;; ;; ; ;
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; ;; ;;
;; ; ;;
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;;; ;; ;;;;
;; ;
;
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;
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; ;;
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;;; ;;;
;
;; ; ;; ;;; ;
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G ABB00613AB
NOTE: Refer to the Fender Shield section on P.3-3 for the welding points with the upper outer frame.
TSB Revision
FRONT PILLAR
NOTE ON REPAIR WORK

.
REMOVAL
Cutting To cut the welding points between the front pillar reinforcement
position lower and side sill reinforcement, cut the side outer panel as
shown.
;;;
;;;
;;
;;;
;;
ABB00461AB
INSTALLATION
1. To reinforce the strength in the front pillar cut area, cut the
Cutting
position A side outer panel at A point [100 mm (3.9 inches)] above the
Cutting cut area and cut the front pillar reinforcement upper at B
position B
point [50 mm (1.97 inches)] above the cut area.
;;
;;;
;;;;;
;;;
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;;
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; 2. Assemble the new front lower inner pillar parts.
3. Assemble the new front upper inner pillar parts.
50 mm 4. Assemble the new front pillar reinforcement upper part.
(1.97 in)
100 mm
(3.9 in)
ABB00462 AB
5. When installing the new front outer pillar parts, apply the
body sealant to the areas as shown in advance.
NOTE:
: Body sealant ABB00463 AB
TSB Revision
FRONT PILLAR (PARTIAL REPLACEMENT)

M4030001200131

Spot welding
MIG spot welding
Braze welding
ABC00530AB
REPAIR WELDS
;
;
;
;
250 mm Cutting
(9.8 in) position

B 50 mm A
(1.97 in)
Cutting Notch
position ;;;
; ;;;
;;;
;;;
D
C
B C ABC00393AB
TSB Revision
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E
ABC00394 AB
NOTE: Refer to the Fender Shield section on P.3-3 for the welding points with the upper outer frame.
NOTE ON REPAIR WORK

.
REMOVAL
Cutting 1. To cut the welding points between the front pillar
position reinforcement lower and side sill reinforcement, cut the side
outer panel as shown.
2. Cut the side outer panel, front pillar reinforcement lower and
;;;
;;;
;;
;;;
;;
front inner pillar lower and remove.
ABB00461AB
TSB Revision
INSTALLATION
1. To reinforce the strength in the front pillar cut area, cut the
side outer panel and the front pillar reinforcement lower 80
Cutting
position mm (3.15 inches) above the cut area and cut the side outer
panel 50 mm (1.97 inches) above the cut area.
2. Assemble the new front inner pillar lower parts.
50 mm
(1.97 in) 3. Assemble the new front pillar reinforcement lower parts.
80 mm
(3.15 in)
ABC00531AB
4. When installing a new front outer pillar, cut the pillar along
the remaining body side. Then, apply the body sealant in the
area shown in the figure.
Cutting position
NOTE:
: Body sealant ABC00396AB
TSB Revision
CENTER PILLAR
CENTER PILLAR
M4030006001373

Spot welding
MIG spot welding
Braze welding
ABB00453AB
REPAIR WELDS
D
A
Cutting position 150 mm (5.9 in)
Notch
A
E
The same position as the The same position as the

new center outer pillar part. new center outer pillar part.
B C
B C ABC00133 AB
TSB Revision
CENTER PILLAR
D E

F
ABB00566AB
TSB Revision
CENTER PILLAR
NOTE ON REPAIR WORK

.
REMOVAL
1. To cut the welding points between the center pillar
Cutting
reinforcement and side sill reinforcement, cut the side outer
Cutting panel as shown.
position position
ABB00468AB
2. Since the center inner pillar upper remaining on the body

side is hard to remove, cut the roof side rail inner up to the
position shown in the figure, and remove the center inner
pillar upper by pulling it towards you.
Cutting
Cutting position
position
Roof side rail inner
Center inner pillar upper
ABB00469AB
INSTALLATION
1. To reinforce the strength in the center pillar cut area, cut the
side outer panel 50 mm (1.97 inches) above the cut area.
50 mm
(1.97 in)
Side outer
panel Cutting
position
ABB00470 AB
2. Remove the center inner pillar lower from the new center
inner pillar parts, and install the center inner pillar to the
body.
ABB00471
TSB Revision
SIDE SILL
SIDE SILL
M4030007001699

Spot welding
MIG spot welding
Braze welding
ABB00454AB
The same position as

REPAIR WELDS The same position as the new the new front floor side
front floor side sill outer part. sill outer part.
C
A
B
A B
C D
ABB00136 AB
TSB Revision
SIDE SILL
(With the center pillar reinforcement removed)
E F
ABC00137AB
NOTE ON REPAIR WORK

.
REMOVAL
1. When removing the side sill reinforcement, cut the center
90 mm pillar reinforcement 90 mm (3.54 inches) downward from the
(3.54 in)
installation hole of the rear door hinge because the center
pillar reinforcement interferes with it.
2. After removing the side sill reinforcement, remove the center
inner pillar lower.
Cutting Center pillar

position reinforcement
ABB00472AB
TSB Revision
SIDE SILL
INSTALLATION
1. Remove the center inner pillar upper from the new center
inner pillar parts, and install the center inner pillar to the
body.
ABB00471
2. When installing the new front floor side sill outer part, apply
the body sealant and adhesives in advance to the areas
shown in the figure.
Adhesive: Epoxyayresin adhesive
Brand: 3M™ AAD Part No.8115 or equivalent
NOTE:
: Body sealant : Adhesive ABB00674AB
TSB Revision
QUARTER OUTER
QUARTER OUTER
M4030008001409

Spot welding
MIG spot welding
Braze welding
ABB00455AB
REPAIR WELDS
B
C
3 points on
left side
The same position as

the new quarter
panel outer parts.
A B
ABC00143 AB
TSB Revision
QUARTER OUTER
50 mm
(1.97 in) 50 mm
(1.97 in)
C D
ABB00572AB
.
NOTE: Partial replacement is possible depending on the range

of damage.
NOTE: : Cuttable range ABB00475AB
NOTE ON REPAIR WORK

.
INSTALLATION
When installing the new quarter panel outer parts, apply the
body sealant and adhesives in advance to the areas shown in
the figure.
Left side Adhesive: Epoxyayresin adhesive
Brand: 3M™ AAD Part No.8115 or equivalent
NOTE:
: Body sealant
: Adhesive ABB00476AB
TSB Revision
REAR END PANEL
REAR END PANEL

M4030000300168

Spot welding
MIG spot welding
Braze welding
ABB00456AB
REPAIR WELDS
ABB00538AB
TSB Revision
REAR FLOOR
REAR FLOOR
M4030010001376

Spot welding
MIG spot welding
Braze welding
ABB00457AB
REPAIR WELDS
D
A B ABB00606AB
TSB Revision
REAR FLOOR
Cutting Cutting
position position
E F
C D
Cutting Cutting
position position
E F
ABC00527AB
NOTE: Refer to the Rear End Panel section on P.3-21 for the welding points with the rear end panel.
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REAR FLOOR
NOTE ON REPAIR WORK

.
REMOVAL
1. When removing the rear floor pan, cut it 60 mm (2.36
60 mm inches) behind the installation hole of the rear seat belt
(2.36 in)
anchor.
2. To remove the rear floor sidemember extension and the rear
floor sidemember reinforcement, follow the steps below:
ABB00639AB
(1) Cut off the rear floor sidemember extension together with
80 mm (3.15 in) the rear floor sidemember reinforcement 80 mm (3.15
<left side> or
50 mm (1.97 in) inches) <left side> or 50 mm (1.97 inches) <right side>
<right side> behind the edge of the extension.
(2) Remove the rear floor sidemember extension remaining
on the body side.
.
INSTALLATION
Rear floor sidemember
extension ABC00518AB
1. Align the new rear floor sidemember reinforcement with the

vehicle body, and cut out an excessive part. Then install it to
the vehicle body.
2. Install the new rear floor sidemember extension.
Cutting position
(left side)
Cutting position
(right side)
ABC00528 AB
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ROOF
ROOF
M4030011001733

Spot welding
MIG spot welding
Braze welding
ABB00458AB
REPAIR WELDS
NOTE:
: Adhesive ABB00636AB
Adhesive: Urethane body sealer

Brand: 3M™ AAD Part No.08360 or equiva-
lent
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QUARTER INNER
QUARTER INNER
M4030012001435

Spot welding
MIG spot welding
Braze welding
ABB00459AB
REPAIR WELDS
(With the quarter outer removed)
A
ABB00630AB
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QUARTER INNER
B C
ABB00632AB
NOTE: Refer to the Quarter Outer section on P.3-19 for the welding points with the quarter outer.
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QUARTER INNER LOWER
QUARTER INNER LOWER

M4030001100327

Spot welding
MIG spot welding
Braze welding
ABB00460AB
REPAIR WELDS
(With the quarter outer removed)
A
ABB00634AB
NOTE: Refer to the Quarter Outer section on P.3-19 for the welding points with the quarter outer.
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FRONT DOOR OUTER PANEL (WELDED TYPE)
FRONT DOOR OUTER PANEL (WELDED TYPE)

M4030001501050

Spot welding
MIG spot welding
Braze welding
ABB00410AB
REPAIR WELDS
50 mm
(1.97 in)
NOTE: A
: Adhesive ABB00403 AB

lent
NOTE: After hemming the new front door panel outer part, MIG spot weld the flange overlap section at a pitch
of 50 mm (1.97 inches).
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FRONT DOOR OUTER PANEL (ADHESION TYPE)
FRONT DOOR OUTER PANEL (ADHESION TYPE)

M4030001701128

Spot welding
MIG spot welding
Braze welding
ABB00409AB
REPAIR WELDS
NOTE:
: Adhesive 1 A
: Adhesive 2 ABB00404AB
• Adhesive 1: Urethane body sealer NOTE ON REPAIR WORK

Brand: 3M™ AAD Part No.08360 or equiv- .
alent INSTALLATION
• Adhesive 2: Epoxyayresin adhesive 1. When installing the new front door panel outer
Brand: 3M™ AAD Part No.8115 or equiva- part, grind the bonding surface and remove the
lent paint to improve adhesion. Then, degrease the
front door panel outer.
2. Install the front door panel outer and hem it. Then,
wipe off the adhesive that squeezed out.
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REAR DOOR OUTER PANEL (WELDED TYPE)
REAR DOOR OUTER PANEL (WELDED TYPE)

M4030001600786

Spot welding
MIG spot welding
Braze welding
ABB00411AB
REPAIR WELDS
50 mm
(1.97 in)
NOTE: A
: Adhesive ABB00405 AB

lent
NOTE: After hemming the new rear door panel outer part, MIG spot weld the flange overlap section at a pitch
of 50 mm (1.97 inches).
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REAR DOOR OUTER PANEL (ADHESION TYPE)
REAR DOOR OUTER PANEL (ADHESION TYPE)

M4030001800768

Spot welding
MIG spot welding
Braze welding
ABB00411AB
REPAIR WELDS
NOTE:
: Adhesive 1
: Adhesive 2 A ABB00406 AB
• Adhesive 1: Urethane body sealer Brand: 3M™ AAD Part No.8115 or equiva-
Brand: 3M™ AAD Part No.08360 or equiv- lent
alent
• Adhesive 2: Epoxyayresin adhesive NOTE ON REPAIR WORK
.
INSTALLATION
1. When installing the new rear door panel outer part, grind the
bonding surface and remove the paint to improve adhesion.
Then, degrease the rear door panel outer.
2. Install the rear door panel outer and hem it. Then, wipe off
the adhesive that squeezed out.
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FRONT END CROSSMEMBER
FRONT END CROSSMEMBER

M4030003100390

Spot welding
MIG spot welding
Braze welding
ABB00449 AB
REPAIR WELDS 7.0 ± 3.0 N·m

62 ± 26 in-lb
7.0 ± 3.0 N·m

62 ± 26 in-lb 10 ± 4 N·m
89 ± 35 in-lb
10 ± 4 N·m
89 ± 35 in-lb
7.0 ± 3.0 N·m
62 ± 26 in-lb A
7.0 ± 3.0 N·m

62 ± 26 in-lb
A
ABC00529AB
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NOTES
4-1
GROUP 4
CORROSION
PROTECTION
CONTENTS
BODY SEALING LOCATIONS . . . . . 4-2 UNDERCOAT APPLICATION

LOCATIONS . . . . . . . . . . . . . . . . . . . . 4-7
4-2 CORROSION PROTECTION
BODY SEALING LOCATIONS

M4040001002565
If the sealant application is directly visible on the NOTE: The bold dotted line indicates the application
outer plate and requires appearance quality of the area on the underside.
application in areas such as the drip rail, pillar, clinch .
and so on, then apply the sealant so that it is flat, or

wipe off any excess mounding after the application.
Be careful not to obstruct the water draining hole.
FLOOR
2 3
ABC00401AB
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CORROSION PROTECTION 4-3
UPPER BODY
6
5 8
ABB00598AB
SIDE BODY
12
10
13
9 14 15 16
11
ABB00599AB
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1 5
2 6
3 7
4 8
ABB00576AB ABC00398 AB
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9 13
10 14
11 15
12 16
ABB00584 AB ABC00417AB
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Hood Rear door
ABB00589AB ABB00591 AB
Front door Tail gate
ABB00590AB ABB00592 AB
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UNDERCOAT APPLICATION LOCATIONS
UNDERCOAT APPLICATION LOCATIONS

M4040003001698
• The under parts of the body is undercoated for • To avoid splashing of undercoat material during
anti-corrosive, anti-rust, anti-chipping, and the coating, protect the plug holes and compo-
anti-vibration performance. nents installation holes with masking tape.
• After correcting the body, restore as shown in the
instructions of the figure, if necessary.
NOTE:
: Undercoat [film thickness is at least 0.8 mm (0.03 in)] ABC00399AB
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NOTES
5-1
GROUP 5
SYNTHETIC-RESIN
PARTS
CONTENTS
LOCATION OF SYNTHETIC-RESIN
PARTS . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 SYNTHETIC-RESIN PARTS
LOCATION OF SYNTHETIC-RESIN PARTS

M4050001002124
The location and material of each of the principal
synthetic-resin parts are shown below.
34 2
12
11
20 3
32
24 21
8
1, 5 25
23 22
6 ABC00204AB
29 30
14 28 15
13
26 27
16
33
10
31 17
18
19
9
ABC00205AB
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SYNTHETIC-RESIN PARTS 5-3
No. Part Name Name Of Resin Abbreviation Heat-resistant

Temp
[°C (°F)]
1 Door mirror outer cover (color) Acrylonitrile butadiene styrene ABS 80 (176)
2 Liftgate spoiler
3 Rear view camera cover
4 Front delta garnish Acrylonitrile styrene acrylate ASA 80 (176)
5 Door mirror outer cover (black)
6 Front side air dam Ethylene Propylene diene EPDM 80 (176)
terpolymer
7 Headlight Polycarbonate PC 120 (248)
8 Door outside handle Polycarbonate+Polyethylene PC+PET 120 (248)
terephthalate
9 Front wheelhouse splash shield High density polyethylene PE-HD 70 − 90
10 Rear wheelhouse splash shield (158 − 194)
11 Rear wiper arm Polyethylene terephthalate PET 80 (176)
12 Antenna base Polypropylene PP 80 (176)
13 Inside rear view mirror
14 Lower center pillar trim
15 Quarter trim lower
16 Rear end trim
17 Rear scuff plate
18 Front scuff plate
19 Cowl side trim
20 Front deck garnish cover Polypropylene+Ethylene PP+EPDM 80 (176)
Propylene diene terpolymer
21 Rear bumper face Talc filled rubber modified PP+E/P-TD10 80 (176)
22 Front bumper face polypropylene (10%)
23 Front bumper under grille
24 Front bumper grille
25 Side air dam Talc filled rubber modified PP+E/P-TD30 110 (230)
polypropylene (30%)
26 Front pillar trim Talc filled polypropylene (10%) PP-TD10 110 − 120
27 Front door trim (230 − 248)
28 Upper center pillar trim
29 Rear door trim
30 Quarter trim upper
31 Floor console assembly
32 Front deck garnish Talc filled polypropylene (20%) PP-TD20 120 − 130
33 Instrument panel (248 − 266)
34 Roof drip molding Polyvinyl chloride PVC 80 (176)
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5-4 SYNTHETIC-RESIN PARTS
NOTE: .
• A slash (/) in the material symbol indicates that two different materials make two-layer construction. A plus
sign (+) indicates that the two different materials mix each other.
• The indicated heat-resistant temperature for parts which are composed of two or more types of material is
the value for the material with the lowest heat-resistant temperature.
• The material symbols for synthetic-resin parts are embossed on the parts in hidden places.
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6-1
GROUP 6
BODY COLOR
CONTENTS
BODY COLOR CODE . . . . . . . . . . . . 6-2 BODY COLOR CHARTS . . . . . . . . . . 6-2

6-2 BODY COLOR
BODY COLOR CODE
BODY COLOR CODE

M4060001001531
.
AC700308 Body color code is stamped on the vehicle information code

plate, which is attached on the underside of the center pillar
(Right side).
MODEL
ENGINE
TRANS
AXLE
COLOR,TRIM
OPT
Body color code

ABC00418 AB
BODY COLOR CHARTS

M4060002004180
Check the vehicle’s body color code, and then use
this body color chart to determine the refinishing
paint supplier from which the color can be pur-
chased.
Color Color Color Color name Coating film Composition of film

code number structure
DARK GRAY A02 CMA10002 Eisen Gray Mica 2P Pearl
SILVER A66 CSA10066 Cool Silver Metallic 2M Metallic
GREEN F24 CSF10024 Pop Green Metallic 2M Metallic
RED P19 CSP10019 Red Metallic 2M Metallic
MEDIUM BLUE T69 CST10069 Cerulean Blue Mica 2P Pearl
PURPLE V08 CSV10008 Cassis Purple Metallic 2M Metallic
WHITE W19 AC11319 White Solid 2S Solid
BLACK X08 AC11008 Black Mica 2P Pearl
NOTE: .
• The coating film structure indicates top coating only (2S: 2 coat solid, 2M: 2 coat metallic, 2P: 2 coat
pearl).
• For painting, inner panel colors should be similar to the outer panel colors.
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9-1
GROUP 9
BASE OF BODY
REPAIR
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . 9-2 STANDARD PROCEDURES FOR

SHEET METAL WORK . . . . . . . . . . . . . . . . 9-27
SUPPLEMENTAL RESTRAINT USING A FRAME STRAIGHTENER . . . . . . 9-28
SYSTEM (SRS) . . . . . . . . . . . . . . . . . 9-2 FRAME REPAIR PROCEDURES . . . . . . . . 9-29
NOTES REGARDING REPAIR WORK . . . . 9-32
WELDING. . . . . . . . . . . . . . . . . . . . . . 9-3 HEAT-WITHSTAND TEMPERATURES
OF RESIN-PLASTIC PARTS . . . . . . . . . . . 9-35
WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
HOW TO DISTINGUISH TYPES
ELECTRIC RESISTANCE SPOT
OF PLASTICS . . . . . . . . . . . . . . . . . . . . . . . 9-37
WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
GAS SHIELD ARC WELDING . . . . . . . . . . 9-9
CORROSION PROTECTION . . . . . . . 9-38
OTHER TYPES OF WELDING . . . . . . . . . . 9-13
ANTICORROSION TREATMENT
AT THE FACTORY . . . . . . . . . . . . . . . . . . . 9-38
BODY REPAIR. . . . . . . . . . . . . . . . . . 9-15
ANTICORROSION TREATMENT AT
STANDARD BODY REPAIR THE TIME OF BODY REPAIR WORK . . . . 9-41
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . 9-15
THEFT PROTECTION . . . . . . . . . . . . . . . . 9-24
REPAIR OF SYNTHETIC-RESIN
ATTACHMENT OF SILENCERS . . . . . . . . 9-25 PARTS . . . . . . . . . . . . . . . . . . . . . . . . 9-45
POSITIONING DIMENSIONS
SYNTHETIC-RESIN PARTS REPAIR
FOR OPENINGS. . . . . . . . . . . . . . . . . . . . . 9-26
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 9-45
9-2 BASE OF BODY REPAIR
GENERAL
GENERAL
M4090000100018
Group 9 is applicable for all models.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

M4090000500016
WARNING
• Improper service or maintenance of any
component of the SRS and any
SRS-related component, can lead to per-
sonal injury or death to service personnel
(from inadvertent firing of the air bag) or
to the driver and passenger (from render-
ing the SRS inoperative).
• The SRS components and seat belt with
pre-tensioner should not be subjected to
heat, so remove the SRS-ECU, air bag
modules, clock spring, front seats, impact
sensor and seat belt with pre-tensioner
before drying or baking the vehicle after
painting.
• SRS-ECU, air bag modules, clock
spring, front seats, impact sensor: 93°
C (199° F) or more
• Seat belt with pre-tensioner 90°C (194°
F) or more
• Service or maintenance of any SRS com-
ponent and SRS-related component must
be performed only at an authorized MIT-
SUBISHI dealer.
• MITSUBISHI dealer personnel must thor-
oughly review workshop manual, and
especially its GROUP 52B - Supplemental
Restraint System (SRS), before begin-
ning any service or maintenance of any
component of the SRS and any
SRS-related component.
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BASE OF BODY REPAIR 9-3
WELDING
WELDING
WELDING
M4090001000058
Welding is the partial joining of two or more metals
by deposition; the welding methods used for body
maintenance and repair can be classified into the fol-
lowing methods.
Fusion methods Shielded arc welding

Temperature: 1,130 – 1,550˚C CO2 gas arc welding
(2,066 – 2,822˚F)
Gas welding
Welding methods
Pressure methods Electric resistance spot welding
[Temperature approximatery 1,500˚C (2,732˚F) or higher at weld area]
Brazing methods Brazing

Temperature: 620 – 950˚C
(1,148 – 1,742˚F)
Soldering
Temperature: 183 – 310˚C
(361 – 590˚F)
AB301447AB
FUSION WELDING BRAZING

Fusion welding is a method of welding in which the Brazing is a method of welding in which the weld
weld connection is made by forming or supplying the connection is made by supplying a filler metal (which
weld metal at the part where the weld is to be made. is molten at a temperature lower than the melting
temperature of the base metal) at the place where
PRESSURE WELDING the joining is to be made without melting the base
Pressure welding is a method of welding in which the metal itself.
weld connection is made by applying external pres-
sure while the part where the weld is to be made is in
a molten or semi-molten condition.
ELECTRIC RESISTANCE SPOT WELDING

M4090002000040
Electric resistance spot welding is a method for fus- ADVANTAGES OF ELECTRIC
ing metal parts together. Two or three metal sheets RESISTANCE SPOT WELDING
are positioned between two copper-alloy electrode
• Because the time required for welding at each
tips, and pressure and a large current are then
point is brief, the work can be done quickly and at
applied, thus causing the contacting surfaces to heat
reduced cost.
up and fuse together because of the electric contact
• Because both metals are fused and pressure
resistance.
applied to make the weld, the strength and reli-
ability are both high.
• Because the time required to make the welds is
short, there is little occurrence of distortion of the
panel due to heat.
.
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WELDING
PROCEDURE
There are three basic stages in electric resistance spot weld-
ing.
1. Initial pressure application stage
This stage precedes the current application. Applying
pressure to the steel panels through the electrode tips
ensures a uniform contact resistance and a smoother
current flow.
AB200026
2. Current application stage

While an ample amount of pressure is being applied, the
current is sent through the electrode tips. The contact
resistance causes the contact surfaces of the steel panels to
heat up and fuse together.
AB200027
3. Holding stage
When the current application is finished and a nugget (a
solidified piece of molten metal) forms at the weld, the
pressure application is continued in order to strengthen the
weld. This is the most important stage of electric resistance
spot welding in ensuring the strength of the weld.
AB200028
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WELDING
NUGGET FORMATION
Cooling water
Weak ← Shear strength per point → Strong
More than C
1.6 mm D Elect-
rode Melting point
(0.063 in)
C' Steel
panel
D'
B'
B 1.6 mm (0.063 in)
or less Nugget
Elect-
C Is The Scatter Point rode
A' A
Small ← Welding current → Large Water 540 1,095 1,650˚C

Cooling water temperature (1,000) (2,000) (3,000)˚F
Max. Heating temperature
AB301468 AD
Generally speaking, the size of the nugget will As the current level increases further, the weld
increase as the welding current increases, and as strength for thick panels [more than 1.6 mm (0.063
the size of the nugget increases, the strength of the inch)] continues to increase proportionately (between
weld will also increase. points B and C); however, for thin panels [1.6 mm
Nugget formation will not begin until the current level (0.063 inch) or less], the weld strength reaches a
reaches a certain point; however, once this welding peak very quickly and will increase only slightly, even
current level is passed, the strength will increase rap- if the current level increases (between points B' and
idly (between points A and B). C').
Then, for both thick panels and thin panels, the mol-
ten metal will scatter if the current level increases
past a certain point.
.
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WELDING
NOTES REGARDING WELDING
90 – 120˚
D : Diameter of the electrode tip
t : Thickness of the panel
AB301455AE
1. Selection of the electrode tips • Make the spot welds at the center of the
• Select the electrode tips according to the flanges to provide sufficient adhesion. When
thickness of the panels to be welded. welding at an edge, make the spot welds at
D = 2t + 3 mm (D = 2t + 0.1 inch) least 5 mm (0.2 inch) from the edge of the
• The angle of the tip should be between 90 flange.
degree angle and 120 degree angle. • The number of spot weld points should be the
• To always keep the end of tip in the correct same as, or slightly more than the number of
shape, use a tip cutter, file or similar tool to original repair welds.
shape it if it becomes worn. • When spot welding three or more panels
2. Alignment of the electrode tips together, if painted surfaces cause a loss of
• Adjust the arms so that the upper and lower conductivity, make the welds at the same
electrode tips are in a straight line. places as the factory welds. If this is done,
3. Alignment and length of the arms extra welds will not be necessary, but if extra
• Adjust the electrode tips so that the upper and welds are necessary, switch to plug welding.
lower arms are parallel. .
• Select an appropriate arm length. Note, how- WELDING REQUIREMENTS

ever, that the arm length should not be more Standard steel plate (SPCC, etc.)
than 350 mm (13.8 inches) in order to ensure CAUTION
nugget strength. If the total thickness of the plates at the weld
4. The weld points places is 3 mm (0.12 inch) or more, use plug
• The overall strength will increase as the pitch welding, because spot welding will not provide
decreases; however, if the pitch decreases sufficient welded strength.
too much, the current will be short-circuit
diverted to the previous weld point and the Example
strength of the individual nuggets will be insuf- • Center pillar (outer): plate thickness 1.4 mm
ficient. (0.055 inch), material SPCC
• Center pillar (inner): plate thickness 1.5 mm
(0.059 inch), material SPCC
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WELDING
The number of weld points are as below when the

outer and inner center pillars are repaired by weld-
ing.
Factory welds (F) Repair welds (R)
8 Points 8 Points 11 Points 11 Points
As shown by the Welding Requirements table, the number of repair welds is as follows.
8 (points) × 130 (%) = 10.4 (points)
The number of weld points should, therefore, be ten or eleven.
If, however, a pitch of 26 mm (1.02 inch) or more cannot be maintained, the plug
welding method (eight weld points) should be used.
AB200031AE
Panel Number of repair weld (percentage of factory weld)

thickness*
[mm (in)]
Safety 1.0 (0.04) or 100% Same number as factory welds
equipment less
area 1.2 (0.047) 150% Maintain pitch of at least 22 mm (0.87 inch); if not possible, plug weld.
1.4 (0.055) or 100% Same number as factory welds; plug welding
more
Other area 1.2 (0.047) or 100% Same number as factory welds
less
1.4 (0.055) 130% Maintain pitch of at least 26 mm (1.02 inch); if not possible, plug weld.
more
NOTE: *: For welding steel plates of different thickness, conform to the welding conditions for the thinner
plate.
.
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WELDING
GALVANIZED STEEL PLATE (SECC)

CAUTION
If the total thickness of the plates at the weld
places is 3 mm (0.12 inch) or more, use plug
welding, because spot welding will not provide
sufficient welded strength.
Panel Number of repair weld (percentage of factory weld)
thickness*
[mm (in)]
Safety 0.9 (0.035 or 100% Same number as factory welds
equipment less
area 1.0 (0.04) 200% Maintain pitch of at least 18 mm (0.71 inch); if not possible, plug weld.
more
Other area 0.9 (0.035) or 100% Same number as factory welds
less
1.0 (0.04) 140% Maintain pitch of at least 18 mm (0.71 inch); if not possible, plug weld.
more
NOTE: *: For welding steel plates of different thicknesses, conform to the welding conditions for the thinner
plate.
.
USING A TEST PIECE TO CHECK NUGGET

FORMATION
Weld a test piece of the same type of steel plate as the panels
to be welded. Try to twist the piece, and also check the nugget
WELD POINT 1 diameter.
Using the weld point as an axis, apply force in the direction indi-
cated by the arrows in the illustration, and determine the
2
strength of the weld.
1. Good (The welded part remains at one side).
3 2. and 3.
The weld conditions are unsatisfactory; adjust the welding
AB200032AB current, the current application time, and/or the applied
pressure.
.
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WELDING
CHECKING NUGGET STRENGTH FOLLOWING

SPOT WELDING
CAUTION
• Stop wedging the tip or the chisel or flat-tipped screw-
driver as soon as the size of the nuggets can be deter-
3 mm (0.12 in) mined; do not wedge it in more than 30 mm (1.18
inches).
• After checking the nugget diameter, correct the place
where the checking was done.
Wedge the tip of a chisel or flat-tipped (-) screwdriver into the
space between two weld points.
• The nuggets should not break apart.
AB200033AC
AB200033 • The nugget diameter should be 3 mm (0.12 inch) or more.
GAS SHIELD ARC WELDING

M4090003000043
Wire
Nozzle
Contact tip
Metal vapor
Shield gas
AB301456 AD
Gas shielded arc welding is one method of arc weld- fuse the area. There are two types of gas shielded
ing. In this method, while the area to be welded is arc welding, classified according to the gas they use
shielded from the air by a layer of inert gas (such as as the shield gas: carbon dioxide (CO2) gas shielded
argon) or carbon dioxide gas, the filler metal (wire) is arc welding, and MIG welding, which uses an inert
fed from the torch nozzle at a constant rate and an gas (such as argon).
electric arc is generated between the tip of the wire However, herein we will refer to all gas shielded arc
and the area being welded, thus generating heat to welding as MIG welding.
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WELDING
MIG SPOT WELDING

Wire
Gas cup
Gas outlet
AB200036AE
This welding method is used in areas where regular 2. Being sure that the two prongs are not leaning to
spot welding cannot be done. The two panels are either side, set them in direct contact with the
stacked together, the tip of the torch (one designed panel to the welded.
for use in MIG spot welding) is positioned on one 3. Welding will begin when the torch trigger is
side, an arc is generated for a short time, and a par- squeezed, and will stop automatically when the
tial melting is done to obtain a spot weld. weld is complete.
.
Procedure .
FEATURES OF MIG SPOT WELDING

CAUTION
• Make sure that the area to be welded is per- In comparison to resistance spot welding, MIG spot
fectly clean; remove oxidation film, scales, welding has the following advantages and disadvan-
rust, dirt, etc. tages.
• The two panels to be welded must be in per-
fect contact with each other.
• The number and pitch of the weld points
should be approximately the same as for the
factory welds.
1. Position the tip of the nozzle at a right angle to the
surface to be welded.
Item Mig spot welding Electric resistance spot welding

Working • Light weight • Although the torch with separate
characteristics • Welding possible at various transformer is lightweight, the torch
positions (no limit upon welding combined with transformer type is heavy.
positions) • The arm must be exchanged to conform
to the weld location.
Weld time/point Slow (0.5 second or more) Fast (0.5 second or less)
Treatment after Necessary (grinding by grinder, Unnecessary
welding etc.)
Power High voltage, low current Low voltage, high current
(15 − 30 V, 50 − 200 A) (2 − 4 V, 4 − 10 kA)
Flux material • CO2 (carbonic acid gas) Unnecessary
• Weld wire
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WELDING
Item Mig spot welding Electric resistance spot welding

Weld points/10 • 25 points or less • 50 − 60 points
minutes • Arc instability and contact tip • Welding rod deformation and transformer
(rate of use) burn if rate of use is exceeded. overheating if rate of use is exceeded.
Distortion caused by Occurs easily Rare
welding
Welding strength Depends on strength of welding • Same as base material
wire itself. • Little oxidation
• Uniform welding quality
Weld traces Button head (slightly convex) Slight concave
(Almost no indentation if swivel tip
used.)
Swivel tip
AB200037AD
Re-repairability Difficult Easy

(cutting away welded (Much welding trace High hardness (Can be separated by spot cutter.)
area) of weld points)
.
The MIG welding done around the doors, wheelhouse arches,

etc., to prevent the flanges from coming undone after hemming
work is also called MIG spot welding.
AB200038 AB
PLUG WELDING
CAUTION
In order to prevent the formation of blowholes, fill in each
5 – 6 mm hole completely in one pass.Be sure that the two panels
(0.2 – 0.24 in) are in perfect contact.Be sure that the penetration goes all
Torch Diameter
hole the way to the bottom panel.
Plug welding is done by making holes 5 − 6 mm (0.2−0.24 inch)
Perfect in diameter in one of the panels to be welded together, position-
contact ing the torch at a right angle to the holes and then filling in the
holes one at a time.
AB301460 AD
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WELDING
CONTINUOUS WELDING
There are several types of continuous welding: fillet (lap joint)
welding, butt welding, T joint welding, gap welding, etc.; these
are called short-circuit arc welding, and provide a stable arc at
a relatively low current.
AB200041
Torch angle and welding technique

There are two welding techniques: forehand welding and back-
hand welding.
Forehand welding: Penetration is shallow and the bead is flat.
Backhand welding: Penetration is deep and the bead has a
convex shape.
The angle of the torch should be 15 − 30 degree angle for
either technique, and the tip should be maintained at a distance
15 – 30˚ 15 – 30˚ of 6 − 10 mm (0.24 − 0.39 inch) from the surface being welded.
Forehand Backhand
technique technique
AB301457AD
Preventing warping
Anti-Warp Welding Techniques 1. Backhand technique
Because the direction for each weld pass and that for the
5 4 3 2 1 fusion progression are opposite, the residual stress is
1.
Backhand technique evenly distributed.
4 2 1 3
2. Symmetrical technique
2. Because the welds are made in symmetrical positions in
Symmetrical technique relation to the center of the joint, the residual stress is also
1 4 2 5 3 symmetrical.
3.
"Stepping stone" technique 3. "Stepping stone" technique
AB200043AD Because the welds are made at random positions, the
residual stress is the most evenly distributed; however, the
possibility of flaws at the starting and stopping points is rela-
tively high.
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WELDING
NOTES REGARDING MIG WELDING 3. Select a welding current to match the thickness of
Note the following notes regarding MIG welding. the panels being welded.
1. The surface to be welded must be perfectly 4. For continuous welding, maintain a constant weld
clean; be sure to remove any non-conductive speed and keep both the height and the width of
paint. the bead constant.
2. If the end of the wire forms into a ball, it will In addition, the tack welding pitch and the welding
adversely affect the formation of the arc; cut the bead should be shorter as the thickness of the
end off with a pair of wire snips or a similar tool. panels being welded decreases.
OTHER TYPES OF WELDING

M4090004000046
BRAZING 1. Brass filler metal (brass solder)

In brazing, a filler metal is melted into the joint of the Brass filler metal is an alloy consisting of 60%
panels to be welded at a comparatively low tempera- copper and 40% zinc with a melting temperature
ture to fuse them together without melting the panels of approximately 850 − 1,050°C (1,562 −
themselves. In other words, through the aid of a flux 1,922°F), and it is the most commonly used braz-
and because of the capillarity phenomenon, the mol- ing filler metal used for body repair.
ten filler metal will flow into the joint between the two The filler metal itself is coated with flux to facili-
panels which are in contact with each other and tate penetration between the panels to be joined.
spread along the metal surfaces. When this molten 2. Silver alloy filler metal (silver solder)
filler metal cools and solidifies, it will from a strong Silver alloy filler metal consists of silver, copper,
joint of the two panels. Note that, if two panels of dif- zinc or cadmium, nickel, and tin, or other metals.
ferent kinds of metal are brazed, the electrolysis gen- This filler metal is most applicable for the brazing
erated between the two metals will cause moisture to of steel and non-ferrous alloy other than alumi-
from, which will result in corrosion. num, magnesium, and others with low melting
Panels should not be connected together by brazing points.
at any place except those places indicated. The fol-
lowing materials (filler metals) are usually used for
brazing.
Notes with regard to brazing work
Examples of brazed joints
AB200044 AF
• Use a wire brush, sandpaper, file etc., to remove • When doing brass brazing, if the panels and the
any oxide film grease, dirt, etc., from the surfaces filler metal are heated excessively, a weak
of the panels to be brazed. iron-copper alloy will form, which could crack
easily. Be careful not to apply excessive heat.
• The joint of the panels must overlap as indicated
in the illustration.
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WELDING
GAS WELDING
Gas welding is a method in which a high temperature flame is
Oxy-acetylene
flame used to melt both a welding rod and the base metal (panels) to
make a fused joint. Oxy-acetylene is the most common type of
gas welding. However, because of the extremely high tempera-
Welding ture of the fused joint, the strength of the steel plate deterio-
rod Deposite rates, and there is a higher possibility of warping. This method,
therefore, is not very suitable for body repair.
Base metal
AB200049AD
The flame in gas welding can be classified according

to the ratio of acetylene and oxygen.
1. Carburizing flame 2. Standard flame 3. Peroxide flame
Flame core Flame core Flame core
Acetylene cone Outer flame Outer flame

Outer flame
AB200050 AE
1. Carburizing flame (acetylene-rich flame) Notes with regard to gas welding

This flame has an excess of acetylene or a defi-
ciency of oxygen. The incomplete combustion 1. Handle the oxygen and acetylene tanks carefully.
gives off a black smoke, and two flame cores can 2. Adjust the flame in accordance with the type of
be seen inside the deformed yellow flame. The metal being welded.
flame itself is large, but the temperature is rela- 3. Select a nozzle to match the work to be done.
tively low, making this flame unsuitable for weld- Avoid overheating and adhesion of foreign matter
ing. (dirt, etc.)
2. Standard flame (neutral-mixture flame) 4. The following points are particularly important
This flame has approximately equal amounts of when welding mild steel plate.
acetylene and oxygen. The length is shorter than • Melt a sufficient amount of welding rod, but be
that of the carburizing flame; the flame core is careful not to melt the base metal. Use the
rounded; and it is clear and bright. same amount of welding rod on both sides.
The carbon in the acetylene is burned completely, • Use the correct amount of welding rod in
resulting in the maximum obtainable temperature. accordance with the melting point of the base
This is the flame most commonly used for weld- metal.
ing. • Avoid welding over places which have been
3. Peroxide flame (oxygen-rich flame) welded before.
This flame has an excess of oxygen or a defi- • In order to avoid warping, do only the amount
ciency of acetylene. The flame core is shorter of tack welding that is absolutely required.
and sharper, and the entire flame has a black-
ish-purplish color. The combustion is unstable,
and the flame flickers continuously.
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BODY REPAIR
BODY REPAIR
STANDARD BODY REPAIR PROCEDURES
M4090006000075
The following is an explanation of the standard repair STANDARD PROCEDURES FOR
procedures for the monocoque body and the REPLACEMENT OF WELDED PANELS
frame-type body. Furthermore, please refer to the
In order to maintain the proper levels of strength,
replacement of welded panels for the applicable
rigidity, and precision when making welded panel
model for information concerning the procedures for
replacements, it is essential to first gain a thorough
replacement of panels (as classified by position) for
understanding of the body structure, and then to per-
the various models.
form all repair operations carefully and correctly. In
NOTE: That reference should be made to page addition, when performing the operations, be sure to
P.9-28 concerning repair procedures for the frame of use the proper protective equipment for each opera-
frame-type vehicles. tion.
.
CAUTION
• Select an appropriate location for the cutting operation,
and perform the work carefully, so as not to cut into the
reinforcements located inside the pillars, panels which
are not be replaced, or any other such parts.
• There are harnesses, hoses, and other such parts
routed inside the front pillar, the rear pillar, the fender
shield, the side sill, etc.; perform the repair work only
after any such material has been removed.
• For overlap cutting, allow an overlap of approximately
AB200051 30 − 50 mm (1.18 − 1.97 inches) when performing the
cutting operation.
1. Rough cutting of panels
First make a rough cutting of a portion of the panel to be
replaced, and then remove that portion, thus making it
easier to break the spot welds.
2. Removal of the paint coat from spot-welded points
In order to clearly identify the spot-welded points, remove
the paint coat from areas where it is difficult to determine the
spot welds.
AB200052
3. Cutting and separation of spot-welded points

In order to perform cutting and separation of spot-welded
points, use a spot weld cutter which is larger than the size of
the nugget to make a hole only in the panels to be replaced.
When cutting and separating spot-welded points in places
where the surrounding panel or other parts interfere with the
spot weld cutter, or if the operation is hampered by a lack of
space, bend back the flanges in order to make the work
easier.
AB200053 If a spot-weld cutter cannot be used at all, cut and separate
the spot welds by using a chisel or similar tool.
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BODY REPAIR
NOTE: If a replacement panel is to be mounted by doing

plug welding from the side of the panel remaining on the
body, either a hole can be made in the panel on the body, or
a hole can be made right through both the panel which is to
remain on the body and the panel to be replaced.
CAUTION
When performing this operation, warping of the surround-
ing panels may occur if an excessive amount of heat is
applied; therefore, be careful to avoid doing this.
4. Breaking of brazing and arc welds
Heat only the brazed or arc welded portion (such as the
upper portion of pillars, etc.), and then separate by using a
screwdriver while melting occurs.
AB200054
5. Finishing work of spot welding

Grind and smooth any weld traces which might be left on the
body surface by using an air grinder or similar tool, being
careful not to damage any of the panels which is not to be
replaced. When performing this operation, be sure to wear
safety goggles (dust proof glasses).
AB200055
6. Making of holes in new parts for MIG plug welding

Make holes approximately 5 − 6 mm (0.2 − 0.24 inch) in
diameter at points where plug welding is to be performed
because spot welding is not possible.
AB200056
AB200057
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BODY REPAIR
7. Flange correction for spot weld traces

Correct any flanges that become bent or deformed when
spot welds are broken or during other work.
AB200058
CAUTION
Do not use a flame for paint coat removal because doing
so might damage the paint coat of panels which are not to
be replaced, thus causing corrosion.
8. Removal of the paint coat from new parts and from the
vehicle body
In order to provide for the proper flow of electric current
during spot welding operations, remove the paint coat from
both sides of the new part and the body by using a polisher
wheel or similar tool.
AB200059
9. Rough cutting of new parts

Cut off the unnecessary portions of new parts. Allow an
overlap of approximately 30 − 50 mm (1.18 − 1.97 inches)
when performing overlap cutting of the pillars, side sills, or
other locations.
AB200060
CAUTION
Carefully select the location for cutting, taking care not to
cut a reinforcement at the inner side of a pillar, etc. or a
panel that is not to be replaced.
10.Overlap cutting of new parts
For locations in which butt welding is to be done, first
temporarily attach the new parts to the body, and then cut
Edge of the the two panels simultaneously.
new part NOTE: If a reinforcement or a panel which is not to be
Edge of the replaced is cut accidentally, first repair the mistake by weld-
panel on the body AB200061AD ing before proceeding with the rest of the work.
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BODY REPAIR
CAUTION
Perform the operations carefully so that the cut ends fit
together properly.
11.Cutting of new parts by using a measurement marking
If overlap cutting is not possible in a place where butt
welding is to be done, make a measurement marking on the
new part at the exact same measurement which was used
for the cutting of the body panel, and then cut the new part
by using this measurement marking.
Twolayer construction • Two-layer construction
When cutting a front pillar or center pillar which has a
two-layer construction but no reinforcement, make the cut-
ting of the inner panel and that of the outer panel approxi-
Outer panel mately 50 mm (1.97 inches) apart in order to obtain
Approx. 50 mm
(1.97in) maximum strength.
Inner panel
AB200062 AD
Three-layer construction • Three-layer construction

When cutting a front pillar or center pillar which has a
three-layer (including a reinforcement) construction (dou-
ble-box construction), cut the outer panel and the reinforce-
ment at the same position, and don't forget to butt weld the
Inner panel
reinforcement. If the inner panel is an assembly replace-
Inner panel
cut line ment part, cut it at two places in order to provide ample
working space for the butt welding of the reinforcement.
Outer panel
and reinforce-
ment cut line
Inner panel cut line AB200063AD
12.Application of spot sealer to spot-welded points

Apply an electro-conductive spot sealer to the connecting
surfaces of both the new parts and the vehicle body in order
to provide corrosion protection.
AB200064
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BODY REPAIR
CAUTION
During temporary mounting, it is extremely important to
obtain accurate measurements for each component. The
mounting positions for the front and rear suspensions are
especially crucial with regard to safety; therefore, it is nec-
essary that all work concerning these areas be done care-
fully and correctly.
13.Temporary mounting of new parts
(1) In order to bring the new parts into the proper mounting
position, measure each part carefully and make any
AB200065 corrections necessary in order to obtain agreement with
the measurements.
(2) In addition, make temporary welds, and then check to
confirm that the closing and fit of the doors, fenders, etc.,
are correct.
For parts which should be symmetrical to the body
center, measure the distances from the body center point
to both the left part and the right part, and confirm that the
distances are the same.
AB200066
CAUTION
Weld completely so that there are no pinholes.
14.Butt welding
For butt welding, make a 10 − 15 mm (0.39 − 0.59 inch) MIG
spot weld, and then, in order to prevent warping which might
be caused by the welding heat, complete the welding by
making welds of the specified width at alternate positions.
AB200067
AB200068
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BODY REPAIR
15.Spot welding
When doing spot welding, it is not only important to correctly
position the electrode tips, but also to hold the two panels
securely together with vise-grip pliers or some other type of
clamps, being sure that they are in perfect contact with each
other.
• Be sure that the force applied by the arm is sufficient.
• Use a test piece to check the secondary current and the
current application time of the spot welder, and adjust the
AB200070
values as appropriate.
16.Plug welding
If spot welds cannot be made, make holes for plug welding
in the new parts, and then MIG weld. Because the quality of
the fusion varies according to the size of the holes, they
should be about 5 − 6 mm (0.2 − 0.24 inch) in diameter. In
addition, be sure the two surfaces are in complete contact
with each other by using vise-grip pliers to securely hold
them.
NOTE: Depending on the working conditions, it might also
AB200070 be necessary to make holes in the panel remaining on the
body
17.Hemming (Adhesion type)
(1) Apply an adhesive to the area to be hemmed of the door
outer panel.
Section
A–A
A
AB401282
A
AB500010 AD
(2) For the area to be hemmed of the door outer panel, apply
an adhesive and smooth the panel with a hammer and a
dolly. Then, hem the panel with a hemming tool.
Hemming tool
AB200072AD
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BODY REPAIR
18.Hemming (Welded type)

(1) For the area to be hemmed of the door outer panel, etc.,
smooth the panel with a hammer and a dolly, and hem it
with a hemming tool.
Hemming tool
AB200072AD
(2) After completing the hemming work, make MIG spot

welds at 50 − 60 mm (1.97 − 2.36 inches) intervals on the
inside.
AB200073
CAUTION
Be sure not to grind the panel down too much. Before
welding the outer panel, be sure to apply an anticorrosion
agent.
19.Finishing work for butt welding and plug welding
Do the finishing work to smooth the protruding weld traces.
However, the butt joints of reinforcements and other internal
parts will be stronger if the weld traces are not finished.
AB200074
20.Application of body sealant

Apply a coating of sealant carefully, without breaks, as
described in the section (of the manual corresponding to
that model).
NOTE: After application has been made to any external sur-
faces, perform smooth-finishing work.
AB200076
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BODY REPAIR
CAUTION
Wipe off any anticorrosion agent which oozes out onto
surfaces to be painted later; the presence of such anticor-
rosion agent would prevent correct adhesion of the paint
coat.
21.Application of an anticorrosion agent
Apply an ample amount of anticorrosion agent to any
welded areas and to all surfaces from which the paint coat
was removed.
The paint coat of welded areas will have been damaged by
AB200077 the heat; be sure to apply an anticorrosion agent to surfaces
to be repaired.
Use an aerosol-type anticorrosion agent for application to
the side sills, the pillars, and other similar parts which have a
hollow construction, by utilizing the trim mounting holes, etc.
AB200078
22.Application of undercoating
If the underbody is repaired or replaced, carefully apply a
coating of undercoating as described in the section (of the
manual corresponding to that model).
AB200079
CAUTIONS REGARDING BODY REPAIR At the time of repair, it is particularly necessary to

Because each component part of a single-unit con- take measurements at the components noted
struction body makes some contribution, more or below, and to make all welds and installations
less, to the overall strength of that body, it is neces- with special care.
sary to sufficiently understand the actual function of • Front sidemember
any part to be repaired before attempting any repair • Rear floor sidemember
or welding procedure. • Front wheelhouse (inner)
. • Rear wheelhouse (inner) (Independent rear
STRENGTH AND RIGIDITY suspension type)
1. The suspension installation part plays an impor- 2. Because the places where the floor panel and
tant role, determining the wheel alignment. Wheel sidemember parts are joined have an important
misalignment is of course potentially very danger- effect upon the rigidity of the entire body, welds in
ous because it can lead to driving instability, these places must be done with particular care.
one-sided braking, abnormal tire wear, abnormal 3. After repairs have been completed, the wheel
vibration, etc. alignment, wheel base, tread, etc., must be care-
fully checked to be sure that there is no deviation.
.
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BODY REPAIR
SAFETY 3. Apply a coating of undercoating if the underbody

1. Procedures related to the installation of any com- is repaired.
ponent related to safety must be done with partic- 4. Use spot sealer if spot welds are made.
ular care in order to assure full maintenance of 5. Repair any scratches to panels made by mold-
safety. ings, sashes, etc.
• Suspension installation parts 6. Carefully apply body sealant to panel connection
• Fuel pipe joints and other fitting places.
• Brakes 7. Tape over any unused holes in the panel inner
• Fuel tank installation parts, etc. side by using sealing tape.
2. Because seat belts are directly related to driver
.
and passenger safety, any welds of seat belt VIBRATION AND NOISE
anchor points or reinforcements must be done
with particular care in order to maintain strength. 1. Prevent any decrease of tensional rigidity caused
by welding distortion.
.
2. Carefully apply body sealant to panel connection

PREVENTION OF CORROSION AND OF joints and other fitting places.
WATER OR DUST ENTRY 3. Tape over any unused holes in the panel inner
1. After any work is completed, it is important to side by using sealing tape.
completely remove any welding residue, particles
.
or residue from cutting, and any other dirt, etc. CONTACT AND ALIGNMENT
2. Corrosion-prevention material must without fail
1. In order to maintain the precision of openings,
be applied at the following places:
make careful measurements as repairs are being
• At any place where paint has flaked off or
made.
peeled away.
• At any surfaces that have been cut. 2. Make contact/alignment adjustments of door
• At the outer and inner side of every welded hinge, lid, and hood hinge installation parts.
place.
• Within any semi-enclosed structure or compo-
nent (aerosol-type rust inhibitors are effective
for difficult-to-reach places).
• At the outer and inner side of any place sub-
jected to heat.
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BODY REPAIR
THEFT PROTECTION
M4090007000067
In order to prevent theft, following Vehicle Identification Number
Theft protection label (VIN) has been engraved and attached, in the form of a label to
For original parts the engine, transaxle, and main of the outer body:
Engine cylinder block, Transaxle housing, Fender,
Doors, Quarter panel, Hood, Liftgate, Trunk lid,
Bumpers
Furthermore, supplementary parts for the main portions of the
outer body have theft protection labels attached and the sup-
plementary parts for the engine and the transaxle are engraved
with the same details.
For replacement parts
AC211646 AD
PANEL REPAIR CAUTION

1. Take care when respraying the original part to cover the theft
protection label with masking tape prior to respraying. In
addition, remember to peel off the masking tape after
completion of the respray.
2. Because theft protection labels on the supplementary parts
are covered with masking tape already, they can be
resprayed just as they are.
3. Take care not to peel off the theft protection labels from
either the original or the supplementary parts.
HOW TO PEEL OFF THE SURFACE MASKING

FILM FROM THE THEFT-PROTECTION LABEL
CAUTION
Be careful not to damage the paint surface or the label
itself.
Knife
1. Using a sharp knife at the corner of the label surface, lift up
the masking film only.
2. Grasp the masking film and peel it all off.
NOTE: If the masking film tears, repeat from step 1. Use the
Masking film knife, however, to lift the opposite corner of the label, rather
than trying to continue peeling from the place where it tore.
AB200080AD
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BODY REPAIR
ATTACHMENT OF SILENCERS
M4090009000052
Dash panel interior side
: Thickness: 1.6 mm (0.063 in)

: Thickness: 3.2 mm (0.126 in) (two 1.6 mm (0.063 in) silencers overlapped) AB200097AD
Silencers (petroleum-asphalt sheets) are attached to welded panel, cut and attach replacement material
the upper surface of the floor and at the interior side (in the shape shown in the figure). For detailed infor-
of the dash panel in order to absorb vibrations and mation concerning the locations where silencers are
shut out exhaust gas heat. If these silencers are to be attached for individual models, refer to the
peeled off in the course of replacement or repair of a manual for that model.
1. Heat the "silencer layer" (petroleum-asphalt sheet) with a

blow drier to soften it.
AB200098
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BODY REPAIR
2. Align the silencer layer in the position where it is to be

installed, and then press it down with a roller or a block of
wood so that it adheres well.
NOTE: An infrared light can also be used to heat both the
silencer layer and the body panels (be sure to wear gloves).
AB200099
POSITIONING DIMENSIONS FOR OPENINGS

M4090010000045
Porta power
AB200100 AD
When replacing the panel of the opening of the front

pillar, center pillar and other openings, make a point
to securely bite the poltapower, etc. so the position of
the opening is not off-center. Upon assembling,
adjust the opening dimensions to the standard speci-
fications and then weld.
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BODY REPAIR
STANDARD PROCEDURES FOR SHEET METAL WORK

M4090012000030
REPAIRS USING A HAMMER AND DOLLY

It a damaged external panel, etc., can be reused, the
usual way to repair it is by using a hammer and dolly
to hammer out the damaged area. The following
describes these repair procedures.
.
1. Check whether or not there is foreign material (mud, etc.) on

the panel surface. If so, clean it away.
CAUTION
The surface of the hammer and dolly must be free of scars,
etc.
2. Select the appropriate hammer and dolly to be used
according to the panel shape.
CAUTION
Care should be taken, as far as possible, not to permit the
(1) panel plates to become elongated.
3. Use the hammer and dolly to repair the dents and other
uneven surfaces of the panel.
(1) First repair the larger areas of damage so that they are as
close as possible to the original condition before the
damage occurred.
(2) Next repair the areas of moderate damage.
(3) Finally, smooth the surface out.
(2)
(3)
AB200101
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BODY REPAIR
CAUTION
• Be careful not to file too much; this will reduce the
strength and rigidity of the panel.
• Do not use the file in one direction only; alternate use
in two directions diagonally opposite each other.
4. Next, file the area so that convex and concave parts are no
longer clearly visible, and at the same time remove small
projections.
5. After once again smoothing the clearly visible dents and
projections by using the hammer and dolly, follow step 4
AB200102 above.
Alternately repeat hammering and filing until there are file
traces over the entire repair area.
6. Make a solder build-up at the repair.
7. Finally, finish up the solder build-up using a body file.
USING A FRAME STRAIGHTENER
M4090013000044
For serious and extensive damage, when for exam- 3. Finally, determine what repair methods should be
ple the damage extends to the frame of members, it used.
is necessary to first use a frame straightener to make • To what extent will frame straightening and other
a rough, overall repair of the body, and then to pro- overall repairs be necessary in order to restore
ceed to careful repairs of each individual area of the damaged areas to the way they were?
damage. When a frame straightener is used for body • At what stage of the repairs should panels adjoin-
repairs, it is a fundamental principle that the pulling ing the components to be frame straightened,
should be in the direction from which the impact was etc., be removed?
sustained, and from the opposite direction. If this is, • Decide upon the work steps and restoration
in error, not done, previously undamaged compo- methods to be followed after the rough, overall
nents will be deformed, and repair may become repairs are completed.
impossible. Select the frame straightener based upon the results
It is for that reason that it is important to decide upon of above, and use it to pull in the appropriate direc-
the method of repair, especially regarding the initial tion. More than one direction may be appropriate,
overall repair, by following the steps below. depending upon the damage.
If the damage is of a moderate degree or less, it may
OVERALL ROUGH REPAIRS be possible to do all that is necessary in one pull.
1. First, analyze the impact. This means analysis If, however, the damage is major, that is to say if
and consideration of the point of collision, the repairs must be made to components of the passen-
speed at the time of collision, and the strength, ger compartment such as the dash panel, etc., it may
weight and shape of the object hit. be necessary, after completing the first pull, to set up
2. Then get a complete understanding of the the frame straightener at a different position and use
condition of the existing damage. In particular, if it again at that position.
the damage extends to the suspension installation
components, an inspection must be made to
determine whether or not there is any deviation of
the frame or body alignment.
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BODY REPAIR
FRAME STRAIGHTENING NOTES

• For safety, no one must be standing in the direction of the
Wires for pull.
protection • Wires or chains should be used for protection in the event
of an accident.
• For frame straightening of body with frame, care should be
taken regarding the position (body mount) of installation to
the frame. The reason for this is that usually mounting rub-
ber pieces are used at the installation part in order to
improve vibration prevention, and these mounting rubber
AB200103AD
pieces might be deformed if there is a deviation of the
installation position.
• If the part to be pulled is made of high-tensile steel (which
has a higher tensional strength and yield point than ordinary
steel), the pulling must be done with care in order to avoid
"over pull" and "spring back". It is particularly important for
the pulling of sidemembers and other reinforcement compo-
nents made of high-tensile steel that the pulling not be all
done at one time; pull gradually while using a hammer to
repair distorted areas as the pulling is done.
FRAME REPAIR PROCEDURES
M4090014000047
The frame is subjected to the following types of These various types of loads are compounded under
loads. various conditions, and are applied to the frame.
• Vertical loads: Vertical loads may occur either As a result, it is important, before attempting to repair
while stopped or during travel. the frame, to carefully observe the shape of the dam-
• Lateral (horizontal) loads: This type of loads aged part and to in that way fully understand the
occurs during turning, start-off and braking. cause of the damage.
• Torsional loads: Torsional loads occur while trav-
eling on roads with poor surface conditions.
CHECKING FOR FRAME CRACKING OR

FLAKING
Check, by using a test hammer, for flaking or cracking of the
Test hammer
welded surface of the sidemembers, crossmembers and brack-
ets.
Sidemember
AB200127 AD
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BODY REPAIR
REPAIRING CRACKS
If the check reveals a crack(s) in the frame, repair as described
bellow.
Crack-stop hole 1. Remove the components near the crack.
A 2. Make φ 6 − 8 mm (0.24 − 0.31 inch) holes (to prevent further
cracking), by using a drill, at points 7 − 8 mm (0.28 − 0.31
A inch) from the crack ends.
Crack
Ø6 – 8 mm
(0.24 – 0.31 in)
A : 7 – 8 mm (0.28 – 0.31 in) AB301469 AD
Ø10 – 12 mm
3. Use a φ 10 − 12 mm (0.39 − 0.47 inch) drill to bevel the hole
(0.39 – 0.47 in) openings.
Ø6 – 8 mm
(0.24 – 0.31 in)
Ø10 – 12 mm
(0.39 – 0.47 in) AB301470 AB
AC
4. Use a chisel or gouging tool to open up the crack and holes,

Crack Crack-stop and then fill the crack and holes by MIG welding.
hole
Approx.
Approx. 8 mm
A (0.31 in)
Approx. 90˚ Approx.
1 mm 1 mm
(0.04 in) (0.04 in)
If a chisel If a gouge
is used is used
A A AB301471AD
CAUTION
• Gas welding should be avoided because it causes ther-
mal distortion of the frame.
• When using a grinder for finishing, be careful not to
grind the frame excessively.
5. Using a grinder for finishing after welding.
AB200131AB
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BODY REPAIR
CAUTION
• The reinforcement plate should completely cover the
cracked part.
• The reinforcement plate should be the same thickness
A and material as the frame.
6. To avoid a concentration of stress, prepare a reinforcement
plate that has been cut to 30 − 45 degree angle at both
A ends.
A : 30 – 45˚
AB301461AB
CAUTION
Be sure that the edges of the reinforcement plate are not
10 mm (0.39 in) near any place where a concentration of stress of the
crossmember or spring hanger installation part, etc. could
easily occur.
7. Attach the reinforcement plate to the repaired crack area by
MIG welding. In order to avoid a concentration of stress at
the time, weld the reinforcement plate at points about 10 mm
(0.39 inch) from its edges.
Welded point
AB200133 AD
(1)
(2)
AB200134 AB
NOTE: If the crack is at the upper side of the frame, attach

the reinforcement plate facing downward, as shown in (1).
If the crack is at the lower side, attach the reinforcement
plate to face upward, as shown in (2).
8. Finally, apply a coating of chassis black to the repaired area
and to any places where the coating has flaked off.
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BODY REPAIR
NOTES REGARDING REPAIR WORK

M4090015000039
SAFETY MEASURES
.
PROTECTIVE GEAR
1
2 3 During body repair work, a work suit, a work cap, and safety
shoes should be worn at all times. Depending on the work
being done, safety glasses, gloves, ear protectors, a dustproof
4 mask, etc., should also be worn as needed.
5 6 1. Safety glasses
2. Work cap
3. Ear protectors
7 8 4. Head protector
5. Work suit
6. Dustproof mask
7. Work apron
8. Welding gloves
9 10 11
9. Foot and ankle protectors
10. Safety shoes
11. Work gloves
AB200104
SUPPLEMENTAL RESTRAINT SYSTEM (6) Never attempt to disassemble or repair the

SRS components (SRS-ECU, air bag module
(SRS) and clock spring). If there is a defect, replace
1. Items to review when servicing SRS the defective part.
(1) Be sure to read Service Manual GROUP 52B, (7) Whenever you finish servicing the SRS, check
Supplemental Restraint System (SRS). For the SRS warning light operation to make sure
safe operation, please follow the directions that the system functions properly.
and heed all warnings. (8) Be sure to deploy the air bag before disposing
(2) Wait at least 60 seconds after disconnecting of the air bag module or disposing of a vehicle
the battery cable before doing any further equipped with an air bag.
work. The SRS system is designed to retain 2. Observe the following when carrying out
enough voltage to deploy the air bag even operations on places where SRS components are
after the battery has been disconnected. installed, including operations not directly related
Serious injury may result from unintended air to the SRS air bag.
bag deployment if work is done on the SRS
(1) When removing or installing parts, do not allow
system immediately after the battery cable is
any impact or shock to occur to the SRS
disconnected.
components.
(3) Warning labels must be heeded when
(2) If heat damage may occur during paint work,
servicing or handling SRS components.
remove the SRS-ECU, the air bag module,
(4) Always use the designated special tools and clock spring, the front impact sensor, the side
test equipment. impact sensor, and the seat belt pre-tensioner.
(5) Store components removed from the SRS in a • SRS-ECU, air bag module, clock spring, front
clean and dry place. The air bag module impact sensor, the side impact sensor: 93 °C
should be stored on a flat surface and placed (200 °F) or more
so that the pad surface is facing upward. • Seat belt pre-tensioner: 90 °C (194 °F) or more
.
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BODY REPAIR
SECURING THE VEHICLE

If the vehicle is raised on a jack, be sure to always support it
with jack stands positioned at the specified points.
.
CLEARING THE AREA OF FLAMMABLE

MATERIALS
Because of the presence of many various kinds of flammable
materials, organic solvents, etc., in the work area, there is
always the possibility of a fire or explosion. It is, therefore,
important to keep the work area as clear as possible of such
dangerous materials.
.
HANDLING ELECTRONIC PARTS AND

SEMICONDUCTORS
WARNING
Battery posts, terminals and related accessories con-
tain lead and lead compounds. WASH HANDS AFTER
HANDLING.
When the body is used as the ground during welding for body
repairs, be absolutely sure to first disconnect the battery's posi-
tive (+) cable.
CAUTION
• Be sure that both the ignition and lighting switches are
"LOCK" (OFF) position before either disconnecting or
reconnecting a battery cable. (If this is not done, equip-
ment containing semiconductors could be damaged).
• Note that the memory of electronic equipment having a
AB200105 memory function will be cleared when the battery cable
is disconnected.
NOTE: Vehicles today include a great many electronic parts
and components, and these are in general very susceptible to
adverse effects caused by overcurrent, reverse current, elec-
tromagnetic waves, high temperature, high humidity, impacts,
etc. In particular, such electronic components can be damaged
if there is a large current flow during welding from the body
side, etc.
This is because, for electronic components that incorporate a
back-up circuit (for memory retention) that functions (by a
trickle current) even when the ignition switch is at OFF, an elec-
tronic circuit is formed even when the switch is at OFF.
.
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BODY REPAIR
HANDLING COMBUSTIBLE MATERIALS

If welding work is to be done in the area of the fuel tank, the fuel
tank must be removed to prevent the generation of flammable
gases. Also be sure to cap the inlet port and the pipes of the
fuel tank after removal to prevent the escape of any fuel or
flammable gases.
Wipe up any fuel, oil, etc., spilled in the work area as soon as
possible.
Only the amounts of paint to be used for the day's work should
be in the work area; do not keep excessive amounts of paint, or
paint which is not going to be used, in the work area.
HEALTH AND SANITATION PROCEDURES

The following points should be noted for employee health and
sanitation.
• The work area should be well ventilated in order to prevent
the inhalation of dust, organic solvent vapors, etc.
• All unused paint cans must be securely covered.
• Care should be taken to avoid exposure to the skin of adhe-
sives, organic solvents, etc.
If an unavoidable exposure occurs, the exposed area
should be immediately washed with clean water.
VEHICLE PROTECTION
• Vehicle covers (fender covers, seat covers, etc.) and tape (if
there is the possibility of damage by tools, equipment, etc.)
should be used to protect painted surfaces, interior/exterior
parts and components, etc., from staining and damage.
AB200106
• For welding operations, a heat-resistant protective cover

should be used to protect glass, seats, instrument panel,
carpeting, etc.
AB200107
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BODY REPAIR
HEAT-WITHSTAND TEMPERATURES OF RESIN-PLASTIC PARTS

M4090016000054
Because resin-plastic parts are deformed by heat,
they should be removed if the heat to be applied is
high enough to cause deformation, as shown by the
table below.
Material name Abbreviation Heat-deformation Where mainly used
temperature °C (°F)
Acrylonitrile ASA 80 (176) Door mirror, Pillar garnish, License
styrene acrylate garnish, Radiator grille
Acrylonitrile ABS 80 (176) Air spoiler, Console box, Radiator grille,
butadiene styrene Rear garnish, Headlight bezel
Cellulose acetate CA 50 − 90 (122 − 194) -
Cellulose acetate CAB 60 − 100 (140 − 212) Door trim molding
butylate
Polyamide PA 140 − 160 (284 − 320) Harness connector, Wheel cover,
Cooling fan, Fuel strainer
Talc filled PA-TD 190 − 200 (374 − 392) Hood garnish, Door outside handle
polyamide
Polybutylene PBT 120 (248) Dome light lens, Headlight lens
terephthalate
Polyethylene PE 100 (212) Heater duct, Fender liner, Washer tank
High density PE-HD (HDPE) 70 − 90 (158 − 194) Fuel tank, Splash shield
polyethylene
Phenole PF 170 − 190 (338 − 374) Ashtray
formaldehyde
Polymethyl PMMA 80 − 100 (176 − 212) Light lens
methacrylate
Polyacetal POM 120 (248) Door regulator handle, Ball joint seat
Polypropylene PP 80 (176) Glove compartment, Bumper face,
Pillar trim, Steering wheel, Heater unit,
Cooling fan
Polyphenylene PPE (PPO) 130 − 140 (266 − 284) Accelerator pedal pad, Wheel cover,
ether Speaker garnish
Talc filled PP-TD (PPF) 100 (212) Front deck garnish, Stone guard, Floor
polypropylene console, Instrument panel
Talc filled PP-TD10 (PPF) 110 − 120 (230 − 248) Center pillar trim
polypropylene
(10%)
Talc filled PP-TD15 (PPF) 110 − 120 (230 − 248) Front pillar trim, Center pillar trim, Rear
polypropylene pillar trim
(15%)
Talc filled PP-TD20 (PPF) 120 − 130 (248 − 266) Beltline trim, Front deck garnish, Front
polypropylene pillar trim
(20%)
Talc filled PP-TD30 (PPF) 130 − 140 (266 − 284) Quarter trim, Rear side trim
polypropylene
(30%)
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BODY REPAIR
Material name Abbreviation Heat-deformation Where mainly used

temperature °C (°F)
Polyurethane PUR 80 − 100 (176 − 212) Bumper, Steering wheel
Polyurethane PUR-E 80 − 100 (176 − 212) Seat cushion, Arm rest, Door trim,
(formed) Instrument panel
Glass fiber PUR-GF [RIM] 100 − 120 (212 − 248) Air dam panel
reinforced RIM
urethane
Polyvinyl alcohol PVAL *1 -
Polyvinyl butyral PVB -
Polyvinyl chloride PVC 80 (176) Steering wheel, Side protector molding,
Shift lever cover, Window molding
Thermoplastic TPO (TEO) 80 (176) Mud guard, Side air dam
elastomer (olefine)
Urea formaldehyde UF 120 − 145 (248 − 293) -
Glass fiber UP-(GT + TD) 200 (392) Rear air spoiler
reinforced [SMC], [BMC]
unsaturated
polyester
Ethylene vinyl E/VAC (EVA) 60 (140) Mud guard
acetate
Talc filled PP + E/P-TD 80 − 100 (176 − 212) Bumper face, Side air dam, Side
polypropylene [HMPP] protector molding
Polyvinyl chloride, PVC, PUR-E *2 Instrument panel pad
Polyurethane
Thermoplastic TES, PP-TD 100 − 120 (212 − 248) Side splash
elastomer
(styrene), Talc filled
polypropylene
Polycarbonate + PC + ABS 120 − 125 (248 − 257) Door outside handle
Acrylonitrile
butadiene
Polycarbonate + PC + PET 120 (248) Door outside handle
Polyethylene
terephthalate
Polycarbonate + PC + PBT 130 − 140 (266 − 284) Door outside handle
Polybutylene
terephthalate
Polyphenylene PPE (PPO) + PA6 150 − 160 (302 − 320) Wheel cover
ether + Polyamide
6
Polyphenylene PPE (PPO) + 160 − 170 (320 − 338) Wheel cover
ether + Polyamide PA66
66
Polyphenylene PPE (PPO) + PS 120 − 130 (248 − 266) Wheel cover
ether + Polystyrene
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BODY REPAIR
NOTE: .
• A slash (/) in the abbreviation indicates that two different materials make two-layer construction.
A plus sign (+) indicates that the two different materials mix each other.
• If the new material symbols designated by the ISO differ form the old symbols, both are given, with the old
symbol being enclosed in brackets. ISO: International Organization for Standardization
• *1: Temperature differs depending on the ratio of the materials included.
• *2: Impossible to fix the temperature due to the multi-layer and foam material structure.
• If an infra-red lamp is used for drying, use a heat-resistant cover, etc., to protect parts.
HOW TO DISTINGUISH TYPES OF PLASTICS

M4090017000035
There are various methods that can be employed to
determine types of plastics, among them (1) using a
chemical solvent, etc., to check it chemically, (2)
scratching the material to determine its make-up, (3)
cutting of a small piece (where the scar can't be
seen) and burning it to judge by the way it burns, etc.
The following is an outline of the burning method,
which is a relatively simple method.
Plastic name Abbrevi Flame color Combustion Self-exting Odor

ation Conditions uishing
Polyvinyl chloride PVC Yellow flame top Burns to black residue Yes Irritating acid
Blue flame bottom odor
Polyethylene PE Yellow flame top Burns cleanly while No Candle-like odor
Blue flame bottom melting
Polypropylene PP Yellow flame top • Burns briskly and No Petroleum-like
Blue flame bottom drips odor
• Slight white smoke
Polyurethane PUR Orange Crackles as burns; drips No Rubber odor
TRUR Orange
Polycarbonate PC Yellow Cinders remain To some Sweet odor
extent
Polyamide PA Yellow flame top Melts and drips Yes Strong formic
(nylon) Blue flame bottom acid odor
Polyester resin UP Yellow Ashes remain No Styrene odor
Glass-fiber-reinfo FRP Yellow Ashes with glass-fiber No Differs according
rced plastic remnants remain to plastic type
Phenol resin PF Yellow Ashes remain Yes Formalin odor
ABS resin ABS Orange Burns accompanied by No Rubber odor
foaming and black
smoke
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CORROSION PROTECTION
ANTICORROSION TREATMENT AT THE FACTORY
M4090019000064
Anticorrosion treatment at the time of production
includes the following measures.
THE USE OF GALVANIZED STEEL PLATE
: locations where galvanized steel

plate is used.
AB200136 AB
Because galvanized steel plate has excellent corro-

sion resistance, it is used in areas which have a high
possibility of painting deficiency.
ZINC PHOSPHATE COATING

In order to improve the adhesive properties of the paint coat on
the steel plate, and also to improve the finish of the paint coat,
1
the entire body is coated with a film of zinc phosphate prior to
2
undergoing the electrodeposition undercoating process.
3
1. Final coat
4
5 2. Intermediate coat
6 3. Anticorrosion primer
4. Undercoat
5. Zinc phosphate film
AB200109 6. Steel plate
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CATIONIC ELECTRODEPOSITION UNDERCOATING
Anionic Cationic
coating coating
Alkali
Counteragent Counteragent solution
Anionic electrodeposition Cationic electrodeposition AB200110AD

AB200110
In the cationic electrodeposition method, the car

body is the negative pole, thus preventing damage to
the zinc plating of the galvanized body panels or to
the chemically formed phosphate crystals. This
method, therefore, maximizes the corrosion resis-
tance and the results obtained are much better than
those from conventional anionic electrodeposition.
BODY SEALING
Sealant has been applied to all body panel joints and seams in
A order to provide resistance to water, dust, and corrosion.
A
SECTION A – A
AB301462 AB
UNDERBODY COATING
An underbody coating has been applied to the underside of the
floor pans, the inside of the doors, etc., in order to provide
resistance to vibration, corrosion, and wear.
AB200112
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WAX INJECTION
Wax injection is used at the lower part of the frame, side sill and
hollow panels, etc., in order to obtain a better anticorrosion
effect.
AB200113
ANTICORROSION PRIMER
1 1
A
A
1. Rocker panel primer application AB701034AB
Anticorrosion primer is used at the side sill outer pan-

els in order to prevent corrosion and to suppress
vibration.
SEALING TAPE
Sealing tape is attached at unused holes, at the inner side of
the panel, for waterproofing and anticorrosion protection.
: Locations for
attachment of sealing tape AB301463
AB301463AF
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ANTICORROSION TREATMENT AT THE TIME OF

BODY REPAIR WORK
M4090020000046
The following procedures should be followed for anticorrosion
protection when making repairs.
AB200116
CORROSION PROTECTION FOR HOLLOW

PARTS
CAUTION
• Wipe away any excess anticorrosion agent on the
coated surface, because it can adversely affect the
coating.
• When spraying the anticorrosion agent, use holes in
different areas to ensure that all weld surfaces of the
hollow structure are well coated.
The insides of hollow parts (such as the side sill, pillars, etc.)
which have been welded are more susceptible to corrosion.
Spray an aerosol-type anticorrosion agent into these parts by
AB200117 using the trim mounting holes and other openings.
ANTICORROSION TREATMENT OF ROUGH CUTS

An anticorrosion agent should be applied to rough cuts made in
the course of welding, because the surface film has been dam-
aged by the heat of welding.
SPOT SEALER
In order to prevent corrosion from occurring at the contact sur-
faces of panels which are spot welded, apply an electroconduc-
tive spot sealer.
.
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SPOT SEALER APPLICATION STEPS

1. Remove all paint, etc., from the areas to be spot welded by
using sandpaper or a pneumatic belt sander.
AB200118
2. Use a brush to apply spot sealer to the contact surfaces of

the panels (both the new panel and the panel remaining on
the body) to be spot welded.
AB200119
3. Do not spot welding.

NOTE: The spot welding can be done as the spot sealer is
dry to the touch.
Dry to the touch: 30 minutes or less at 20°C (68°F)
AB200120
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BODY SEALING
Even if a car body is restored to the exact specified dimen-
sions, the body repair work cannot be considered to be com-
plete if an ample amount of sealant is not applied to each of the
panel joints and seams. Insufficient sealant will result in water
leakage, corrosion, etc.
NOTE: Use a piece of clean cloth dampened in lead-free gaso-
line or a similar material to clean parts and areas where sealant
is applied.
• When applying sealant to areas at which the external
Clean away appearance is important (areas which can be seen or where
any excess the condition of the paint coat is important), be sure to apply
the sealant so that it is perfectly level with the surrounding
panels.
AB301490AD
AB301490
• Apply the sealant at the fuel port so that it is perfectly level

with the surrounding panel so that drops of fuel will not col-
lect.
AB200122
• After applying sealant to the door-stop, etc., clean away any

excess so as to be sure that there is no interference with
installed parts, etc.
AB200123
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UNDERCOATING
: Undercoating application locations

AB301464 AD
• Be sure to mask any parts installation holes, and If the undercoating application inside the wheel
the area around the place where undercoating is housing, on the under body, etc., is insufficient, it can
to be applied, before applying it. result in corrosion. Be sure, therefore, to apply a
• Be sure not to apply the undercoating to tires or good coating of undercoating to such parts after
to the drive shaft and other drive components. repairs are completed.
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REPAIR OF SYNTHETIC-RESIN PARTS

SYNTHETIC-RESIN PARTS REPAIR PROCEDURES
M4090000300090
Bumper is taken as a repair work example for expla-
nation.
FLOWCHART
Hole (diameter 50 mm Crack, tear (length Scratch (length 200 mm x

(1.97 in) or smaller) width 120 mm (7.8 x 4.7 in)
200 mm (7.8 in) or smaller)
or smaller)
1. Cleaning
2. Reshaping of damaged area
3. Fixing of glass cloth (backing)
4. Adhesive application
5. Base surface preparation (surface grinding)
6. Rough grinding
7. Filling (putty application)
8. Surface grinding
9. Surface preparation for primer-surfacer
10. Cleaning and degreasing
11. Masking
12. Primer-surfacer coating
13. Primer-surfacer grinding
14. Coating
AB401319 AB
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REPAIR JUDGMENT
.
REPAIRABLE AREA
• In case of a hole, the damaged area is reshaped to be a cir-
cle or ellipse for easier filling of the repair agent. The diame-
ter or major diameter should be 50 mm (1.97 inches) or
smaller.
• In case of a crack or tear, if the both ends of the crack or
tear are not separated from the body, the length of the area
should be 200 mm (7.8 inches) or smaller. If one of the ends
reaches the bumper edge, the length of the damaged area
should be 200 mm (7.8 inches) or smaller, and also the
width should be a half or less of the bumper width.
• In case of a scratch, the area should be 200 x 120 mm (7.8
x 4.7 inches) or smaller.
.
UNREPAIRABLE COMPONENTS
Black-base area is raw urethane base and repairable, however,
its color does not match in color of the repair agent (ash gray).
In this case, the replacement of the bumper is preferable.
.
BUMPER REMOVAL AND CLEANING

• The damage of holes, cracks, and tears requires a repair
work from the rear surface. Remove the bumper to clean
the whole surface, degrease the front and rear surfaces of
the repair area using SU Silicone Off, and then repair, hold-
ing the bumper to avoid twisting.
• In case of a scratch, a softener is applied to the bumper as
repair paint. The repair area cannot be polished after paint-
ing, and surface/gloss matching is difficult. Therefore, do
not apply gradated topcoat painting, and paint the whole
surface as a rule.
REPAIR PROCEDURE
.
1. CLEANING
Using SU Silicone Off, degrease the repair area, and then
remove the wax and oil completely.
.
AB401311AB
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2. RESHAPING OF DAMAGED AREA

CAUTION
The grind surface area should be larger than the resin
putty application area.
Remove burrs on the rear surface reinforcement point, and
grind with a sandpaper #60 to #80, as a surface preparation for
painting. When using a sander #80, grind at a low speed 6000
r/min. For PP, apply PP primer after grinding.
PRIMER : PP PRIMER
BRAND : 3M™ Automix Polyolefin Adhesion Promoter
5907 or equivalent
AB401317AB .
3. FIXING OF GLASS CLOTH (BACKING)

CAUTION
• After applying the instant adhesive, fix the repair area.
• For PP, apply PP primer.
Apply the adhesive to the glass cloth fixing area of the repair
part in order to adhere the glass cloth.
• TAPE: Glass cloth tape
BRAND: 3M™ Glass Cloth Tape 6400 or equivalent
• ADHESIVE: Urethane adhesive
BRAND: 3M™ Duramix Plastic Repair Semi-rigid
4040 or equivalent
AB401293AB
AB
.
4. ADHESIVE APPLICATION
Apply a resin adhesive to cover the fixing glass cloth and its
surrounding area. Then smooth it, using a spatula, and dry.
AB401312AB
5. BASE SURFACE PREPARATION (SURFACE

GRINDING)
Remove burrs on the surface, and grind with a sandpaper #120
Background to make the repair area surface lower than the surrounding
area. When using a sander #120, grind at a low speed 6000
r/min.
.
Old paint layer

AB401316AE
AB401316
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6. ROUGH GRINDING
Grind the base surface area with a sandpaper #80 as a surface
preparation for painting.
AB401315AB
7. FILLING (PUTTY APPLICATION)

CAUTION
When mixing the two kinds of liquid, be sure that the air is
not mixed in.
1. Using SU Silicone Off, degrease the repair area, and then
remove the wax and oil completely.
2. For scrape, apply putty to the repair area.
• PUTTY: Epoxy resin putty
BRAND: 3M™ Automix EZ Sand Flexble Parts 5887
or equivalent
• PUTTY: Epoxy resin putty
AB401291AB BRAND: 3M™ Resin Putty No.1, 8120 or equivalent
NOTE: .
• The amount to be applied at a time is approximately 1.5 mm
(0.059 inches). Therefore, recoat it as needed.
• For tear and scratch, apply putty after sanding the surface.
AB401296AB
8. SURFACE GRINDING
After drying, grind with a sandpaper #120.
.
AB401297AB
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9. SURFACE PREPARATION FOR

PRIMER-SURFACER
Grind with a sandpaper #180 to #240. Grind the primer-sur-
facer application area as a surface preparation for painting. In
addition, remove the grind mark.
AB401297AB
10. CLEANING AND DEGREASING

Using SU Silicone Off, degrease and wipe off completely.
.
11. MASKING
To avoid splashing of primer-surfacer during the coating, apply
masking.
MASKING: Masking paper tape
BRAND: 3M™ Scotch Block Masking Paper or equiva-
lent
.
AB401318AB
12. PRIMER-SURFACER COATING
CAUTION
• If an excessive amount is applied at a time, or
force-dried in a short time, the coating film may crack.
• For color separation, use masking tape.
While taking flash off time, apply 1 to 3 times of double coating,
using a spray gun.
AB401298AB
13. PRIMER-SURFACER GRINDING

1. Grind the base surface with a sandpaper #240 to #320.
AB401299AB
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2. Apply the putty to cover pinholes, grind marks, and slight

distortion. Do not apply an excessive amount at a time.
Repeat application of small amount, taking a drying time.
AB401300AB
3. Grind with a sandpaper #240 to #320. If the PP base surface

is exposed, apply PP primer.
PRIMER : PP PRIMER
BRAND : 3M™ Automix Polyolefin Adhesion Promoter
5907 or equivalent
AB401299AB
CAUTION
If an excessive amount is applied at a time, or force-dried
in a short time, the coating film may crack.
4. While taking flash off time, apply 1 to 3 times of double
coating, using a spray gun.
AB401302AB
5. Dry sand with a sandpaper #240 to #300 or finer. Then, as a

surface preparation for painting, grind lightly so as not to
expose the base surface. Finally, use a sandpaper #600
(#800 for dark color coating) or finer to remove grind marks.
AB401303AB
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Mitsubishi Mirage 2014 Body Repair Manual

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2014 GROUP INDEX

MITSUBISHI BODY CONSTRUCTION . . . . . . . . . 1

SERVICE MANUAL MSCD-016B-2015

Mitsubishi Motors Corporation reserves the right to make changes in

2014 Mitsubishi Motors Corporation

Page number Group title

1-8 BODY CONSTRUCTION

1. Harness 2-way bracket 9. Ground bracket

Page number Group title

1-8 BODY CONSTRUCTION

1. Harness 2-way bracket 9. Ground bracket

BODY COMPONENTS. . . . . . . . . . . . 1-2 SIDE BODY . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

BODY MAIN CROSS-SECTIONAL VIEWS

B Roof panel E Center pillar seat belt

C Front pillar F Side sill Side outer panel

G Front pillar reinforcement upper J

Front inner pillar

H Center pillar Rear door hinge K

Gate pillar inner L

Panel positioning notch AB201388AB

SIDE OUTER PANEL

Center outer pillar

Front outer pillar

Quarter panel outer

Front floor side sill outer

BODY CONSTRUCTION CHARACTERISTICS

HEADLIGHT SUPPORT • The bolt-on headlight support panel is used to

1. Front panel crossmember lower

A crash box has been established in order to effi-

1. Engine mounting gusset FRONT SIDEMEMBER REINFORCEMENT

1. Front sidemember plate 8. Front sidemember reinforcement rear lower

NOTE: *: Indicates 590MPa-high-tensile steel panels.

1. Front sidemember rear A 8. Brake hose bracket

1. Cowl top inner panel 5. Wiper center bracket

1. Dash panel crossmember 6. Brake reinforcement

1. Front inner pillar lower 28. Rear light housing

SIDE STRUCTURE REINFORCEMENT

Front pillar Gate pillar brace

Center pillar reinforcement

Front pillar Side sill reinforcement

REAR END PANEL

1. Rear end inner panel 5. Rear end outer panel

1. Roof front rail inner 5. Roof rear rail inner

1. Backbone panel 10. Front seat side bracket rear

1. Fuel tank protector 11. Spare tire bracket

REAR FLOOR SIDEMEMBER

NOTE: *: Indicates 590MPa-high-tensile steel panels. 7* 6* ABC00315AB

1. Rear floor sidemember 6. Side sill inner rear reinforcement

1. Front door panel outer 13. Rear door panel outer

(Left side) (Right side)

URETHANE FOAM USAGE LOCATIONS

Front door inner

Center pillar pad

BODY DIMENSIONS AND TYPE B (ACTUAL-MEASUREMENT

BODY DIMENSIONS AND MEASUREMENT METHODS

Projected dimension • Type A (projected dimensions) is the dimension when a

• Type B (actual-measurement dimensions) is the actual dis-

• Insert the tracking gauge probes securely into the measure-

• When using a notch for dimension measurement, set the

Bolt • When measuring the suspension mounting arm, or link

NOTE: : Indicates 590MPa-high-tensile steel panels. 7 6* ABC00315AB