BRZ Body L4440BEV0

VehicleExterior INTRODUCTION IN
BODY WELD POINT WP

BODY DIMENSIONS BD
PAINTING / COATING PC
Vehicle Exterior
INTRODUCTION
HOW TO USE THIS MANUAL IN

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-1
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-2
ILLUSTRATION OF WELD POINT SYMBOLS . . . . . . . . . . . . . . . . . . . . IN-4
WORK NOTICES AND PRECAUTIONS
WHEN REPAIRING THE VEHICLE BODY . . . . . . . . . . . . . . . . . . . . . . . IN-5
PRECAUTIONS FOR REPAIRING BODY STRUCTURE (INCLUDING
CRUSH BOXES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-6
PRECAUTIONS FOR WELDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-7
ANTI-RUST TREATMENT AFTER INSTALLATION OF BODY STRUC-
TURE PARTS OR OUTER PANELS . . . . . . . . . . . . . . . . . . . . . . . . . IN-9
PRECAUTIONS FOR SRS AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . IN-10
NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP VEHI-
CLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-15
WHEN REMOVING,INSTALLING,REPAIRING OR REPLACING
PARTS
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-19
PROCEDURES NECESSARY WHEN ECU OR OTHER PARTS ARE
REPLACED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-38
WHEEL ALIGNMENT STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-39
ABOUT THIS VEHICLE
STRUCTURAL OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-44
DAMAGE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-50
EXTERIOR RESIN PARTS AND RESIN CHARACTERISTICS . . . . . . . IN-54
IN
INTRODUCTION － HOW TO USE THIS MANUAL IN-1
HOW TO USE THIS MANUAL

Vehicle Exterior
INTRODUCTION
GENERAL INFORMATION
1. Scope of the repair work explanation
(a) This text explains the welding panel replacement instructions from the vehicle's white body
condition. We have abbreviated the explanations of the removal and reinstallation of the IN
equipment parts up to the white body condition and of the installation, inspection, adjustment
and final inspection of equipment parts after replacing the weld panel.
(b) When repairing, do not cut and join areas that are not shown in this manual. Only work on the
specified contents to maintain body strength.
(c) Make sure to perform the following essential procedures, although they are omitted in this
manual.
(1) Clean and wash removed parts, if necessary.
(2) Visual inspection.
(d) This manual has references to the Repair Manual.
(1) vehicle interior section
(2) vehicle exterior section
2. Section categories
(a) This manual has been divided as shown below.
Section Title Contents Examples
SYMBOLS
INTRODUCTION Explanation of general body repair.
PRECAUTIONS FOR WELDING
Instructions for replacing the weld panels from
the white body condition, from which bolted CUT AND JOIN REPLACEMENT SECTION
BODY WELD POINT
parts have been removed, with individual ASSEMBLY REPLACEMENT
supply parts.
THREE-DIMENSIONAL DISTANCE
BODY DIMENSIONS Body aligning measurements.
TWO-DIMENSIONAL DISTANCE
Scope and type of anti-rust treatment, etc. APPLICATION AREAS
PAINTING / COATING
together with weld panel replacement. INSTALLATION AREAS
3. REPAIR PROCEDURES
(a) Illustrations of similar vehicle models are sometimes used. In these cases, minor details may be
different from the actual vehicle.
(b) About a symmetrical part, only one side is described.
4. TERM DEFINITIONS
CAUTION Possibility of injury to you or other people.
NOTICE Possibility of damage to components being repaired.
HINT Provides additional information to help you perform repairs.
5. INTERNATIONAL SYSTEM OF UNITS

(a) The units used in this manual comply with the International System of Units (SI UNIT) standard.
Other units from the metric system and the English systems are also provided.
Example:
Torque: 30 N*m (310 kgf*cm,22 ft.*lbf)
IN-2 INTRODUCTION － HOW TO USE THIS MANUAL
SYMBOLS
REPAIR AREA INDICATOR REPAIR METHOD INDICATOR
ILLUSTRATION
SYMBOLS SYMBOLS
CUT AND JOIN

LOCATION (Saw Cut)
IN
CUT AND JOIN
LOCATION (Cut Location
for Supply Parts)
CUT
CUT LOCATION
CUT WITH DISC

SANDER, ETC.
BRAZING OR ARC
BRAZE BRAZING FOR
REMOVAL
BRAZE BRAZE
SPOT WELD OR PLUG

WELD WELD (See the
-
POINTS ILLUSTRATION OF
WELD POINT SYMBOLS)
BUTT WELD
WELDING
FILLET WELD
INTRODUCTION － HOW TO USE THIS MANUAL IN-3
REPAIR AREA INDICATOR REPAIR METHOD INDICATOR

ILLUSTRATION
SYMBOLS SYMBOLS
BODY
BODY SEALER
SEALER
IN
ASSEMBLY STANDARD HOLE FOR

- -
MARK INSTALLATION
FLAT FINISHING
BODY
-
SEALER
NO FLAT FINISHING
IN-4 INTRODUCTION － HOW TO USE THIS MANUAL
ILLUSTRATION OF WELD POINT SYMBOLS

REMOVAL INSTALLATION
IN
*1 Position of panels that are removed *1 Welding method and panel position
*2 Weld points *2 Weld points
SYMBOLS MEANING ILLUSTRATION SYMBOLS MEANING ILLUSTRATION
Remove Weld
Spot Welding
Points
Position of
Panel Being
Replaced is on
Outside
Plug Welding
Position of
Panel Being
Replaced is in
Center
Spot MIG
Position of
Welding
Panel Being
Replaced is on
Inside
INTRODUCTION － WORK NOTICES AND PRECAUTIONS IN-5
WORK NOTICES AND PRECAUTIONS

Vehicle Exterior
INTRODUCTION
WHEN REPAIRING THE VEHICLE BODY

1. VEHICLE PROTECTION
*1 (a) When welding, cover glass, seats, carpets, etc. with
heat resistant fireproof covers to protect them. IN
Text in Illustration
*1 Glass Cover
*2 Seat Cover
*2
K100254E01
2. SAFETY
(a) Never stand in the path of the chain when using a
puller on the body of frame, and be sure to attach a
safety cable.
K100255
(b) If it is necessary to use a flame in the area of the

fuel tank, first remove the tank and plug the fuel line.
K100256
3. SAFETY WORK CLOTHES

*5
(a) In addition to the usual mechanic's wear, cap and
*1
safety shoes, the appropriate gloves, head
protector, welder's glasses, ear plugs, face
*2 *6
protector, dust mask, etc. should be worn as the
situation demands.
*3 *7 Text in Illustration
*1 Dust mask
*4 *8 *2 Face protector
K100257E01 *3 Safety glasses
*4 Safety shoes
*5 Welder's glasses
*6 Ear plugs
*7 Head protector
*8 Welder's gloves
IN-6 INTRODUCTION － WORK NOTICES AND PRECAUTIONS
PRECAUTIONS FOR REPAIRING BODY STRUCTURE (INCLUDING

CRUSH BOXES)
1.
PROHIBITION OF HEAT REPAIR FOR BODY FRAME
PARTS
(a) Rustproof high strength steel sheets are used for
IN the body frame. Therefore, if these parts are heat
repaired using an acetylene torch or equivalent, the
crystalline structure changes, causing the strength
of the steel sheets to decrease. Also, the zinc
coating which is used to protect the body from rust
will be damaged. This causes the surface of the
K100258 steel sheets to become oxidized, which reduces
their ability to resist rust.
2. NOTES ON ULTRA HIGH STRENGTH STEEL PANEL REPAIR
(a) Make sure that the frame aligning machine does not affect undamaged areas when aligning the
frame.
(b) Do not butt weld because the heat decreases the
strength of the steel.
K100259
(c) Use a spot cutter suitable for high strength steel when removing spot welds. The cutter should
be able to cut welding nuggets smoothly.
(d) Always follow the welding instructions when welding. (Refer to the PRECAUTIONS FOR
WELDING)
(e) Do not heat the panel when repairing.
K100261
3. WHEN TO REPLACE FRAME PARTS

NOTICE:
Replace the sections of the frame where kinks have
occurred.
HINT:
What is kink?
A deformation on a steel sheet that cannot be returned to
its original shape by pulling or hammering due to the
deformation angle being sharp.
K100263
4. REPAIR OF DOOR SIDE IMPACT BEAM IS

PROHIBITED
(a) The impact beam is designed so that it performs at
100% in its original shape. However, if the impact
beam is repaired, its performance may not be the
same as before the accident.
PARTS WHICH ARE PROHIBITED TO BE IN
REPAIRED:
Door side impact beam
K100264
K100265
5. REPAIR OF BUMPER REINFORCEMENT IS

PROHIBITED
(a) The bumper reinforcement is designed so that it
performs at 100% in its original shape. However, if
the bumper reinforcement is repaired, its
performance may not be the same as before the
accident.
PARTS WHICH ARE PROHIBITED TO BE
REPAIRED:
K100266 Bumper reinforcement
PRECAUTIONS FOR WELDING

1. REMOVAL OF ADJACENT COMPONENTS
(a) To prevent damage to the body and parts, apply
protective tape to the body and tools before
removing the parts.
NOTICE:
If the paint film is damaged, make sure to
refinish the paint.
K100267
2. CUTTING WORK
(a) When cutting a panel, be careful not to damage the
surrounding panels or any panels underneath.
NOTICE:
If any panels are damaged, be sure to repair
them.
IN
K104359
3. ANTI-RUST TREATMENT BEFORE WELDING

(a) Apply welding primer to the contact surfaces of the
welding areas to protect them from rust.
NOTICE:
Do not apply welding primer outside of the
contact surfaces.
K100268
4. WELDING WORK
(a) To assure sufficient weld strength, it is recommended to follow the welding conditions below
when welding ultra high strength steel.
• It is recommended to perform spot welding according to board thickness and number of
overlapping sheets under the following conditions (*1 - *4).
• When conditions can't be met, it is recommended to perform the plug welding following *5.
Weld work for 1500 MPa ultra high strength steel
Plug welding Plug diameter 8.5 mm (0.33 in)
Wire AWS A5.18 ER70S
Gas CO2
Total number of 2 or 3 overlapping sheets
Plug diameter 8.5 mm (0.33 in)
Wire AWS A5.18 ER70S-3
Gas Gas mixture (argon: 80%, CO2: 20%)

Spot welding Compression 2.6 kN
*1 Current 6.0 kA Total number of 2 overlapping sheets
Welding time 10 Cyc.
Compression 4.0 kN
Compression 3.5 kN
Compression 4.4 kN
Plug welding Plug diameter 8 mm (0.31 in) or more

Gas CO2
*5 Total number of 2 or 3 overlapping sheets
Plug diameter 8 mm (0.31 in) or more
IN
NOTICE:
Inspect the welds after spot welding. For points with insufficient weld strength join the
panels using plug welds.
(b) Spot weld locations
*1 Text in Illustration
*1 Old Spot Locations
*2 New Spot Locations
Avoid welding over previously welded areas.
*2
K100274E01
5. MAKING HOLES FOR PLUG WELDING

*1 Puncher
(a) For areas where a spot welder cannot be used, use

a puncher or drill to make holes for plug welding.
Thickness of welded portion Diameter of plug hole
Under 1.0 mm (0.04 in.) Over 5.0 mm (0.20 in.)
*1 1.0 to 1.6 mm (0.04 to 0.06 in.) Over 6.5 mm (0.26 in.)
K100275E01
1.7 to 2.3 mm (0.07 to 0.09 in.) Over 8.0 mm (0.31 in.)
Over 2.4 mm (0.09 in.) Over 10 mm (0.39 in.)
ANTI-RUST TREATMENT AFTER INSTALLATION OF BODY

STRUCTURE PARTS OR OUTER PANELS
1. BODY SEALER APPLICATION
*1
*1 Sealer Gun
PURPOSE:
For water-proofing and anti-rust measures, always apply
the body sealer to the body panel seams and hems of
the doors, hood, etc.
NOTICE:
K100276E01
Apply body sealer neatly to parts that require a high
quality appearance.
2. UNDERCOAT APPLICATION
PURPOSE:
To prevent corrosion and protect the body from gravel,
always apply a sufficient undercoating to the areas
indicated.
IN
K100277
3. VEHICLE BODY ANTI-RUST AGENT APPLICATION

PURPOSE:
The purpose is to protect areas from rust which are
difficult to paint such as the backside of the box-shaped
cross section frame parts.
METHOD:
Apply anti-rust agent through the service holes and/or
installation holes of the parts.
K100278
PRECAUTIONS FOR SRS AIRBAG SYSTEM

1. HANDLING OF A VEHICLE THAT HAS BEEN DAMAGED IN A COLLISION
(a) Refer to the SUBARU Repair Manual for the SRS airbag system inspection procedures.
(b) If impacts are likely to occur to the front sub sensors, front door impact sensors, side airbag
sensors, curtain airbag sensors, satellite safing sensor or airbag control module remove each
sensor as necessary beforehand.
(c) Do not allow the front sub sensors, front door impact sensors, side airbag sensors, curtain
airbag sensors, satellite safing sensor or airbag control module to become heated to high
temperatures.
(d) Check the wire harnesses and connectors for damage and/or melting, as some areas of the
airbags and seat belt pretensioners may heat up to several hundred degrees when they operate.
2. PRECAUTIONS FOR USING ELECTRIC WELDER
(a) Check the Diagnostic Trouble Codes (DTCs).
(1) If one or more DTCs are displayed:
• Disconnect the negative (-) terminal cable from the battery.
• Disconnect all the malfunctioning circuit connectors.
• Disconnect the airbag control module connector.
(2) If DTCs are NOT displayed:
• Inspect for damage to the electric wiring harnesses and connectors.
• Disconnect the negative (-) terminal cable from the battery.
• Disconnect the airbag control module connector.
3. PARTS LOCATION
Seat belt pretensioner (RH)

Engine compartment relay block
IN
- A/B MAIN fuse Side airbag sensor (RH)
- MPX-B fuse
Curtain airbag sensor (RH)
Seat belt pretensioner (LH)
Curtain airbag sensor (LH)
Side airbag sensor (LH)
Front sub sensor (LH)
Front door impact sensor (LH)
Front sub sensor (RH)
Front door impact sensor (RH)
K106295E01
Curtain airbag module (RH)

IN
Side airbag module (RH)
Side airbag module (LH)
Curtain airbag module (LH)
K106296E01
PASSENGER’S AIRBAG MODULE
IN
INSTRUMENT PANEL JUNCTION
BLOCK ASSEMBLY
- GAUGE FUSE
FRONT SEAT ASSEMBLY RH

DRIVER’S AIRBAG MODULE
- OCCUPANT DETECTION ECU
SATELLITE SAFING SENSOR

AIRBAG CONTROL MODULE
FRONT SEAT INNER BELT

ASSEMBLY
K106526E01
IN
PASSENGER AIRBAG
SRS WARNING LIGHT ON/OFF INDICATOR
COMBINATION METER
ASSEMBLY
CLOCK ASSEMBLY
AIRBAG CONTROL
MODULE
DLC3
FRONT SEAT ASSEMBLY RH
OCCUPANT DETECTION ECU)

(OCCUPANT DETECTION SENSOR)
FRONT SEAT INNER BELT ASSEMBLY RH
(SEAT BELT BUCKLE SWITCH RH)
AB-03339
NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP

VEHICLE
1. LIFT AND JACK
When using a lift or shop jack to raise a vehicle or using rigid rack to support a vehicle, always follow
instructions concerning jack-up points and weight limits to prevent the vehicle from falling, which
could result in injury. Be especially careful that the vehicle is balanced before raising it. Be sure to set IN
the wheel stoppers when jacking-up only the front or rear side of the vehicle.
CAUTION:
Select the lift attachment so that the side sill does not contact the lift arm.
NOTICE:
• When using a lift, follow its operation manual.
• When the side sill cover contacts the lift arm, use a lift attachment.
• Do not work or leave unattended while the vehicle is supported with jack, support it with
rigid racks.
• Be sure to use the rigid racks with rubber attached to cradle to support the vehicle.
• When using a lift, use an attachment or something similar.
• When using a plate lift, use a rubber attachment.
Place the attachment to the specified position of
the vehicle, by adjusting front/rear and left/right
sides accordingly.
*A 80 mm (3.1 in) or more
*A
*B 80 - 100 mm (3.15 - 3.94 in)
*C *C 120 - 200 mm (4.72 - 7.87 in)
*B
K106528E01
• Align the cushion rubber center part of plate lift with the center part of rubber attachment.
• Do not use the plate lift whose attachment does not reach the supporting locations.
(a) Support locations
*1 *1
K106529E01
*1 Jack-up point
(b) Pantograph jack

CAUTION:
When storing the jack holder after use, store with the jack handle mount of the jack facing
the inside of the trunk.
IN
*1 *1
K106530E01
*1 Jack-up point
(c) Lift
K106531
CAUTION:
For models with side under skirt, use a spacer or an attachment to lift up the vehicle
securely at jack up point, without contact of side under skirt and lift.
(d) Rigid rack
IN
*A
K106532E01
*A Attachment
(e) Plate lift
*1 *2 *1
K106533E01
*1 Jack-up point
*2 Attachment
(f) Jack-up point (When using a garage jack)
*A
IN *1
*B
*2
K106534E01
*A Front
*B Rear
*1 Frame
*2 Rear differential
CAUTION:
If jacking up the front side of the vehicle, make sure that the jack is attached at the center
of the jack-up plate not at the sides.
INTRODUCTION － WHEN REMOVING,INSTALLING,REPARING OR REPLACING PARTS IN-19
WHEN REMOVING,INSTALLING,REPAIRING OR
Vehicle Exterior
INTRODUCTION
REPLACING PARTS
COMPONENTS
HINT:
The shapes and names of parts and the general layout may differ depending on the vehicle grade and
IN
options.
1. FRONT BUMPER
32 {326, 23.6}
Front bumper beam COMPL
Front bumper
x8 stay bracket
x3
7.5 {77, 5.5}
Front bumper energy
absorber 7.5 {77, 5.5}
x3
x5
Front bumper
retainer UPR
x2
Front bumper
cover LWR
x7
Front bumper cover
x3
Front bumper
Front bumper reinforcement 7.5 {77, 5.5}
hole cover plate LH
License plate
Side turn
bracket
signal light
bracket LH
Front side
x2 marker light
ASSY LH
x2 x2
Front bumper
Front bumper cover side support LH
x2
(without fog lights)
x7
Fog light cover Fog light ASSY
(with fog lights) (with fog lights)
x2
Front bumper side x4
cover 7.5 {77, 5.5}
7.5 {77, 5.5}
Front bumper
front support LH
N*m {kgf*cm, ft*lbf} : Tightening torque
EI-10372
IN-20 INTRODUCTION － WHEN REMOVING,INSTALLING,REPARING OR REPLACING PARTS
2. REAR BUMPER
IN
Rear floor finish plate
x3
Trunk floor mat
Trunk side tray LH
Rear bumper
reinforcement No. 1
Rear bumper reinforcement No. 2
x5 x2
x2
x2
x2
Trunk trim cover INN LH

x6
7.5 {77, 5.5}
Rear bumper cover x2
x2
Back-up light ASSY

EI-10077
Rear bumper side retainer RH

IN
x2
Rear bumper side bracket RH
x3
Rear bumper side seal RH
x2
x2 x3
Rear bumper side bracket LH
Rear bumper side retainer LH
Rear bumper bracket CTR

Rear bumper bracket CTR
Rear bumper beam COMPL

x2
x2
Rear bumper side
seal LH
45 {459, 33.2}
x4 45 {459, 33.2}
N•m {kgf•cm, ft•lbf}: Tightening torque
Non-reusable parts
EI-03941
3. INSTRUMENT PANEL
IN
39 (398, 28.8)
Driver side air bag module
N*m {kgf*cm, ft*lbf} : Tightening torque Steering wheel ASSY
PS-10073
Instrument cluster
Meter hood SUB-ASSY finish panel SUB-ASSY
(Large type)
Instrument panel Instrument panel

IN
meter ornament UPR ornament
Instrument cluster
finish panel
SUB-ASSY CTR
Steering column cover UPR
Turn signal switch ASSY

w/steering roll connector
With smart entry:

x2
Steering column cover support
Steering column cover LWR
Knee guard plate
x2
Instrument side x2
panel LH
Instrument panel under cover
SUB-ASSY No.1
PS-10075
Front pillar garnish clip
Front pillar garnish LH
IN
Front pillar garnish RH
Front pillar garnish clip
Instrument panel speaker panel

SUB-ASSY No.1
Instrument panel speaker panel

SUB-ASSY No.2
For 8 speakers :
For 6 speakers : Speaker ASSY FR No.2
Speaker ASSY FR No.2

7.5 {77, 5.5}
7.5 {77, 5.5} x2
x2

EI-10392
x3
Side defroster nozzle duct No.1

Defroster nozzle ASSY
IN
Side defroster nozzle duct No.2
x3
x3
Heater-to-resistor duct No.1
Heater-to-resistor
duct No.2
Passenger side airbag module
x2
x2
7.5 {77, 5.5}
Combination meter ASSY

Instrument cluster
finish panel SUB-ASSY
(large type)
Instrument cluster finish panel

SUB-ASSY CTR
Instrument panel ornament

EI-10393
Automatic light control sensor

system specifications
Automatic light control sensor
IN
Defroster nozzle garnish NO.1
Defroster nozzle
garnish NO.2
Instrument panel cushion

Defroster nozzle
garnish NO.3
Instrument panel SUB-ASSY
x2
7.5 {77, 5.5}
x6
Instrument panel resistor

SUB-ASSY NO.1
SUB-ASSY NO.2 Instrument panel
resistor bezel
x2
Instrument panel
resistor bezel
SUB-ASSY CTR
N*m (kgf*cm, ft*lbf) : Tightening torque
Non-reusable parts
EI-04507
Instrument cluster finish panel SUB-ASSY

(large type)
Instrument panel ornament IN
Instrument cluster finish panel SUB-ASSY CTR
Instrument cluster finish panel garnish No.1
Instrument cluster finish panel garnish No.2
Instrument panel finish panel

SUB-ASSY UPR
Instrument panel finish panel

SUB-ASSY UPR
x2
Air conditioner control ASSY
EI-10386
For automatic air conditioning system :

IN
x2
For manual air conditioning system :
x2
EI-10387
Meter hood SUB-ASSY
IN
Instrument panel meter
ornament UPR
Instrument side panel RH
Instrument side panel LH
Instrument panel under cover

SUB-ASSY NO.1
x2
Glove compartment door damper
Glove compartment door ASSY
EI-03835
Instrument panel SUB-ASSY LWR
Glove compartment door

IN reinforcement
x2
x2
Glove compartment
retainer
x9 7 {71, 5.2}
Clip
Power supply outlet socket ASSY NO.2
Glove compartment cushion

N*m (kgf*cm, ft*lbf) : Tightening torque
EI-04509
4. INTERIOR TRIM
Tether clip
x3
Quarter trim lid RH IN

Quarter rear trim
garnish FR RH Rear window side
garnish RH
7.5 {77, 5.5}

x2
7.5 {77, 5.5}

7.5 {77, 5.5} x2
Center pillar garnish RH
Separate type rear seat cushion

ASSY RH
30 {306, 22.1}
13 {133, 9.6} Trunk trim INN RH
7.5 {77, 5.5}
30 {306, 22.1} x2
30 {306, 22.1}
Front seat outer belt ASSY RH
Quarter lower trim RH
Front door scuff plate RH
Front door opening trim weather

strip RH

SB-10017
IN Separate type rear seat

cushion ASSY
Rear seat belt ASSY inner 13 {133, 9.6}
30 {306, 22.1}
N•m {kgf•cm, ft•lbf} : Tightening torque

SB-00712
Tether clip
x3
Quarter trim lid RH

IN
Separate type rear seat Rear window side
cushion ASSY RH garnish RH
30 {306, 22.1}
7.5 {77, 5.5}

13 {133, 9.6}
30 {306, 22.1}
30 {306, 22.1}
Trunk trim INN RH
Rear seat 3-point type belt

ASSY OUT RH x2

strip RH

SB-10018
IN
Bench type rear seat backrest ASSY
x3
Separate type rear seat

33 {336, 24.3}
cushion ASSY
x2
Trunk trim cover INN RH
x2
13 {133, 9.6}

strip RH
33 {336, 24.3} x3
25 {255, 18.4}
x2
Rear seat hinge RH
Child restraint seat anchor bracket

RH
SB-10020
x3 Tether clip
Quarter trim lid RH

x4
IN
Rear window side
garnish RH 7.5 {77, 5.5}
Package tray trim panel ASSY
Rear seat backrest lock Quarter trim lid LH Tether clip

striker cover RH
33 {337, 24.3} x3
Rear seat backrest lock

x2
striker cover LH
Rear seat backrest lock 7.5 {77, 5.5}

striker SUB-ASSY RH
Rear window side
Rear seat backrest lock
garnish LH
striker SUB-ASSY LH x2
33 {337, 24.3}
Trunk trim INN RH
Front door opening

trim weather strip RH
x2
Trunk trim cover INN LH
x2

strip LH
Quarter lower trim LH
N*m {kgf*cm, ft*lbf} : Tightening torque Front door scuff plate LH

SE-10084
5. SEAT
IN
Front seat headrest ASSY
53 {540, 39.1}
x4 Front seat ASSY LH

SE-10085
Bench type rear seat backrest ASSY

IN
x3
Separate type rear seat cushion ASSY RH x2
33 {337, 24.3}
33 {336, 24.3} x3
x2
13 {133, 9.6}
Rear seat hinge LH
Center console silencer No.1
13 {133, 9.6}
Separate type rear seat cushion ASSY LH
SE-10089
PROCEDURES NECESSARY WHEN ECU OR OTHER PARTS ARE

REPLACED
Each inspection procedure refers to the SUBARU Repair Manual.
1. List of replacement procedures
IN Replaced parts and procedures Required procedures

Possible phenomena/unavailable
functions (unless required procedure is
performed)
Engine control computer 1. ID code registration Engine start inoperable
• Transmission control computer ASSY
• Automatic transmission ASSY
• Transmission valve body ASSY • High revving of engine
1. AT learning values initialization
• Transmission wire • Large shift shock
• Each solenoid
• Engine ASSY
• Brake actuator ASSY
• Steering sensor
• VSC system does not operate normally
• Steering column ASSY 1. VSC sensor mid point setting
(warning light is illuminated)
• Rack & pinion power steering gear ASSY
• Front wheel alignment adjustment
• P/S warning light illumination
Power steering computer ASSY 1. Steering zero point correction
• EPS control
Steering column ASSY 1. Steering zero point correction • Different left/right steering control force
With smart entry
• Electrical key transmitter SUB-ASSY
• ID CODE BOX (Immobilizer CODE ECU) • Wireless function
• Smart key computer ASSY (collation 1. ID code registration • Smart function
ECM) • Engine start inoperable
• Steering lock actuator ASSY (steering
lock ECM)
No smart entry
• Key
• Main body ECM (network gateway
1. ID code registration • Engine start inoperable
computer)
• TRANSPONDER KEY ECM
• Combination meter assembly
• Power window regulator motor ASSY
(RH, LH) • Door glass automatic opening/closing
• Front door window regulator SUB-ASSY function
RH (RH, LH) • Anti-pinching function
• Front door glass SUB-ASSY (RH, LH), 1. Power window system initialization • Operating functions after key OFF (IG
front door frame SUB-ASSY RR LWR OFF)
(RH, LH) or front door sash (RH, LH) • Seat remote operation using driver's seat
• Front door opening trim weather strip switch
(RH, LH)
• Main body ECM (network gateway
1. Customize • Functions are inoperable
computer)
WHEEL ALIGNMENT STANDARD

1. Vehicle height inspection
(a) Perform vehicle height inspection after bouncing the
vehicle at the corners by large amounts to stabilize
the suspension.
Standard value IN
Dimension A - Dimension B Dimension C - Dimension D
A [mm (in)] [mm (in)]
B
146 110
(5.75) (4.33)
CAUTION:
• Perform the inspection while the vehicle is at
curb weight (with the spare tire, jack, and
service tools loaded and with a full fuel tank).
• These values are for adjusting the wheel
alignment and do not indicate the actual
vehicle height.
D
C NOTE:
• Dimension A: Center of front wheel
• Dimension B: Center of the tip of the front arm
FS-10007 ASSY front side bushing mounting bolt
• Dimension C: Center of the rear wheel
• Dimension D: center of the rear end of the rear
lower arm No.2 bushing mounting bolt threaded
portion
2. Inspection of camber, caster, and kingpin angle (FRONT)

CAUTION:
Perform the inspection while the vehicle is at curb weight (with the spare tire, jack, and
(a) Place the front wheel on the turning radius gauge.
Standard value
Tire Size Camber Caster Kingpin angle
215/45R17 0°00±0°45 5°55' (Reference) 15°30' (Reference)
NOTE:
Make sure the ground contact surfaces of the front and rear wheels are at the same height.
(b) Set the adapter into the center of wheel, and then
(3) set the wheel alignment gauge.
Captions in illustration
*1 Wheel alignment gauge
(1) *2 Turning radius gauge
*3 Adapter
(2)
FS-00603
(c) Measure the camber angle in accordance with the operation manual for wheel alignment gauge.
(d) Check whether the measured value is within standard value.
(e) Measure the caster angle in accordance with the operation manual for wheel alignment gauge.
(f) Check whether the measured value is within standard value.
3. Toe-in inspection (FRONT)

(a) Bounce the vehicle to stabilize the suspension.
(b) Move the vehicle straight 5 m (16.4 ft.) forward by manually pushing it.
CAUTION:
If the vehicle has been moved backward, be sure to move it forward by the same
distance.
IN (c) Adjust the height of the toe-in gauge pointer so that
it is at the same height as the center of the front
A wheel axis, and set it behind the tire.
*1 Toe-in gauge
*a Tread center
*b Dimension B
B Front of vehicle
*a
*1
*b
*1
C148423E02
(d) Place a tread center mark on the back of both front tires, and measure the distance between the
marks (dimension B).
(e) Move the vehicle forward by pushing it slowly to rotate the front wheels 180°.
CAUTION:
Be sure not to rotate more than 180°, and if the wheels have been over-rotated, repeat
from the setting up of the toe-in gauge.
(f) Measure the distance between the marks at the
A
front of the vehicle (dimension A).
*1 Toe-in gauge
*a Dimension A
Front side of vehicle

B
(g) Calc ulate the toe-in.

*a Standard value
Toe-in [mm (in)]
0±3 {0±0.12} (at curb weight)
*1
NOTE:
C148424E02 Toe-in = Dimension B - Dimension A
4. Wheel turning angle inspection

(a) Set the turning radius gauge.
(b) Check the wheel turning angle.
*a *b *b *a *a Inside
*b Outside
IN
Front
Standard value
Inside Outside
C148075E01
36°54' 31°12'
(Reference) (Reference)
CAUTION:
• Perform the inspection while the vehicle is at
curb weight (with the spare tire, jack, and
• While the vehicle is at curb weight, apply the
foot brake using a brake pedal depressor, etc.
to prevent the front wheels from rotating
during the inspection.
• Remove the stop light fuse to prevent the
stop light from illuminating during the
inspection.
5. Toe-in inspection (REAR)

(a) Bounce the vehicle to stabilize it.
(b) Move the vehicle straight 5 m (16.4 ft.) forward by manually pushing it.
CAUTION:
If the vehicle has been moved backward, be sure to move it forward by the same
distance.
*1
(c) Adjust the height of the toe-in gauge pointer so that
it is at the same height as the center of the rear
*a wheel axis, and set it behind the tire.
*b
*1 Toe-in gauge
*a Tread Center
*b Dimension B
Front of vehicle
*1
C103063E03
(d) Place a tread center mark on the back of both rear tires, and measure the distance between the
marks (dimension B).
(e) Move the vehicle forward by pushing it slowly to rotate the rear wheels 180°.
CAUTION:
Be sure not to rotate the tires more than 180°. If the wheels have been over-rotated, repeat
from the setting up of the toe-in gauge.
(f)
Measure the distance between the marks at the
front of the tires (dimension A).
A Captions in illustration
*1 Toe-in gauge
*a Dimension A
*a
IN B Front of vehicle
*1 C218856E02
(g) Calculate the toe-in.

Standard value:
2±3mm {0.08±0.12in}
NOTE:
Toe-in = Dimension B - Dimension A
6. Camber inspection (REAR)
(a) Lift up the vehicle on a level surface.
(b) Set the wheel alignment gauge.
(c) Calibrate the wheel alignment gauge.
(d) Lower the vehicle and Check the camber.
Standard value
Camber
-1°10’ ±45’
CAUTION:
• Perform the inspection while the vehicle is at curb weight (with the spare tire, jack, and
• The limit of difference between the left and right camber values is 45'.
• Remove foreign matter from the axle hub end surface before performing the
inspection.
(e) Remove the wheel alignment gauge.
7. Rear suspension inspection
(a) Inspection of rear suspension member
(1) Check the distance between the center of rear
suspension arm ASSY No. 2 LH and RH
mounting bolts.
Standard value:
457.5±3mm {18.01±0.12in}
NOTE:
If it is out of standard value, replace with a new
C257519 rear suspension member.
(b) Inspection of rear suspension arm ASSY No. 2

(1) Check the distance between the center of rear
suspension arm ASSY No. 2 mounting bolts.
Standard value:
450.9±2 mm {17.75±0.08 in}
NOTE:
If it is out of standard value, replace with a new
rear suspension arm ASSY No. 2.
C257520
(c) Inspection and adjustment of toe-in and camber

(1) Inspect the toe-in and camber.
Check the toe-in and camber, and if they are out
of standard value, adjust them with the play in
the mounting portion of the rear suspension
member or that of the upper control arm and
rear suspension arm. IN
IN-44 INTRODUCTION － ABOUT THIS VEHICLE
ABOUT THIS VEHICLE

Vehicle Exterior
INTRODUCTION
STRUCTURAL OUTLINE
1. MODEL CODE AND LINE-UP
(a) MODEL CODE
IN
*1 *2 *3 *4 *5 *6 *7
B1607051003
*1 MODEL NAME Z: BRZ

*2 BODY TYPE C: COUPE
*3 DISPLACEMENT, DRIVE TYPE, SUSPENSION 6: 2.0L FR
*4 MODEL YEAR E: 2017MY
*5 DESTINATION Y: U.S.A.*
B: Premium
*6 GRADE
E: Limited
7: DOHC MPI+DI 6AT
*7 GEAR SHIFT TYPE, ENGINE SPECIFICATION
8: DOHC MPI+DI 6MT
*: Destination packages for Canada is included.

(b) MODEL LINE-UP
DESTINATION ENGINE TRANSMISSION GRADE MODEL CODES
Premium ZC6-EYB8
TL70
Limited ZC6-EYE8
U.S.A.* FA20
Premium ZC6-EYB7
TX6A
Limited ZC6-EYE7
*: Destination packages for Canada is included.

2. STRUCTURAL OUTLINE
Aluminium Adhesive Application Area

INTRODUCTION － ABOUT THIS VEHICLE IN-45
IN
K105163
1500 MPa Ultra High Strength Steel 980 MPa Ultra High Strength Steel
590 MPa High Strength Steel 440 MPa High Strength Steel
IN
IN
K106332
Anti-rust Coating Steel - -
IN
IN
K105188
DAMAGE DIAGNOSIS
*1 Reinforce Pillar Front Lower *2 Beam Front
*3 Frame Side Front *4 Reinforce Sill Side Outer
*5 Frame Side Rear *6 Floor Panel Front Center
IN *7
*9
Brace Center
Cross Member Front Seat Front
*8
*10
Reinforce Rail Side Outer
Reinforce Pillar Center
Confirmation Point Collision Direction
Collision Force Absorption Direction - -

IN
*1
*4
*3
*2
*1
*3 *4
K105166E01
IN
*4
*6 *5
K105167E02
IN
*7
*8
*10
*9
K105168E01
EXTERIOR RESIN PARTS AND RESIN CHARACTERISTICS

1. PLASTIC PROPERTIES CHART
When repairing, some parts may be deformed by the heat. Therefore, confirm the properties of the
plastic parts, and remove parts beforehand as necessary.
Heat resistant
IN Code Material name temperature
limit* °C (°F)
Resistance to alcohol or gasoline Notes
Alcohol is harmless if applied only for short time

Acrylonitrile Acrylic Avoid gasoline and organic or
AAS 80 (176) in small amounts.
Styrene aromatic solvents.
(e.g., quick wiping to remove grease)
Acrylonitrile Butadiene Avoid gasoline and organic or
ABS 80 (176) in small amounts.
Acrylonitrile Ethylene Avoid gasoline and organic or
AES 80 (176) in small amounts.
Acrylonitrile Styrene Avoid gasoline and organic or
ASA 80 (176) in small amounts.
Acrylate aromatic solvents.
Avoid gasoline and organic or
CAB Cellulose Acetate 80 (176) in small amounts.
aromatic solvents.
Carbon Fiber
CFRP 200 (392) in small amounts. Avoid battery acid
Reinforced Plastic
Alcohol is harmless. Gasoline is harmless if Most solvents are harmless but avoid
EPDM Ethylene Propylene 100 (212)
applied only for short time in small amounts. dipping in gasoline, solvents, etc.
Avoid gasoline and organic or
EVA Ethylene Acetate 70 (158) in small amounts.
aromatic solvents.
Ethylene/ Vinyl Acetate Avoid gasoline and organic or
E/VAC 70 (158) in small amounts.
Copolymer Resin aromatic solvents.
Fiber Reinforced
FRP 180 (356) Alcohol and gasoline are harmless. Avoid alkali.
Plastics
PA Polyamide (Nylon) 80 (176) Alcohol and gasoline are harmless. Avoid battery acid.
Polybutylene
PBT 160 (320) Alcohol and gasoline are harmless. Most solvents are harmless.
Terephthalate
Avoid gasoline, brake fluid, wax, wax
PC Polycarbonate 120 (248) Alcohol is harmless. removers and organic solvents. Avoid
alkali.
PE Polyethylene 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless.
PEI Polyetherimide 160 (320) Alcohol and gasoline are harmless. Most solvents are harmless.
Polyethylene
PET 75 (167) Alcohol and gasoline are harmless. Avoid dipping in water.
Terephthalate
Polypropylene Glass
PGM 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless.
Fiber Pulp
Polymethyl Avoid dipping or immersing in alcohol,
PMMA 80 (176) in small amounts.
Methacrylate gasoline, solvents, etc.
Polyoxymethylene
POM 100 (212) Alcohol and gasoline are harmless. Most solvents are harmless.
(Polyacetal)
PP Polypropylene 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless.
PPC Polyphthlate Carbonate 149 (300) Alcohol and gasoline are harmless. Most solvents are harmless.
Avoid dipping or immersing in alcohol,
PPE Polyphenylene Ether 80 (176) in small amounts (e.g., quick wiping to remove
gasoline, solvents, etc.
grease).
Composite Reinforced
PPF 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless.
Polypropylene
Heat resistant
Code Material name temperature Resistance to alcohol or gasoline Notes
limit* °C (°F)
Modified Gasoline is harmless if applied only
PPO 100 (212) Alcohol is harmless.
Polyphenylene Oxide for quick wiping to remove grease.
Alcohol and gasoline are harmless if applied Avoid dipping or immersing in alcohol,
PS Polystyrene 60 (140)
only for short time in small amounts. gasoline, solvents, etc.
Alcohol is harmless if applied only for very short
IN
PUR Polyurethane 80 (176) time in small amounts.
Alcohol and gasoline are harmless if applied
Polyvinylchloride Avoid dipping or immersing in alcohol,
PVC 80 (176) only for short time in small amounts.
(Vinyl) gasoline, solvents, etc.
SAN Styrene Acrylonitrile 80 (176) in small amounts.
Alcohol and gasoline are harmless if applied
Silicon Acrylonitrile Avoid gasoline and organic or
SAS 80 (176) only for short time in small amounts.
Sheet Molding
G-SMC 220 (428) Alcohol and gasoline are harmless. Most solvents are harmless.
Compound
Thermoplastic Alcohol is harmless. Gasoline is harmless if Most solvents are harmless but avoid
TPE 80 (176)
Elastomer applied only for short time in small amounts. dipping in gasoline, solvents, etc.
Alcohol is harmless. Gasoline is harmless if Most solvents are harmless but avoid
TPO Thermoplastic Olefine 80 (176)
applied only for short time in small amounts. dipping in gasoline, solvents, etc.
Thermoplastic Avoid dipping or immersing in alcohol,
TPU 80 (176) in small amounts.
Polyurethane gasoline, solvents, etc.
TOYOTA Super Olefine
TSOP 80 (176) Alcohol and gasoline are harmless. Most solvents are harmless.
Polymer
UP Unsaturated Polyester 110 (233) Alcohol and gasoline are harmless. Avoid alkali.
*The heat resistant temperature means a temperature that may cause heat deformation during a
procedure.
2. THE PLASTIC BODY PARTS MATERIAL LIST
*1 License Plate Base (PP) *2 Ornament (ABS)
*3 Front Bumper (PP) *4 Headlight (PC/PP)
*5 Cowl Panel Side (PP/TPO) *6 Cowl Top Ventilator Louver (PP)
*7 Roof Moulding (TPO) *8 Intake Cover Front (PP)
*9 Nozzle Cover (ABS) *10 Fog Light Cover (PP)
*11 Fog Light (PC) *12 Side Turn Light (PMMA/PC)
*13 Fender Garnish (PP/ABS/ASA) *14 Rear View Mirror (AES/ABS,AES)
*15 Door Outside Handle (PC/PBT,PA) *16 Air Flap Plate (PP)
*17 Antenna Base (PC/ASA) *18 Rear Spoiler (ABS/ASA/EPDM)
*19 Ornament (ABS) *20 Trunk Garnish (ABS)
*21 Rear Combination Light (PMMA/ASA) *22 Rear Bumper (PP)
*23 Letter mark (ABS) *24 Back-up Light (PC/PBT/PET)
*25 License Plate Light (PC) - -
/ Made up of 2 or more kinds of materials.

, Resin material differs with model.
*5
IN
*6 *7
*4
*3
*2
*1
*16
*15
*8
*14
*9
*13
*12
*10
*11
*17 *18
*19
*20
*25
*21 *24
*23
*22
B1604051001
Vehicle Exterior
BODY WELD POINT
RADIATOR SIDE SUPPORT

ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP-1
WP
RADIATOR LOWER SUPPORT
RADIATOR SUPPORT
FRONT FENDER MOUNTING BRACKET
FRONT FENDER APRON
FRONT SIDE MEMBER
CUT AND JOIN REPLACEMENT SECTIONS (SMALL AREAS) . . . . . . WP-32
ASSEMBLY REPLACEMENT (PATTERN 1) . . . . . . . . . . . . . . . . . . . . . WP-37
ASSEMBLY REPLACEMENT (PATTERN 2) . . . . . . . . . . . . . . . . . . . . . WP-43
COWL TOP TO APRON BRACE
FRONT BODY PILLAR LOWER GUSSET
FRONT BODY PILLAR
CUT AND JOIN REPLACEMENT SECTIONS . . . . . . . . . . . . . . . . . . . . WP-57
CENTER BODY PILLAR
ROCKER OUTER PANEL
QUARTER PANEL
QUARTER WHEEL HOUSING OUTER PANEL
QUARTER PANEL END HOUSING
BODY LOWER BACK PANEL
REAR FLOOR PAN
REAR FLOOR SIDE PANEL
REAR FLOOR SIDE MEMBER
ROOF PANEL
SPECIFIED TORQUE
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP-142
WP FIT STANDARD / ADJUSTMENT METHOD

ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP-145
CAUTION LABEL
ATTACHMENT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP-153
BODY WELD POINT － RADIATOR SIDE SUPPORT WP-1
RADIATOR SIDE SUPPORT

VehicleWELD
BODY Exterior
POINT
ASSEMBLY REPLACEMENT
WP
K105340
1. REMOVAL
Symbol meaning
Remove Weld Points
REMOVAL POINT
1. *1: Bolts.
WP-2 BODY WELD POINT － RADIATOR SIDE SUPPORT
*1
WP x4
x2
x2
*1
K105034E01
BODY WELD POINT － RADIATOR SIDE SUPPORT WP-3
2. INSTALLATION
Symbol meaning
Plug Weld
INSTALLATION POINT
1. Inspect the fitting of the related parts around the new parts before welding. This affects the appearance
of the finish. WP
2. Temporarily install the new parts and measure each part of the new parts in accordance with the body
dimension diagram. (See the body dimensions)
3. *1: Bolts.
4. After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section
structural weld points.
WP-4 BODY WELD POINT － RADIATOR SIDE SUPPORT
18 (184, 13.3)
*1
WP x4
x2
x2
*1
7.5 (77, 5.5) RADIATOR PANEL SIDE
N*m (kgf*cm, ft.*lbf) : Specified torque
K105035E02
BODY WELD POINT － RADIATOR LOWER SUPPORT WP-5
RADIATOR LOWER SUPPORT

VehicleWELD
BODY Exterior
POINT
WP
K105341
1. REMOVAL
Symbol meaning
Remove Weld Points
Remove Weld Points
REMOVAL POINT
1. *1: Bolts.
WP-6 BODY WELD POINT － RADIATOR LOWER SUPPORT
WP
*1
*1
x2
x2
x2
*1
K105036E01
LH Side:
2
WP
4
1 1 5
K105037E01
RH Side:
WP
4
5
5 1 1
K105038E01
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Plug Weld
INSTALLATION POINT
of the finish.
3. *1: Bolts.
LH Side:
2
WP
4
1 1 5
RADIATOR FRAME PANEL LOWER 1
K105039E02
RH Side:
WP
4
5
5 1 1
K105040E02
WP
18 (184, 13.3)
18 (184, 13.3)
*1
*1
x2
x2
x2
*1
18 (184, 13.3)
K105041E01
BODY WELD POINT － RADIATOR SUPPORT WP-13
RADIATOR SUPPORT
VehicleWELD
BODY Exterior
POINT
WP
K105342
1. REMOVAL
Symbol meaning
Remove Weld Points
Remove Weld Points

WP-14 BODY WELD POINT － RADIATOR SUPPORT
LH Side:
1
WP
2
4
2
1 1
K105042E01
WP
K105043E01
RH Side:
1
WP
4 2
1 1
K105044E01
WP
K105045E01
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Plug Weld
INSTALLATION POINT
of the finish.
4. Measure the dimensions before installing the headlights.
Reference Value
Area Measurement Area Measurement
*a 1360 mm (53.54 in.) *b 1278 mm (50.31 in.)
*c 1097 mm (43.19 in.) *d 888 mm (34.96 in.)
*e 881 mm (34.68 in.) *f 889 mm (35.00 in.)
*g 805 mm (31.69 in.) - -
LH Side:
1
WP
2
4
2
FRONT PANEL
1
1 1
K105046E02
WP
K105047E01
RH Side:
1
WP
4 2
1 1
K105048E02
WP
K105049E01
WP
*d *e
*f
*a
*b
*c
*g
K105050E01
WP-24 BODY WELD POINT － FRONT FENDER MOUNTING BRACKET
FRONT FENDER MOUNTING BRACKET

VehicleWELD
BODY Exterior
POINT
With the radiator side support removed.
WP
K105343
1. REMOVAL
Symbol meaning
Remove Weld Points
Remove Weld Points
REMOVAL POINT
1. *1: Bolts.
BODY WELD POINT － FRONT FENDER MOUNTING BRACKET WP-25
2 WP
*1
x2
*1
K105051E01
WP-26 BODY WELD POINT － FRONT FENDER MOUNTING BRACKET
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Plug Weld
INSTALLATION POINT
of the finish.
dimension diagram. (See the body dimension diagram)
3. *1: Bolts.
BODY WELD POINT － FRONT FENDER MOUNTING BRACKET WP-27
2 WP
*1
7.5 (77, 5.5)
1
APRON REINFORCEMENT LOWER
x2
*1
7.5 (77, 5.5)
K105052E02
WP-28 BODY WELD POINT － FRONT FENDER APRON
FRONT FENDER APRON

VehicleWELD
BODY Exterior
POINT
With the front fender mounting bracket and front body pillar
lower gusset removed.
WP
K105344
1. REMOVAL
Symbol meaning
Remove Weld Points
Remove Weld Points
Cut with Disk Sander etc.

BODY WELD POINT － FRONT FENDER APRON WP-29
1 5
WP
2
24
1
4
K105054E01
WP-30 BODY WELD POINT － FRONT FENDER APRON
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Plug Weld
Fillet Weld
INSTALLATION POINT
of the finish.
3. *1 is only for RH.
4. Make sure to attach correctly in accordance with the body dimension diagram as this part affects the
front wheel alignment.
5. After welding, apply body sealer and undercoating to the corresponding parts. (See the painting /
coating)
BODY WELD POINT － FRONT FENDER APRON WP-31
20 1 5
2
WP
x2 1
15 (0.59)
2
15 (0.59) 1
FRONT SUSPENSION BRACKET
4
1 1 1
BATTERY ROD BRACKET
*1
mm (in.) 3
K105581E01
WP-32 BODY WELD POINT － FRONT SIDE MEMBER
FRONT SIDE MEMBER

VehicleWELD
BODY Exterior
POINT
CUT AND JOIN REPLACEMENT SECTIONS (SMALL AREAS)

With the radiator support and front fender mounting bracket
removed.
WP
K105345
1. REMOVAL
Symbol meaning
Remove Weld Points
Cut and Join Location
REMOVAL POINT
1. Carefully cut the member so not to damage *1.
Reference Value
Area Measurement Area Measurement
*a 135 mm (5.31 in.) *b 271 mm (10.67 in.)
*c 410 mm (16.14 in.) *d 135 mm (5.31 in.)
*e 271 mm (10.67 in.) *f 410 mm (16.14 in.)
BODY WELD POINT － FRONT SIDE MEMBER WP-33
60 (2.36)
WP
360 (14.17)
mm (in.)
K105058E01
LH:
*1
WP
*a
*b
*c
RH:
*1
*d
*e
*f
K105059E01
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Butt Weld
INSTALLATION POINT
coating)
WP
FRONT SIDE FRAME FRONT
1 6
CLOSING PLATE
3
1
2 5
K105060E02
ASSEMBLY REPLACEMENT (PATTERN 1)

With the radiator support and front fender mounting bracket
removed.
WP
K105346
1. REMOVAL
Symbol meaning
Remove Weld Points
Remove Weld Points
REMOVAL POINT
1. After removing the toe board reinforcement, remove the side frame.
1 4
WP
13
1 4 2
TOE BOARD REINFORCEMENT
SIDE FRAME
K105061E02
WP
24
2 7
K105062E01
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Plug Weld
Fillet Weld
INSTALLATION POINT
2. After welding the side frame to the vehicle side, install the toe board reinforcement.
coating)
5 1
WP
SIDE FRAME
K105063E02
WP
2 24
x2
15 (0.59)
2 7
15 (0.59)
1 4
13
1 4 2
mm (in.)
K105064E02
ASSEMBLY REPLACEMENT (PATTERN 2)

With the radiator support and front fender apron removed.
WP
K105346
1. REMOVAL
Symbol meaning
Remove Weld Points
REMOVAL POINT
1. After removing the toe board reinforcement, remove the side frame.
1 4
WP
13
1 4
SIDE FRAME
K105065E02
WP
K105066E01
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
INSTALLATION POINT
2. After welding the side frame to the vehicle side, install the toe board reinforcement.
coating)
5 1
SIDE FRAME WP
1
K105067E02
WP 11
2 7
1 4
13
1 4
K105068E02
BODY WELD POINT － COWL TOP TO APRON BRACE WP-49
COWL TOP TO APRON BRACE

VehicleWELD
BODY Exterior
POINT
WP
K105347
1. REMOVAL
Symbol meaning
Remove Weld Points
Remove Weld Points
REMOVAL POINT
1. *1: Bolts.
2. After removing the patch frame side upper, remove the front side panel reinforcement.
WP-50 BODY WELD POINT － COWL TOP TO APRON BRACE
*1
WP x3
PATCH FRAME SIDE UPPER
2
3 5
3 2
6
FRONT SIDE PANEL REINFORCEMENT
K105069E02
BODY WELD POINT － COWL TOP TO APRON BRACE WP-51
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Plug Weld
Fillet Weld
INSTALLATION POINT
of the finish.
3. *1: Bolts.
4. After welding the front side panel reinforcement to the vehicle side, install the patch frame side upper.
5. After welding, apply body sealer to the corresponding parts. (See the painting / coating)
WP-52 BODY WELD POINT － COWL TOP TO APRON BRACE
WP 3 5
3 2
15 (0.59)
6
FRONT SIDE PANEL REINFORCEMENT
7.5 (77, 5.5)

*1
x3
N*m (kgf*cm, ft.*lbf) : Specified torque PATCH FRAME SIDE UPPER
mm (in.)
K105070E02
BODY WELD POINT － FRONT BODY PILLAR LOWER GUSSET WP-53
FRONT BODY PILLAR LOWER GUSSET

VehicleWELD
BODY Exterior
POINT
With the cowl top to apron brace removed.
WP
K105348
1. REMOVAL
Symbol meaning
Remove Weld Points
Remove Weld Points
Remove Weld Points

WP-54 BODY WELD POINT － FRONT BODY PILLAR LOWER GUSSET
3
WP
3
2
7
1 1 2
1
2
K105071E01
BODY WELD POINT － FRONT BODY PILLAR LOWER GUSSET WP-55
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Plug Weld
Plug Weld
INSTALLATION POINT
of the finish.
3. When welding *1, make a hole on a new part for plug welding and weld the panel with the panel behind
completely.
WP-56 BODY WELD POINT － FRONT BODY PILLAR LOWER GUSSET
3
WP
5
1
FRONT PILLAR GUSSET

2
3
3
2
7
*1
1 1 2
1
2
K105583E01
BODY WELD POINT － FRONT BODY PILLAR WP-57
FRONT BODY PILLAR

VehicleWELD
BODY Exterior
POINT
CUT AND JOIN REPLACEMENT SECTIONS

With the front body pillar lower gusset removed.
WP
K105349

To assure sufficient weld strength, it is recommended to follow the welding conditions below
• It is recommended to perform spot welding according to board thickness and number of overlapping
sheets under the following conditions (*1 - *3)
Compression 3.5 kN
*2 Current 7.0 kA
Total number of 3 overlapping sheets
Compression 4.4 kN
*3 Current 7.5 kA
Gas CO2
1. REMOVAL
Symbol meaning
Remove Weld Points
Remove Weld Points
Remove Weld Points
Cut with Disc Sander etc.

WP-58 BODY WELD POINT － FRONT BODY PILLAR
Symbol meaning
REMOVAL POINT
1. Do not butt weld or heat repair because the heat decreases the strength of areas where ultra high
strength steel is used. (See the introduction)
WP
WP
1
1
10 1
5
6 8
120 (4.72)
120 (4.72)
mm (in.)
K105129E01
WP
1
2 2
K105130E01
170 (6.69)
WP
1
4
1
1 2
2
20 (0.79)
1
2
8
mm (in.)
K105131E01
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Plug Weld
Plug Weld
Fillet Weld
Butt Weld
Body Sealer
INSTALLATION POINT
of the finish.
3. If the entire supply part is not needed, remove the part of the supply part that is needed.
4. Before installing a new part, apply body sealer.
HINT:
Apply body sealer in an even, continuous bead.
5. To assure sufficient weld strength, it is recommended to follow the welding conditions when welding *1,
*2, *3 or *4. (See the introduction)
6. Before temporarily installing the new parts, weld the front pillar inner upper and front pillar inner center
with the standard number of welding points.
7. When welding *5, make a hole on a new part for plug welding and weld the panel with the panel.
8. After welding the front pillar inner lower the vehicle side, install the front pillar inner upper and front
pillar inner center.
9. After welding the front pillar inner upper, front pillar inner center and front pillar inner lower the vehicle
side, install the side sill reinforcement outer.
10.After welding the front pillar inner upper, front pillar inner center, front pillar inner lower and side sill
reinforcement outer the vehicle side, install the front pillar reinforcement lower.
11.After welding the front pillar inner upper, front pillar inner center, front pillar inner lower, side sill
reinforcement outer and front pillar reinforcement lower the vehicle side, install the front pillar outer and
side sill outer.
12.After welding, apply body sealer to the corresponding parts. (See the painting / coating)
13.After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section
WP
WP
20 (0.79)
FRONT PILLAR INNER UPPER
FRONT PILLAR INNER CENTER
SIDE SILL REINFORCEMENT OUTER
440 (17.32)
mm (in.)
K105132E02
1
WP
2
1
1
1
*5
1
FRONT PILLAR INNER LOWER
1
2
*5
1
K105133E02
WP
1
2 2
*1
1
*1
1
x3
mm (in.) 15 (0.59)
K105134E02
5
1 1
WP
1
5 13
*4
4 1
FRONT PILLAR REINFORCEMENT LOWER *4

2
1 *4
1
14
5 2
2
8
*2
1
K105584E01
WP
FRONT PILLAR OUTER
3
4
4
1
5 1
1 1 2
SIDE SILL OUTER
3 2 1 2
1 1 1
6 3 2
K105585E01
*3
4 WP
6
*3
4
5 (0.20)
2 1
mm (in.)
K105137E02
WP-70 BODY WELD POINT － CENTER BODY PILLAR
CENTER BODY PILLAR

VehicleWELD
BODY Exterior
POINT

With the quarter panel removed.
WP
K105350

Compression 3.5 kN
*2 Current 7.0 kA
Total number of 3 overlapping sheets
Compression 4.4 kN
*3 Current 7.5 kA
Gas CO2
1. REMOVAL
Symbol meaning
Remove Weld Points
Remove Weld Points

BODY WELD POINT － CENTER BODY PILLAR WP-71
REMOVAL POINT
2. *5 is reused.
WP
WP
2
1
2
14
12
30 (1.18)
mm (in.)
B1607040024
*5
40 (1.57)
WP
150 (5.91)
180 (7.09)
1 90 (3.54)
4
1
3
1
1 2
5
2
4
mm (in.)
K105139E02
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Plug Weld
Fillet Weld
Butt Weld
INSTALLATION POINT
of the finish.
3. If the entire supply part is not needed, remove the part of the supply part that is needed.
5. Before temporarily installing the new parts, weld the center pillar reinforcement and side sill
reinforcement outer with the standard number of welding points.
6. After welding the center pillar inner the vehicle side, install the center pillar reinforcement and side sill
reinforcement outer.
7. After welding the center pillar inner, center pillar reinforcement and side sill reinforcement outer the
vehicle side, install the *5.
WP
480 (18.90)
SIDE SILL REINFORCEMENT OUTER
CENTER PILLAR REINFORCEMENT
3 12
mm (in.)
K105140E02
CENTER PILLAR INNER
WP
13
2
x3
20 (0.79)
15 (0.59)
mm (in.)
B1607040025
*3
15 *1
4 *3
2 *1
8
5
WP
1
1 3
6
1 2 2 1
1 1
*4
5 *4
2
*4
2
*2
*2 1
1
*2
2
*5
*4
1
*3
1
*3 4
1
B1607040026
WP-78 BODY WELD POINT － ROCKER OUTER PANEL
ROCKER OUTER PANEL

VehicleWELD
BODY Exterior
POINT
WP
K105351
1. REMOVAL
Symbol meaning
Remove Weld Points
Cut Location for Supply Parts

BODY WELD POINT － ROCKER OUTER PANEL WP-79
WP
50 (1.97)
mm (in.)
K105143E01
WP-80 BODY WELD POINT － ROCKER OUTER PANEL
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Butt Weld
INSTALLATION POINT
of the finish.
BODY WELD POINT － ROCKER OUTER PANEL WP-81
WP
SIDE SILL OUTER
3 2
K105587E01
WP-82 BODY WELD POINT － QUARTER PANEL
QUARTER PANEL
VehicleWELD
BODY Exterior
POINT
WP
K105073
1. REMOVAL
Symbol meaning
Remove Weld Points

BODY WELD POINT － QUARTER PANEL WP-83
320 (12.60) WP
12
mm (in.)
B1607040027
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Butt Weld
INSTALLATION POINT
of the finish.
coating)
WP
10
8 REAR QUARTER OUTER
B1607040028
WP
K105076
Quarter Panel Replacement Using Adhesive

Work Procedure
1. Cut the wheel arch portion.
2. Heat the quarter panel adhesive area and remove the quarter panel.
HINT:
Using an industrial heater gun or gas burner, heat the quarter panel to 110 to 140°C. Make sure the
quarter panel does not warp.
3. Clean off any adhesive that remains on the vehicle.
HINT:
• Using an industrial heater gun or gas burner, heat the adhesive to 110 to 140°C.
• Using a scraper, scrape away the adhesive.
• If adhesive remains, the strength of any subsequently applied adhesive will be weak.
4. Using a disc grinder or belt sander, scuff and sand any adhesive that remains on the vehicle.
HINT:
Scuff at a width of approximately 10 mm (0.39 in.) over the previous adhesive coating.
5. Apply adhesive to the exposed metal areas on the vehicle. Using a spatula, spread the adhesive
evenly.
6. Apply adhesive to the vehicle again.
7. Using #60-120 grit sandpaper, scuff the adhesive application area on the new quarter panel.
8. Apply adhesive to the new quarter panel. Using a spatula, spread the adhesive evenly.
9. Using a vise grip or the palms of your hands, press the quarter panel so that the thickness of the
adhesive is even.
10.Complete installation the new quarter panel.
11.Dry the adhesive areas of the new quarter panel.
HINT:
• With dryer or equivalent (60°C): 60 minutes (complete hardening: 90 minutes)
• Ambient temperature (25°C): 12 hours (complete hardening: 24 hours)
1. REMOVAL
Symbol meaning
Remove Weld Points
Remove Weld Points
Remove Weld Points

Symbol meaning
REMOVAL POINT
1. *1 in illustration above indicates where the adhesive is located.
2. Roughly cut open the panel so that the adhesive can be reached. Cut through the adhesive with a cut
chisel to remove the panel. WP
HINT:
In cases where the adhesive cannot be removed with a cut chisel, heat the adhesive with an industrial
heater gun or gas burner taking care not to cause panel deformation by overheating.
70 (2.76) 50 (1.97)
WP 245 (9.65)
*1
a
19
*1
a-a
mm (in.)
B1604270005
17
WP
2
7
1
2 8 4
B1604270006
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Plug Weld
Plug Weld
Butt Weld
INSTALLATION POINT
of the finish.
completely.
4. Apply adhesive (3MTM AutomixTM Panel Bonding Adhesive #8115) to the area indicated by *2 in the
illustration.
HINT:
Apply enough adhesive for the panels to stick to each other.
5. Perform spot-welding on the flange indicated by *3 in the illustration. Modify/cut the spot tip as shown
in the illustration*4 so that it can fit in to the narrow flange.
9
WP
*2
a
17
2 a
*3
6
REAR QUARTER OUTER

8
Spot Tip
3 (0.12)
*2
5 (0.20)
*4
a-a
mm (in.)
B1604270007
13
4
WP
*1
1
2
7
1
2 8 4
FUEL LID
RIVETS
B1604270008
BODY WELD POINT － QUARTER WHEEL HOUSING OUTER PANEL WP-93
QUARTER WHEEL HOUSING OUTER PANEL

VehicleWELD
BODY Exterior
POINT
With the quarter panel removed.
WP
K105081
1. REMOVAL
Symbol meaning
Remove Weld Points
Remove Weld Points
Remove Weld Points
REMOVAL POINT
1. *1 and *2 is reused.
2. After removing the *1, *2 and rear quarter reinforcement inner, remove the rear arch inner.
WP-94 BODY WELD POINT － QUARTER WHEEL HOUSING OUTER PANEL
LH:
WP
3
110 (4.33)
5
2 11
4 *1
150 (5.91)
7 *2
mm (in.)
K105602E01
REAR QUARTER REINFORCEMENT

INNER
1 WP
4
3 1 1 1 1
3
6
2
2 3
3 REAR ARCH INNER

4
B1607040029
RH:
WP
3 110 (4.33) 5
11 2 4
*1
150 (5.91)
*2 7
mm (in.)
K105603E01

INNER
1
WP
5
5
3 1 1 4
2
6
1
3
5
4 3
REAR ARCH INNER
B1607040030
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Plug Weld
Plug Weld
Butt Weld
Assembly Mark
INSTALLATION POINT
completely.
2. For positioning of the new parts, align the installation standard holes of the outer panel and the inner
panel.
3. After welding the rear arch inner to the vehicle side, install the rear quarter reinforcement inner, *2 and
*3.
coating)
LH:
*1 *1
3 1 1 1 1
3
WP
6
2
1
1
2
2
3
4
REAR ARCH INNER

INNER
1
B1607040031
2
WP
7 2
*2
3
4
2 11
5 *3
K105605E01
RH:
REAR ARCH INNER

*1 *1
3 1 1 4
WP
2
6
1
1
2 3
2
4 3

INNER 1
5
5
B1607040032
WP 2
2
7 *2
11 2 5
*3
K105607E01
BODY WELD POINT － QUARTER PANEL END HOUSING WP-103
QUARTER PANEL END HOUSING

VehicleWELD
BODY Exterior
POINT
WP
K105090
1. REMOVAL
Symbol meaning
Remove Weld Points
Remove Weld Points
REMOVAL POINT
1. Cut the rear quarter outer and fold it upward as shown in *1. Then cut through the welded area of the
rear pillar patch, and remove the rear quarter end.
WP-104 BODY WELD POINT － QUARTER PANEL END HOUSING
WP
1 8
REAR QUARTER OUTER
REAR PILLAR PATCH

*1
1 1
REAR QUARTER END

1 1
K105091E02
BODY WELD POINT － QUARTER PANEL END HOUSING WP-105
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Plug Weld
Butt Weld
INSTALLATION POINT
of the finish.
WP-106 BODY WELD POINT － QUARTER PANEL END HOUSING
9
REAR QUARTER END
WP
1 8
1 1
1
1
K105092E02
BODY WELD POINT － BODY LOWER BACK PANEL WP-107
BODY LOWER BACK PANEL

VehicleWELD
BODY Exterior
POINT
WP
K105093
1. REMOVAL
Symbol meaning
Remove Weld Points

WP-108 BODY WELD POINT － BODY LOWER BACK PANEL
WP
2 2
8 8
16 or 14
LH Side: RH Side:
9 9
3 3
5 5
K105094E02
BODY WELD POINT － BODY LOWER BACK PANEL WP-109
2. INSTALLATION
Symbol meaning
Spot Weld
INSTALLATION POINT
of the finish. WP
WP-110 BODY WELD POINT － BODY LOWER BACK PANEL
WP
2 2
8 8
16
REAR SKIRT
LH Side: RH Side:
9
9
3 3
5 5
K105095E02
BODY WELD POINT － REAR FLOOR PAN WP-111
REAR FLOOR PAN

VehicleWELD
BODY Exterior
POINT

With the body lower back panel removed.
WP
K105096
1. REMOVAL
Symbol meaning
Remove Weld Points
Remove Weld Points
Remove Weld Points
Cut Location
REMOVAL POINT
1. After removing the rear side frame upper and rear bumper bracket, remove the rear floor pan rear.
WP-112 BODY WELD POINT － REAR FLOOR PAN
LH:
6 1 1
WP
5
REAR SIDE FRAME UPPER
8
1
REAR BUMPER BRACKET
1 1 2
2
K105097E03
RH:
1 1 6
WP
5
REAR BUMPER BRACKET
2 1
1 2
K105098E02
WP
30 (1.18) 30 (1.18)
5 5
REAR FLOOR PAN REAR
mm (in.)
K105099E02
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Plug Weld
Plug Weld
Cut Location
Fillet Weld
Body Sealer
INSTALLATION POINT
1. Cut the new part so that it overlaps the previous cut location.
completely.
3. *1: Perform plug-welding in the area where the panel are overlapped. Apply body sealer to both sides
of each panel.
HINT:
• Confirm that the panels are securely welded together.
• Apply body sealer in an even, continuous bead.
4. After welding the rear floor pan rear to the vehicle side, install the rear side frame upper and rear
bumper bracket.
coating)
WP
130 (5.12) 130 (5.12)
20 (0.79) 20 (0.79)
290 (11.42) 290 (11.42)
REAR FLOOR PAN REAR
*1
5 2 6 2 *1 5
*1
mm (in.)
a-a
K105100E02
LH:
*2
6 1 1
WP
5
*2
2
8
1
REAR BUMPER BRACKET 2
1 2 1 2
K105101E03
RH:
*2
1 1 6
WP
5 REAR SIDE FRAME UPPER
*2
2
REAR BUMPER BRACKET
1
2
2 1 2 1
K105102E03
BODY WELD POINT － REAR FLOOR SIDE PANEL WP-119
REAR FLOOR SIDE PANEL

VehicleWELD
BODY Exterior
POINT
WP
K105103
1. REMOVAL
Symbol meaning
Remove Weld Points
Remove Weld Points
Remove Weld Points
REMOVAL POINT
1. After removing the rear side frame upper and rear bumper bracket, remove the rear floor side.
WP-120 BODY WELD POINT － REAR FLOOR SIDE PANEL
LH:
6 1 1
WP
5
8
1
REAR BUMPER BRACKET
1 1 2
2
K105097E03
WP
REAR FLOOR SIDE
4
4
K105106E02
RH:
1 1 6
WP
5
REAR BUMPER BRACKET
2 1
1 2
K105098E02
WP
REAR FLOOR SIDE
4
4
K105107E02
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Plug Weld
Plug Weld
INSTALLATION POINT
completely.
2. After welding the rear floor side to the vehicle side, install the rear side frame upper and rear bumper
bracket.
LH:
*1
2
WP
REAR FLOOR SIDE
*1
1
4
4
K105108E02
*1
6 1 1
WP
5
*1
2
8
1
1 2 1 2
K105101E04
RH:
*1
1
WP
REAR FLOOR SIDE
*1
1
4
4
K105109E02
*1
1 1 6
WP
5 REAR SIDE FRAME UPPER
*1
2
REAR BUMPER BRACKET
1
2
2 1 2 1
K105102E04
BODY WELD POINT － REAR FLOOR SIDE MEMBER WP-129
REAR FLOOR SIDE MEMBER

VehicleWELD
BODY Exterior
POINT
WP
K105112
1. REMOVAL
Symbol meaning
Remove Weld Points
Remove Weld Points
Remove Weld Points
REMOVAL POINT
1. After removing the rear side frame upper and rear bumper bracket, remove the rear floor frame rear.
WP-130 BODY WELD POINT － REAR FLOOR SIDE MEMBER
6 1 1
WP
5
8
1
REAR BUMPER BRACKET
1 1 2
2
K105097E04
1 3 2
7
WP
REAR FLOOR FRAME REAR
1
1
K105114E02
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Plug Weld
Plug Weld
INSTALLATION POINT
completely.
2. After welding the rear floor frame rear to the vehicle side, install the rear side frame upper and rear
bumper bracket.
coating)
*1
1 3 2
7
WP
REAR FLOOR FRAME REAR
1 1
K105115E02
*1
6 1 1
WP
5
*1
2
8
1
1 2 1 2
K105101E04
BODY WELD POINT － ROOF PANEL WP-135
ROOF PANEL
VehicleWELD
BODY Exterior
POINT
WP
K105117

Compression 4.4 kN
Gas CO2

When conditions can't be met, it is recommended to perform the plug welding following *4.
Plug welding Plug diameter 8.5 mm (0.33 in)
Gas CO2
Plug diameter 8.5 mm (0.33 in)
1. REMOVAL
Symbol meaning
Remove Weld Points
1. After removing the roof panel, remove the roof center brace.
WP-136 BODY WELD POINT － ROOF PANEL
WP
13
WP
3
2 15
13
ROOF PANEL
ROOF CENTER BRACE
K105608E01
2. INSTALLATION
Symbol meaning
Spot Weld
Plug Weld
WP
Body Sealer
INSTALLATION POINT
of the finish.
4. Before temporarily installing the new parts, apply body sealer to the front roof rail, roof brace, center
roof brace and rear roof rail.
HINT:
Apply just enough body sealer for the new parts to make contact.
5. After welding the roof center brace to the vehicle side, install the roof panel.
WP
*4
4
*4
2
ROOF CENTER BRACE
*4
4
K105609E01
WP
B1607040033
WP
13
1
*2
2
*1
6
*2
2 15
*1
6
*2
2
13
ROOF PANEL
K106313E01
WP-142 BODY WELD POINT － SPECIFIED TORQUE
SPECIFIED TORQUE
VehicleWELD
BODY Exterior
POINT
COMPONENTS
WP
25 (255, 18.4)
x2
x2 x2
25 (255, 18.4)
x2
25 (255, 18.4)
18 (184, 13.3)
x4
18 (184, 13.3)
x2
7.5 (77, 5.5)
x3
x4 x3
7.5 (77, 5.5)
x4 x6
32 (326, 23.6)
7.5 (77, 5.5)

K105121E02
BODY WELD POINT － SPECIFIED TORQUE WP-143
WP
x2 x2
x2 x2
25 (255, 18.4) 30 (306, 22.1)
K105122E02
WP-144 BODY WELD POINT － SPECIFIED TORQUE
WP
x2
18 (184, 13.3)
x2
x2
18 (184, 13.3)
x2
18 (184, 13.3)
x2
x2
45 (459, 33.2)
45 (459, 33.2)
N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part
K105124E02
BODY WELD POINT － FIT STANDARD / ADJUSTMENT METHOD WP-145
FIT STANDARD / ADJUSTMENT METHOD

VehicleWELD
BODY Exterior
POINT
ADJUSTMENT
1. Inspection of the hood ASSY (hood SUB-ASSY)
*b *d
WP
*c *e
*a
EB-10053
(a) Inspect if each placement dimension is within the reference values.

Reference values
*a 5.8 to 9.8 mm {0.2283 to 0.3858 in} *b 3.0 to 7.0 mm {0.1181 to 0.2756 in}
*c -2.0 to 2.0 mm {-0.0787 to 0.0787 in} *d 2.0 to 5.0 mm {0.0787 to 0.1969 in}
*e -2.0 to 1.0 mm {-0.0787 to 0.0394 in} - -
WP-146 BODY WELD POINT － FIT STANDARD / ADJUSTMENT METHOD
2. Adjustment of the hood ASSY (hood SUB-ASSY)

(a) Adjustment of the forward and backward directions,
and the rear left and right directions
(1) Loosen the bolts of the hood hinge ASSY to
adjust.
Torque: 25N·m {255kgf·cm} {18.4ft·lbf}
CAUTION:
When adjusting, use the bolt supplied and
WP adjust the placement.
B312163
(b) Adjustment of the vertical direction of both sides of

the hood's front end
(1) Turn the 2 cushions to adjust the height.
B312164
(c) Adjustment of the vertical and left and right

directions of the hood's front end.
(1) Loosen the 3 bolts to adjust.
B314955
(2) In the order shown in the figure, tighten the 3

bolts.
CAUTION:
3 1 When adjusting, use the bolt supplied and
adjust the placement.
2
B313112E02
(3) Connect the cable ASSY front hood (hood lock

control cable ASSY).
WP
B310901
3. Inspection of the front door LH

F
D
E G H
J
M
K
L
I
EB-10057
(a) Inspect if each placement dimension is within the reference values range.
Reference values
*a -1.0 to 2.0 mm {-0.039 to 0.079 in} *b 5.5 to 8.5 mm {0.217 to 0.335 in}
*c 3.5 to 6.5 mm {0.138 to 0.256 in} *d 5.2 to 8.2 mm {0.205 to 0.323 in}
*e 13.5 to 16.5 mm {0.5315 to 0.6496 in} *f 2.5 to 5.5 mm {0.0984 to 0.2165 in}
*g 0.0 to 1.5 mm {0.0 to 0.0591 in} *h 4.8 to 7.8 mm {0.1890 to 0.3071 in}
*i 3.1 to 5.6 mm {0.122 to 0.220 in} *j -1.0 to 1.5 mm {-0.0394 to 0.0591 in}
*1 Front Glass *2 Front Door
HINT:
The procedures described below are for the LH side. The RH side and the LH side follow the same steps.
4. Adjustment of the front door glass
*1 (a) Insert the SST in the front door glass and measure
*a the placement dimensions.
SST 61299CA000
WP *b
*1 SST
Reference values
*a 3.5 to 6.5 mm {0.138 to 0.256 in}
B314931E01
*b 5.2 to 8.2 mm {0.205 to 0.323 in}
(b) Adjust the front door glass so that the placement

dimensions are within the reference values.
(c) Loosen the nut of the front door sash stopper and
the bolt of the front door frame SUB-ASSY RR LWR
RH stopper section, and adjust the vertical direction
of the front door glass.
Torque: 7.5N·m {77kgf·cm} {5.5ft·lbf}
B312234
(d) Loosen the 2 nuts of the front door frame SUB-

ASSY RR LWR RH, and adjust the forward and
backward direction of the front door glass.
WP
B312235
(e) Loosen the bolt of the door glass stabilizer INN, and
adjust the side to side direction of the front door
glass.
(f) Loosen the nut of the front door frame SUB-ASSY
RR LWR RH, turn the bolt with a flat tip screwdriver,
and adjust the side to side direction of the front door
glass.
B314930
(g) Insert the SST in the side fix window and measure
*1 the placement dimensions.
SST 61299CA010
*a *1 SST
*b Reference values
*a 2.5 to 5.5 mm {0.0984 to 0.2165 in}
*b 5.2 to 8.2 mm {0.2047 to 0.3228 in}
B314932E01
(h) Loosen the 3 nuts of the front door sash and adjust
the vertical direction of the front door sash so that
the placement dimensions are within the reference
values.
Torque: 14 N·m {143kgf·cm} {10.3ft·lbf} (lower
side)
7.5N·m {77kgf·cm} {5.5ft·lbf} (upper
side)
WP
B312236
5. Adjustment of the front door LH

(a) Loosen the bolts on the body side, and adjust the
door's front and rear, and vertical directions.
K106506
(b) Loosen the striker installation screws until the striker

can move. Using a brass bar, hit the striker lightly
and adjust the side to side and vertical directions of
the rear end of the door and the front door lock
striker plate ASSY.
B309232
6. Inspection of the trunk lid COMPL (luggage compartment door panel SUB-ASSY)
D WP
C
E
F
G
H
EI-03882
(a) Inspect if placement dimensions are within the reference values.

Reference values
*a 7.8 mm {0.3071 in} *b 2.0 to 5.0 mm {0.0787 to 0.1969 in}
0 mm {0 in} (section of 150 mm {5.906 in} from the back
*c *d 5.8 to 10.2 mm {0.2283 to 0.4016 in}
end of the trunk)
*e 4.3 to 7.3 mm {0.1693 to 0.2874 in} *f -2.0 to 1.0 mm {-0.0787 to 0.0394 in}
*g 150 mm {5.906 in} - -
7. Adjustment of the trunk lid COMPL (luggage

compartment door panel SUB-ASSY)
(a) Loosen the bolts before adjusting the door's forward
and backward direction, and the side to side
direction of the door's front end.
CAUTION:
When adjusting, use the bolt supplied and
WP adjust the placement.
B310950
(b) Loosen the bolts before adjusting the side to side

direction of the door's rear end and the striker.
B314945
BODY WELD POINT － CAUTION LABEL WP-153
CAUTION LABEL
VehicleWELD
BODY Exterior
POINT
ATTACHMENT POSITION
1. After using a degreasing agent to clean the surfaces of the body where the caution labels will be
attached, attach the caution labels to the positions shown in the illustration.
HINT:
• Make sure the caution label is not attached over a spot weld.
• When attaching the caution label, make sure not to touch the label's adhesive surface. WP
• To prevent the edges of the caution label from peeling, apply extra pressure to the label's periphery.
• If the work area's temperature is 5°C or less, the caution label's adhesive will deteriorate. It is
recommended that you heat the label to 20 to 40°C.
Cooler Service Caution Label
Engine Service Information Label Emission Control Information Label
Fuel Information Label
K105125E01
WP-154 BODY WELD POINT － CAUTION LABEL
WP Name Label
Side Air Bag Caution Label
Name Label
Tire Pressure Information Label
Side Air Bag Caution Label
K105127E01
Vehicle Exterior
BODY DIMENSIONS
MEASURING INFORMATION
DIAGRAM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BD-1
ENGINE COMPARTMENT
THREE-DIMENSIONAL DISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . BD-3 BD
FRONT DOOR
THREE-DIMENSIONAL DISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . BD-5
LUGGAGE DOOR
UNDER BODY
TWO-DIMENSIONAL DISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BD-12
FRONT SUSPENSION CROSSMEMBER
REAR SUSPENSION CROSSMEMBER
ENGINE COMPARTMENT REFERENCE VALUES
UNDER BODY REFERENCE VALUES
OTHER REFERENCE VALUES
BD
BODY DIMENSIONS － MEASURING INFORMATION BD-1
MEASURING INFORMATION
VehicleDIMENSIONS
BODY Exterior
DIAGRAM DESCRIPTION
HINT:
• There are two types of dimensions in the diagram.
• In cases in which only one dimension is given, left and right are symmetrical.
• For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen
from rear).
*1
1. Three-Dimensional Distance
(a) Straight-line distance between the centers of two
BD
measuring points.
*1 Distance between the centers of the measuring points
K100523E04
2. Two-Dimensional Distance
(a) Horizontal distance in forward/rearward between the
centers of two measuring points.
(b) Distance from the Imaginary Datum Line.
*1 Center-to-center horizontal distance in forward/rearward
*2 Vertical distance to center
*1 *3 Vertical distance to lower surface

*4 Imaginary Datum Line
*3
*2
*4
K101082E01
3. Imaginary Datum Line

(a) The imaginary line used to measure height is a line
which connects the points described in the following
chart (actual dimensions are listed in the next
*1
chapter of this manual).
*1 Under surface of the Rocker Panel
<1> <2> <3> *2 Imaginary Datum Line
A B C
*2
K101080E01 Symbol Measuring Points
The place that was lowered <1> mm from the under surface of
A
the rocker panel centered on the front jack up point.
BD-2 BODY DIMENSIONS － MEASURING INFORMATION
Symbol Measuring Points

B
the rocker panel centered between A and C.
C
the rocker panel centered on the rear jack up point.
4. Measurement
(a) Basically, all measurements are to be done with a
tracking gauge. For portions where it is not possible
*1 to use a tracking gauge, a tape measure should be
BD used.
(b) Use only a tracking gauge that has no looseness in
the body, measuring plate, or pointers.
(c) When using a tape measure, avoid twists and bends
*3 in the tape.
*2 *1 Tracking Gauge
*2 Master Gauge
Wrong Correct *3 Pointer
*3
K101083E01
HINT:
• The height of the left and right pointers must be equal.
• Always calibrate the tracking gauge before measuring or after adjusting the pointer height.
• Take care not to drop the tracking gauge or otherwise shock it.
• Confirm that the pointers are securely in the holes.
BODY DIMENSIONS － ENGINE COMPARTMENT BD-3
ENGINE COMPARTMENT
VehicleDIMENSIONS
BODY Exterior
HINT:
• Point E, e on the vehicle are asymmetrical.
from rear).
Measuring Point Name
Symbol Name
Hole Diameter BD
mm (in.)
A, a Fender Extension Installation Nut M6 (0.24)
B, b Front Suspension Installation Hole φ9.5 (0.37)
C, c Hood Hinge Installation Nut M8 (0.31)
D Cowl Panel Installation Hole φ7 (0.28)
E, e Earth Installation Nut M6 (0.24)
F, f Side Frame Standard Hole φ14 (0.55)
G, g Radiator Upper Frame Center Installation Nut M8 (0.31)
H, h Front Beam Installation Nut M8 (0.31)
J, j Bumper Lower Center Stay Installation Nut M6 (0.24)
K, k Fender Bracket Standard Hole φ8 (0.31)
L, l Radiator Upper Frame Center Installation Nut M8 (0.31)
M, m Fender Extension Installation nut M6 (0.24)
N, n Fender Extension Installation nut M6 (0.24)
O, o Headlight Installation Nut M6 (0.24)
BD-4 BODY DIMENSIONS － ENGINE COMPARTMENT
1512
(59.53) c
832
(32.76) 808
1587 (31.81)
N (62.48)
1505
1424 D 714 (59.25)
1689
1200 542 (56.06) (28.11) (66.50) 335
A (47.24) (21.34)
M 546 (13.19)
BD 625
B
(21.50)
1014
773
(30.43) 281
n
(24.61) 1432 (39.92)
1179 (11.06)
(56.38)
(46.42) 555 b
(21.85) m
O 1428 900 221
F 1278 (56.22) (35.43) (8.70)
365 (50.31)
(14.37)
801 1023 920 a
(31.54) (40.28) (36.22) 798
L (31.42) f o
714
G (28.11) l
E 716
K
(28.19)
934
H (36.77) g e
602
(23.70) 383
1012 (15.08)
499 562 (39.84) k
(19.65) (22.13)
560 h
(22.50)
J j
F, f
B, b
A, a E e
N, n
O, o D
M, m
Distance between points other than those above Height from Imaginary Datum Line
E-e F-f K-k M-m A - L, a - l A, a C, c H, h

855 780 1568 1401 467 646 745 278
(33.66) (30.71) (61.73) (55.16) (18.39) (25.43) (29.33) (10.94)
A - N, a - n A - l, a - L A - n, a - N B - L, b - l B - c, b - C L, l
499 1113 1511 669 1351 580
(19.65) (43.82) (59.49) (26.34) (53.19) (22.83)
B - l, b - L C - M, c - m C - O, c - o C - m, c - M C - o, c - O
1082 615 910 1580 1661
(42.60) (24.21) (35.83) (62.20) (65.39)
L - N, l - n L - n, l - N M - O, m - o M - n, m - N M - o, m - O
875 1335 297 1440 1371
(34.45) (52.56) (11.69) (56.69) (53.98)
mm
(in.) K104846E01
BODY DIMENSIONS － FRONT DOOR BD-5
FRONT DOOR
VehicleDIMENSIONS
BODY Exterior
HINT:
• Use specification *1 when performing centering measurements for the body dimensions.
from rear).
Symbol Name
Hole Diameter BD
mm (in.)
A, a Roof Panel Corner -
B, b Hood Hinge Installation Nut M8 (0.31)
C, c Front Door Hinge Installation Nut M8 (0.31)
D, d Front Door Hinge Installation Nut M8 (0.31)
E, e Front Outer Body Pillar Assembly Mark -
F, f Front Outer Body Pillar Assembly Mark -
G, g Front Outer Body Pillar Assembly Mark -
H, h Side Sill Outer Assembly Mark -
J, j Side Sill Outer Assembly Mark -
K, k Front Outer Body Pillar Assembly Mark -
L, l Rear Quarter Outer Assembly Mark -
M, m Rear Quarter Outer Assembly Mark -
N, n Front Door Lock Striker Installation Nut M8 (0.31)
O, o Front Filler Crossmember Standard Hole φ14 (0.55)
*1 Hand Brake Installation Nut M8 (0.31)
BD-6 BODY DIMENSIONS － FRONT DOOR
771
(30.35) 1091
(42.95)
B
k
a
1498
(58.98)
BD 1512
l
855
(59.53) e (33.66)
1110
(43.70)
859
(33.82)
f 1297 n
b (51.06) 892
996 (35.12)
c 507 (39.21)
(19.96) 1015
662 (39.96) 1058 m
(26.06) (41.65)
g
j
h
d
A, a
E, e, F, f, G, g,
H, h, J, j, K, k,
L, l, M, m
Distance between points other than those above
E-e F-f G-g H-h J-j K-k L-l M-m

1389 1440 1445 1465 1465 1220 1364 1441
(54.68) (56.69) (56.89) (57.68) (57.68) (48.03) (53.70) (56.73)
N-n C - N, c - n D - N, d - n E - J, e - j E - g, e - G E - h, e - H E - j, e - J E - k, e - K
1552 1247 1280 785 1546 1573 1628 1467
(61.10) (49.09) (50.39) (30.91) (60.87) (61.93) (64.09) (57.76)
E - l, e - L E - m, e - M F - J, f - j F - K, f - k F - g, f - G F - h, f - H F - j, f - J F - k, f - K
1620 1673 773 970 1474 1539 1645 1643
(63.78) (65.87) (30.43) (38.19) (58.03) (60.59) (64.76) (64.68)
F - l, f - L F - m, f - M G - K, g - k G - j, g - J G - k, g - K G - l, g - L G - m, g - M H - L, h - l
1788 1751 1198 1641 1788 1911 1789 1040
(70.39) (68.94) (47.17) (64.61) (70.39) (75.24) (70.43) (40.94)
H - j, h - J H - k, h - K H - l, h - L J - k, j - K J - l, j - L K - M, k - m K - m, k - M L - m, l - M
1509 1679 1755 1589 1625 678 1489 1500
(59.41) (66.10) (69.09) (62.56) (63.98) (26.69) (58.62) (59.06)
mm
(in.) K104847E02
BODY DIMENSIONS － FRONT DOOR BD-7
e 1132
(44.57) l BD
912 1157
(35.91) *1
(45.55)
f O
806
(31.73)
o
711 812
g (27.99) 509 579 (31.97)
(20.04) m
(22.80)
h j
E, e, F, f, G, g,
H, h, J, j, K, k,
L, l, M, m *1
o O
H - o, h - O J - o, j - O K - o, k - O
987 1025 1370
(38.86) (40.35) (53.94)
mm
(in.)
K104848E01
BD-8 BODY DIMENSIONS － LUGGAGE DOOR
LUGGAGE DOOR
VehicleDIMENSIONS
BODY Exterior
HINT:
• Point G, g and H, h on the vehicle are asymmetrical.
from rear).
BD Symbol Name
Hole Diameter
mm (in.)
A, a Roof Panel Corner -
B, b Rear Quarter Outer Standard Hole φ10 (0.39)
C, c Rear Pillar Patch/Panel Rear Center Adjoining Portion -
D, d Rear Quarter End/Rear Pillar Patch Adjoining Portion -
E, e Rear Quarter End/Rear Skirt Adjoining Portion -
F, f Rear Quarter Outer Standard Hole φ12 (0.47)
G Trim Installation Hole 8X20 (0.31X0.79)
g Trim Installation Hole 8X25 (0.31X0.98)
H, h Striker Installation Nut M12 (0.47)
J, j Rear Suspension Installation Hole φ13 (0.51)
K, k Rear Floor Pan Standard Hole φ10 (0.39)
L, l Front Outer Body Pillar Assembly Mark -
BODY DIMENSIONS － LUGGAGE DOOR BD-9
A
1017
(40.04)
a
565
1211
(22.24) BD
(47.68)
2196
(86.46) B
1831
(72.09) 1130
(44.49)
b C
1107
(43.58)
c 829 379
411 (32.64) (14.92)
(16.18) D
207 936
(8.15) K
k (36.85)
619
799 (24.37)
d (31.46) F
J
858
250 (33.78)
(9.84) 472 720 E
(18.58) (28.35) 274
j 530
(20.87) (10.79)
f e 249 G
(9.80) g
h H
D, d
B, b C, c
A, a
E, e

g G
h H
C-c F-f J-j B - C, b - c B - c, b - C
688 1495 1059 321 939 L, l
(27.09) (58.86) (41.69) (12.64) (36.97)
C-G c-G E-g E - j, e - J e-G

485 600 479 1021 454
(19.09) (23.62) (18.86) (40.20) (17.87)
G-J G-K G-j G-k g-J g-K

653 847 787 868 807 874
(25.71) (33.35) (30.98) (34.17) (31.77) (34.41)
g-j g-k H-K h-k J - K, j - k J - k, j - K

636 847 854 854 564 728
(25.04) (33.35) (33.62) (33.62) (22.20) (28.66)
mm
(in.) K104849E02
BD-10 BODY DIMENSIONS － UNDER BODY
UNDER BODY
VehicleDIMENSIONS
BODY Exterior
HINT:
• Point J, j and K, k on the vehicle are asymmetrical.
from rear).
BD Symbol Name
Hole Diameter
mm (in.)
A, a Under Cover Installation Nut M8 (0.31)
B, b Front Beam Installation Nut M8 (0.31)
C, c Side Frame Standard Hole φ18 (0.71)
D, d Front Suspension Member Installation Nut M12 (0.47)
E, e Front Suspension Member Installation Nut M12 (0.47)
F, f Lower Member Installation Nut M10 (0.39)
G, g Toe Board Reinforcement Lower Standard Hole φ25 (0.98)
H, h Front Side Frame Rear Standard Hole φ18 (0.71)
J, j Transmission Crossmember Installation Nut M10 (0.39)
K, k Propeller Shaft Installation Nut M10 (0.39)
L, l Front Floor Rear Frame Standard Hole φ13 (0.51)
M, m Side Frame Gusset Standard Hole φ13 (0.51)
N, n Rear Suspension Support Installation Nut M10 (0.39)
O, o Rear Suspension Member Installation Nut M14 (0.55)
P, p Rear Suspension Member Installation Nut M14 (0.55)
Q, q Rear Floor Frame Rear Standard Hole φ18 (0.71)
BODY DIMENSIONS － UNDER BODY BD-11
Front
LH RH
1012
(39.84)
a A
590
b (23.23) B
c
910
(35.83)
BD
1063 950 C
(41.85) (37.40)
d 880 D
672 (34.65)
(26.46) 619 B, b
870 (24.37)
e (34.25) E
1205
(47.44)
f 819 F
(32.24)
1100 Distance between points other than
g (43.31) G
277 297 those to the left
(10.91) 888 1009 (11.69)
(34.96) 856 (39.72)
h (33.70) H J-j K-k A - F, a - f
210 181 776
(8.27) (7.13) (30.55)
j J
A - f, a - F C - D, c - d C - E, c - e
986 1042 190 333
(38.82) 1299 (41.02) (7.48) (13.11)
(51.14)
C - H, c - h C - d, c - D C - h, c - H
914 915 1270
k K (35.98) (36.02) (50.00)
D - E, d - e D - e, d - E J-K
836 L 143 887 505
l (32.91) (5.63) (34.92) (19.88)
1040 261
(40.94) (10.28) J-k j-K j-k
1212
(47.72) 538 545 507
m 1225 M (21.18) (21.46) (19.96)
1222
642 (48.23) (48.11)
(25.28) 1139
n (44.84) N M - N, m - n N - O, n - o O - Q, o - q
457 1186
(46.69) 251 218 876
(17.99) (9.88) (8.58) (34.49)
1142
(44.96)
1060
o (41.73) O
1290
1121 (50.79)
(44.13) 593 807
(23.35) (31.77)
1293
(50.91)
854
p (33.62) P
901
286 (35.47)
(11.26)
854
q (33.62) Q
mm
(in.) K104850E01
HINT:
• Length measurements are indicated at the points where the arrows extending from the zero point
intersect the lines that extend towards the outside of the illustration from each point.
• Point K, k and L, l on the vehicle are asymmetrical.
from rear).
BD Symbol Name
Hole Diameter
mm (in.)
A, a Under Cover Installation Nut M8 (0.31)
B, b Front Beam Installation Nut M8 (0.31)
C, c Side Frame Standard Hole φ18 (0.71)
D, d Front Suspension Member Installation Nut M12 (0.47)
E, e Front Suspension Installation Hole φ9.5 (0.37)
F, f Front Suspension Member Installation Nut M12 (0.47)
G, g Lower Member Installation Nut M10 (0.39)
H, h Toe Board Reinforcement Lower Standard Hole φ25 (0.98)
J, j Front Side Frame Rear Standard Hole φ18 (0.71)
K, k Transmission Crossmember Installation Nut M10 (0.39)
L, l Propeller Shaft Installation Nut M10 (0.39)
M, m Front Floor Rear Frame Standard Hole φ13 (0.51)
N, n Side Frame Gusset Standard Hole φ13 (0.51)
O, o Rear Suspension Support Installation Nut M10 (0.39)
P, p Rear Suspension Member Installation Nut M14 (0.55)
Q, q Rear Suspension Installation Hole φ11 (0.43)
R, r Rear Suspension Member Installation Nut M14 (0.55)
S, s Rear Floor Frame Rear Standard Hole φ18 (0.71)
Wheel Base
Wheel Base 2570 mm (101.18 in.)
BODY DIMENSIONS － UNDER BODY BD-13
Front
LH RH
295
a (11.61) A
2033 2046
506 (80.55)
(80.04) b (19.92) B
c
455
(17.91)
1876
(73.86)
BD
C
d D
1687 440
(66.42) (17.32)
e E 1569
1544 435 627 B, b
(24.68) (61.77)
(60.79) (17.13) F
f
g G
409 1279
1230 550 (16.10) (50.35)
(48.43) (21.65)
h H
428
(16.85)
J 986
j 105 (38.82)
(4.13)
781 781
(30.75) k K (30.75)
105
(4.13)
99
(3.90)
l L 276
276
(10.87) (10.87)
77
(3.03)
0 418 418 0
(16.46) (16.46)
m M
178 606
(7.01) n (23.86) N
o O
593 429
(23.35) (16.89)
620 530
(24.41) p (20.87) P
q Q
530 991
(20.87) (39.02)
1193 427
(46.97) r (16.81)
R
427 1478
s (16.81) S (58.19)
mm
(in.) K104851E01
Front
BD
<1> <2> <3>

A, a B, b D, d F, f H, h J, j K k L l M, m N, n O, o P, p Q, q R, r S, s
C, c E, e G, g
Imaginary Datum Line
Height from Imaginary Datum Line Imaginary Datum Line
A, a B, b C, c D, d <1> <2> <3>

100 278 277 277 105 100 102
(3.94) (10.94) (10.91) (10.91) (4.13) (3.94) (4.02)
E, e F, f G, g H, h
649 277 118 119
(25.55) (10.91) (4.65) (4.69)
J, j K k L
74 177 177 164
(2.91) (6.97) (6.97) (6.46)
l M, m N, n O, o
208 75 111 113
(8.19) (2.95) (4.37) (4.45)
P, p Q, q R, r S, s
197 466 312 339
(7.76) (18.35) (12.28) (13.35)
mm
(in.) K104852E01
BODY DIMENSIONS － FRONT SUSPENSION CROSSMEMBER BD-15
FRONT SUSPENSION CROSSMEMBER

VehicleDIMENSIONS
BODY Exterior
HINT:
from rear).
Hole Diameter
Symbol Name
mm (in.) BD
A Front Suspension Crossmember Installation Hole 15X16 (0.59X0.63)
a Front Suspension Crossmember Installation Hole φ16 (0.63)
B, b Gear Box Installation Hole φ15 (0.59)
C, c Front Suspension Lower Arm Installation Hole φ12.5 (0.49)
D, d Front Suspension Lower Arm Installation Hole φ12.5 (0.49)
E Front Suspension Crossmember Installation Hole φ13.5 (0.53)
e Front Suspension Crossmember Installation Hole 12.5X16 (0.49X0.63)
F, f Gear Box Installation Hole φ14 (0.55)
BD-16 BODY DIMENSIONS － FRONT SUSPENSION CROSSMEMBER
BD
Front
LH RH
a A
880
887 (34.65)
b (34.92) B
143 c C
(5.63)
809 D
d (31.85) 526
e f F E
(20.71)
B-b C-c E-e

526 809 870
(20.71) (31.85) (34.25)
A - C, a - c D - E, d - e D - F, d - f D - f, d - F
114 104 150 669
(4.49) (4.09) (5.91) (26.34)
mm
(in.)
K104853E01
HINT:
from rear).
Hole Diameter
Symbol Name
mm (in.) BD
A Front Suspension Crossmember Installation Hole 15X16 (0.59X0.63)
a Front Suspension Crossmember Installation Hole φ16 (0.63)
B, b Gear Box Installation Hole φ15 (0.59)
C, c Front Suspension Lower Arm Installation Hole φ12.5 (0.49)
D, d Front Suspension Lower Arm Installation Hole φ12.5 (0.49)
E Front Suspension Crossmember Installation Hole φ13.5 (0.53)
e Front Suspension Crossmember Installation Hole 12.5X16 (0.49X0.63)
F, f Gear Box Installation Hole φ14 (0.55)
BD-18 BODY DIMENSIONS － FRONT SUSPENSION CROSSMEMBER
BD
Front
LH RH
440
a (17.32) A
404 113
263 (15.91) (4.45)
66 b B
(2.60) (10.35) 62
c C (2.44)
d 404 404 D
0 0
(15.91) (15.91) F
30 f 39
(1.18) e E (1.54)
435
(17.13) 263
(10.35)
mm
(in.)
K104854E02
BD
C, c E, e B, b A, a
D, d F, f
Height from Imaginary Datum Line
A, a B, b C, c D, d E, e F, f
219 94 124 124 219 94
(8.62) (3.70) (4.88) (4.88) (8.62) (3.70)
mm
(in.)
K104855E01
BD-20 BODY DIMENSIONS － REAR SUSPENSION CROSSMEMBER
REAR SUSPENSION CROSSMEMBER

VehicleDIMENSIONS
BODY Exterior
HINT:
from rear).
Hole Diameter
BD Symbol Name
mm (in.)
A, a Rear Suspension Crossmember Installation Hole φ60 (2.36)
B, b Rear Suspension Crossmember Standard Hole φ10 (0.39)
C, c Rear Suspension Lower Arm Installation Hole 14.5X25 (0.57X0.98)
D, d Rear Suspension Upper Arm Installation Hole φ13.5 (0.53)
E, e Rear Suspension Upper Arm Installation Hole φ13.5 (0.53)
F, f Rear Suspension Lower Arm Installation Hole φ12.5 (0.49)
G, g Rear Suspension Crossmember Installation Hole φ60 (2.36)
BODY DIMENSIONS － REAR SUSPENSION CROSSMEMBER BD-21
BD
Front
LH RH
a A
1060
(41.73)
821 288
(32.32) (11.34)
b 558
(21.97) B
c 786 C
(30.94)
722
d (28.43) 699
113 D
(27.52) 346 595
(4.45) (13.62) (23.43)
659
e 604 (25.94) E
(23.78)
439
f (17.28) F
854
g (33.62)
G
A - F, a - f A - f, a - F A - g, a - G C - F, c - f C - f, c - F
532 865 1122 295 657
(20.94) (34.06) (44.17) (11.61) (25.87)
mm
(in.)
K104856E01
HINT:
from rear).
Hole Diameter
Symbol Name
BD mm (in.)
A, a Rear Suspension Crossmember Installation Hole φ60 (2.36)
B, b Rear Suspension Crossmember Standard Hole φ10 (0.39)
C, c Rear Suspension Lower Arm Installation Hole 14.5X25 (0.57X0.98)
D, d Rear Suspension Upper Arm Installation Hole φ13.5 (0.53)
E, e Rear Suspension Upper Arm Installation Hole φ13.5 (0.53)
F, f Rear Suspension Lower Arm Installation Hole φ12.5 (0.49)
G, g Rear Suspension Crossmember Installation Hole φ60 (2.36)
BODY DIMENSIONS － REAR SUSPENSION CROSSMEMBER BD-23
BD
Front
LH RH
a A
530 340
(20.87) (13.39)
b B
233 279
(9.17) (10.98)
c C 143
393
109 361 (15.47) (5.63)
(4.29) d (14.21) D
330 330 0
0 (12.99) (12.99)
e E
92 220
(3.62) f (8.66) F
427 234
g (16.81) (9.21)
G
mm
(in.)
K104857E01
BD
D, d G, g B, b E, e F, f C, c A, a
Height from Imaginary Datum Line
A, a B, b C, c D, d E, e F, f G, g
130 222 159 301 300 118 247
(5.12) (8.74) (6.26) (11.85) (11.81) (4.65) (9.72)
mm
(in.)
K104858E01
BODY DIMENSIONS － ENGINE COMPARTMENT REFERENCE VALUES BD-25
ENGINE COMPARTMENT REFERENCE VALUES

VehicleDIMENSIONS
BODY Exterior
HINT:
• Measure points with the engine cover removed.
from rear).
Symbol Name
Hole Diameter BD
mm (in.)
A, a Bracket Corner Installation Bolt M6 (0.24)
B, b Headlight Installation Bolt M6 (0.24)
C, c Front Fender Installation Bolt M6 (0.24)
D, d Front Fender Installation Bolt M6 (0.24)
E, e Patch Frame Side Upper Installation Bolt M6 (0.24)
BD-26 BODY DIMENSIONS － ENGINE COMPARTMENT REFERENCE VALUES
E
D
1400
1400 (55.12)
545 (55.12)
(21.46) 902 1460
(57.48) e
(35.51)
BD C 1507
(59.33) 1444
(56.85)
d
1352
1423 (53.23)
B (56.02)
476
285 784 (18.74)
(11.22) 1360 (30.87)
1278 (53.54)
(50.31)
A 1090
(42.91) c
866 1144
(34.09) (45.04) b
C, c
E, e
A, a B, b
D, d
A - C, a - c B - C, b - c B - E, b - e B - c, b - C B - e, b - E C - E, c - e D - E, d - e D - e, d - E
361 79 671 1321 1497 606 149 1408
(14.21) (3.11) (26.42) (52.01) (58.94) (23.86) (5.87) (55.43)
mm
(in.) B1604200002
BODY DIMENSIONS － UNDER BODY REFERENCE VALUES BD-27
UNDER BODY REFERENCE VALUES

VehicleDIMENSIONS
BODY Exterior
HINT:
• Measure points with the engine under cover removed.
from rear).
Symbol Name
Hole Diameter BD
mm (in.)
A, a Plate Arm Installation Bolt M14 (0.55)
B, b Lower Member Installation Bolt M10 (0.39)
C, c Lower Member Installation Bolt M10 (0.39)
D, d Front Side Frame Rear Standard Hole φ18 (0.71)
BD-28 BODY DIMENSIONS － UNDER BODY REFERENCE VALUES
BD
A 723 a
(28.46)
845
796 (33.27) 422
(31.34) (16.61)
1150
(45.28)
B b
741
(29.17)
924
(36.38) 383
(15.08)
1016
(40.00)
954
(37.56) c
C
631 943
(24.84) 269
(37.13) (10.59)
856
D (33.70) d
A - D, a - d A - d, a - D
1052 1314
(41.42) (51.73)
mm
(in.)
K104860E01
BODY DIMENSIONS － OTHER REFERENCE VALUES BD-29
OTHER REFERENCE VALUES

VehicleDIMENSIONS
BODY Exterior
Front Beam installation
RH: LH:
A-A B B-B
A
4X M8 NUT 81
0.8 1.8 4X M8 NUT 81
0.8
1.8 BD
3.8 3.8
2.3 2.3
145.7 164.6 164.6 145.7
15.2 15.2
3 72 6 6 72 3
A B
Front Suspension installation Rear suspension installation
C
E
28.7
Ǿ 111 3 XǾ9.5 C-C 67.3 62.3 2 XǾ13 E-E
3.2
7.3 63.9 3.3 q 3.2

F F 17.9 q
Ǿ36
56.5
D D 1.8
69.3 40.6 E
C D-D F-F
4.5 q
5.9 q 26.1 36.3
6.8 0.7
7.4 2.6
mm K104861E02
BD
Vehicle Exterior
PAINTING / COATING
BODY PANEL SEALING

APPLICATION AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PC-1
BODY PANEL UNDERCOATING
BODY PANEL ANTI-RUST AGENT MATERIAL PC
SILENCER SHEET
INSTALLATION AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PC-14
BODY PANEL ANTI-CHIPPING PAINT
PC
PAINTING / COATING － BODY PANEL SEALING PC-1
BODY PANEL SEALING

Vehicle Exterior
PAINTING / COATING
APPLICATION AREAS
1. Be sure to apply body sealer to the body panel joints and door edges (tip of outer panel folded part),
etc., to waterproof and rustproof them.
HINT:
• Apply degreasing agent to a clean cloth and clean the sealer application areas.
• After removing the applied spot sealer from the sealer application areas using thinner or equivalent,
rust-proof the areas by applying primer or equivalent. Then apply body sealer.
• If sealer is unnecessarily applied to an area, apply degreasing agent to a clean cloth and clean off
the body sealer immediately.
PC
Flat Finishing No Flat Finishing
K105237
PC-2 PAINTING / COATING － BODY PANEL SEALING
PC
K104839
PC
B1604190001
a
a
PC
a-a
B1604190002
PC
B1604190003
PC
B1604190004
PC
LH:
RH:
B1604190022
PC
K104844
PC
K104845
PC-10 PAINTING / COATING － BODY PANEL UNDERCOATING
BODY PANEL UNDERCOATING

Vehicle Exterior
PAINTING / COATING
APPLICATION AREAS
CAUTION:
Work must be performed while wearing the appropriate protective gear and in a well-ventilated
area.
NOTICE:
Do not coat high temperature areas, such as the tailpipe, or moving parts, such as the drive shaft.
1. Apply undercoating to the chassis, floor underside, sheet metal fitting weld points of the body, and
inside of the wheel house to prevent rust and noise, as well as protect the body from gravel.
HINT:
PC • Apply degreasing agent to a clean cloth and clean any dirt and oil from the application areas.
• Cover the surrounding areas of the application areas with masking paper to avoid coating
unnecessary areas.
• Do not leave any gaps between the panel joints.
• Apply body sealer to the panel joints in advance.
• Referring to the notes above, undercoating should be applied according to the specifications for
your country.
LH:
RH:
B1604190007
PAINTING / COATING － BODY PANEL ANTI-RUST AGENT MATERIAL PC-11
BODY PANEL ANTI-RUST AGENT MATERIAL

Vehicle Exterior
PAINTING / COATING
APPLICATION AREAS
1. Apply anti-rust agent (wax) to the doors and hood edges (tips of outer panel folded parts) and
undersides, areas around hinges, etc., to prevent rust. Coat the undersides of the edges using a
nozzle and air gun, and coat the areas around the hinges using a brush.
HINT:
If anti-rust agent (wax) is unnecessarily applied to an area, apply degreasing agent to a clean cloth and
clean off the anti-rust agent (wax) immediately.
PC
a <1>
b
a
<2>
b
a-a
<1>
b-b
<2>
B1604190008
PC-12 PAINTING / COATING － BODY PANEL ANTI-RUST AGENT MATERIAL
PC
FF

B1604190009
PAINTING / COATING － SILENCER SHEET PC-13
SILENCER SHEET
Vehicle Exterior
PAINTING / COATING
INSTALLATION AREAS
PC
Thickness of Silencer Sheet mm (in.)
3.0 (0.118)
4.0 (0.157)
B1604190010
PC-14 PAINTING / COATING － BODY PANEL ANTI-CHIPPING PAINT
BODY PANEL ANTI-CHIPPING PAINT

Vehicle Exterior
PAINTING / COATING
APPLICATION AREAS
CAUTION:
Work must be performed while wearing the appropriate protective gear and in a well-ventilated
area.
1. To protect the body from damage due to gravel, apply the anti-chipping paint to the rocker panels, roof
panel, front body pillar, doors, wheel arches and hood.
HINT:
• Apply anti-chipping paint to the indicated areas first, before applying the top coat.
• If anti-chipping paint is unnecessarily applied to an area, apply degreasing agent to a clean cloth
PC and clean the paint off immediately.
b
b
c
c
a
d
a
a-a
c-c
b-b
Soft-Chipping Primer Protection Tape
Anti-Chipping Paint
(Intermediate Coat)
d-d
B1604190011

BRZ Body L4440BEV0

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VehicleExterior INTRODUCTION IN

BODY WELD POINT WP

HOW TO USE THIS MANUAL IN

HOW TO USE THIS MANUAL

5. INTERNATIONAL SYSTEM OF UNITS

CUT AND JOIN

CUT WITH DISC

SPOT WELD OR PLUG

REPAIR AREA INDICATOR REPAIR METHOD INDICATOR

ASSEMBLY STANDARD HOLE FOR

ILLUSTRATION OF WELD POINT SYMBOLS

WORK NOTICES AND PRECAUTIONS

WHEN REPAIRING THE VEHICLE BODY

(b) If it is necessary to use a flame in the area of the

3. SAFETY WORK CLOTHES

PRECAUTIONS FOR REPAIRING BODY STRUCTURE (INCLUDING

3. WHEN TO REPLACE FRAME PARTS

4. REPAIR OF DOOR SIDE IMPACT BEAM IS

5. REPAIR OF BUMPER REINFORCEMENT IS

PRECAUTIONS FOR WELDING

3. ANTI-RUST TREATMENT BEFORE WELDING

Weld work for 980 MPa ultra high strength steel

Plug welding Plug diameter 8 mm (0.31 in) or more

Avoid welding over previously welded areas.

5. MAKING HOLES FOR PLUG WELDING

(a) For areas where a spot welder cannot be used, use

ANTI-RUST TREATMENT AFTER INSTALLATION OF BODY

3. VEHICLE BODY ANTI-RUST AGENT APPLICATION

PRECAUTIONS FOR SRS AIRBAG SYSTEM

Seat belt pretensioner (RH)

Seat belt pretensioner (LH)

Curtain airbag sensor (LH)

Side airbag sensor (LH)

Front sub sensor (LH)

Front door impact sensor (LH)

Front sub sensor (RH)

Front door impact sensor (RH)

Curtain airbag module (RH)

Side airbag module (RH)

Side airbag module (LH)

Curtain airbag module (LH)

PASSENGER’S AIRBAG MODULE

FRONT SEAT ASSEMBLY RH

SATELLITE SAFING SENSOR

FRONT SEAT INNER BELT

FRONT SEAT ASSEMBLY RH

OCCUPANT DETECTION ECU)

NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP

(b) Pantograph jack

(e) Plate lift

(f) Jack-up point (When using a garage jack)

Trunk floor mat

Trunk side tray LH

Rear bumper reinforcement No. 2

Trunk trim cover INN LH

Rear bumper cover x2

Back-up light ASSY

N*m {kgf*cm, ft*lbf} : Tightening torque

Rear bumper side retainer RH

Rear bumper side bracket RH

Nm {kgfcm, ft*lbf} : Tightening torque

Nm {kgfcm, ft*lbf} : Tightening torque Steering wheel ASSY

Nm {kgfcm, ft*lbf} : Tightening torque

Nm {kgfcm, ft*lbf} : Tightening torque

Nm (kgfcm, ft*lbf) : Tightening torque

Nm {kgfcm, ft*lbf} : Tightening torque