PREFACE
This manual covers information about and instructions for repairing SAFRANE’s body structures
and replacing its body parts. For quick and accurate service, please utilize this manual to the utmost, along with other related information. This manual is based upon models produced in July
2008. As changes are made to newer models, there will be differences between this manual and the
newer models’ manuals. There may be changes in specifications and methods at any time without
notice.
This manual adopts SI unit as its units of measurement. Other units of measurement are shown in
( ) or { } too for your reference.
CAUTION
SI unit is an abbreviation of Systeme International d Unites in French. It is also called International Systems of Units in English and is the most widely used system of units in
the world.
Warning
Changing or altering devices or electric wiring systems may:
• Cause malfunctions or even catch fire because of short lines or too high levels of current.
• Exclude warranty coverage offered by Renault.
When dissembling or assembling critical parts, such as the engine or brake system, the work
must be performed by qualified technicians in a certified or licensed service shop.
Please contact a near Renault Auto-station for servicing the vehicle or replacing its parts.
2008
Without Renault’s permission, this manual or its section(s) should not be copied or revised.
© Renault Motors
1
CONTANTS
1. Body Construction..........................................................................................................4
2. Touch-up Products .......................................................................................................12
3. Plastic Materials............................................................................................................14
4. Body Sealing .................................................................................................................16
5. Corrosion Protection ....................................................................................................19
6. Wheel Alignment...........................................................................................................21
7. Body Alignment ............................................................................................................22
8. Parts Replacement........................................................................................................32
8-1. Hoodledge Panel (Replacement) ................................................................................................ 34
8-2. Hoodledge Panel (Partial Replacement).....................................................................................36
8-3. Front Side Member (Replacement)............................................................................................. 38
8-4. Front Side Member (Partial Replacement).................................................................................. 39
8-5. Front Pillar (Replacement) .......................................................................................................... 40
8-6. Center Pillar (Replacement)........................................................................................................ 43
8-7. Seal Outer (Replacement) .......................................................................................................... 45
8-8. Rear Fender (Replacement) ....................................................................................................... 48
8-9. Rear Wheelhouse Outer (Replacement)..................................................................................... 50
8-10. Rear Panel (Replacement)........................................................................................................ 52
8-11. Rear Floor Rear (Replacement) ................................................................................................ 53
8-12. Rear Side Member (Replacement) ........................................................................................... 54
8-13. Rear Side Member Extension (Replacement)........................................................................... 56
8-14. Roof Panel (Replacement)........................................................................................................ 57
9. Service Parts .................................................................................................................58
9-1. Underbody................................................................................................................................... 58
9-2. Body Side & Roof........................................................................................................................ 60
3
1. BODY CONSTRUCTION
1. Body Construction
1-1. Body Construction
SM7-4001
Front pillar upper hinge brace
Dash upper
Cowl top side
Front pillar upper
hinge brace
Hinge upper
plate
Wheel side adapter
Hoodledge reinforcement
Front pillar
inner upper
Body side
outer
Section A-A
Section B-B
Hinge lower plate
Dash lower
Front pillar lower
reinforcement
Dash side
Dash side Front pillar lower
hinge brace
Body side outer
Seal inner
Dash lower rear
Front pillar lower
hinge brace
Front floor
Seal outer
reinforcement
Body side outer
Front side member
outer rear
Section C-C
Section D-D
4
1. BODY CONSTRUCTION
Center pillar reinforcement
Center pillar inner
Body side outer
Seal inner
Seal inner
reinforcement
Center pillar lower
hinge brace
Seal outer
reinforcement
Body side outer
Front floor
Section E-E
Section F-F
Center pillar
lower brace
Center pillar inner
Seal outer reinforcement
Center pillar
hinge brace
Hinge lower plate
Seal inner
Body side outer
Seal inner
reinforcement
Body side outer
Section G-G
Section H-H
Rear wheelhouse
outer extension
Rear side member
reinforcement
Rear wheelhouse
outer extension
Front floor
Rear pillar inner
Body side outer
Rear side member
Seal inner
reinforcement
Seal inner
extension
Seal outer
reinforcement
Rear fender
Section I-I
Section J-J
Rear wheelhouse inner
Rear pillar inner
Rear wheelhouse outer
Rear fender
Rear fender
Section K-K
Section L-L
5
1. BODY CONSTRUCTION
1-2. Body Center Marks
The center of the vehicle is marked on each of the major body parts of the vehicle.
When repairing body parts damaged by an accident which might have twisted the vehicle
members or pillars, more accurate and effective repair will be possible by using these marks
along with information from Chapter 7. Body Alignment.
SM7-6001
(Embossing)
(Protruding Flange)
(Hole)
Front
SM7-6002
1) Dash Upper
Front
SM7-6003
2) Roof Front End
Front
SM7-6004
3) Front Floor
Front
Front
Front
(Center)
(Embossing)
(Embossing)
SM7-6006
SM7-6005
4) Roof Rear End
5) Rear Waist
SM7-6007
6) Rear Panel
6
1. BODY CONSTRUCTION
1-3. Matching Marks for Panel Parts
Corresponding parts have matching marks for easy and efficient replacement.
Type A
(Hole ~ Hole)
Type D
(Hole ~ Embossing)
Type B
(Indention ~ Hole)
Type E
(Indention ~ Indention)
Type C
(Indention ~ Embossing)
Type F
(Indention ~ Protruding flange)
(1) Front section
Front
Front
SM7-7002
SM7-7001
(2) Rear section
(3) Rear section
Front
Front
SM7-7004
SM7-7003
Front
Front
SM7-7006
SM7-7005
7
1. BODY CONSTRUCTION
1-4. Measurements
Hood
A
D
12.7 {1.3}
B
C
Hood lock
Bolt
Dimensions
2. Nuts
3. Hood lock
8
23.6 {2.4}
SNRD023_D1
A : 2.5 ~ 4.5
B : 2.5 ~ 6.5
C : 2.5 ~ 6.5
D : 4.0 ~ 8.0
Unit : mm
: MP Special grease
: N.m {kgf-m}
1. Hood hinge
: Apply grease
: N.m {kgf-m}
4. Bolts
1. BODY CONSTRUCTION
Door
Front door upper and lower hinges
5
A
B
A
C
B
C
A
20.6 {2.11}
Rear door upper hinge
Dimensions
3
1
20.6 {2.11}
7
4
8
Rear door lower hinge
3.6 ~ 5.6
3.6 ~ 5.6
3.6 ~ 5.6
9
2
Section A-A
Section B-B
Section C-C
Unit : mm
: N.m {kgf-m}
1. Front fender
2. Front door outer panel
3. Rear door outer panel
6
4. Rear fender
5. Front door hinges
6. Bolts
9
20.6 {2.11}
7. Nuts
8. Rear door hinge (Upper)
9. Rear door hinge (Lower)
1. BODY CONSTRUCTION
Trunk Lid
5.1 {0.52}
13.5 {1.4}
Adjustment (Striker section)
Dimensions
1
1
3.0 ~ 5.0
1
4.0 ~ 7.0
2
Section A-A
3
Section B-B
4
Section C-C
Unit : mm
: N.m {kgf-m}
1. Trunk lid assembly
2. Rear fender
3. Combination lamps
4. Rear bumper fascia
5. Trunk lid hinge
6. Bolts
10
7. Trunk lid striker
8. Bolts
5.0 ~ 9.0
1. BODY CONSTRUCTION
1-5. Locations of Fusible Insulator
Fusible insulators (melting sheets) are installed on the floor surface and dash panels°Ø inside
to block noise, dust and heat from the exhaust system.
: Indicates where fusible insulators need to be installed.
[Symmetrically identical
on both sides]
t = 4.0mm
[Symmetrically identical
on both sides]
t = 4.0mm
t = 2.0mm
[Symmetrically identical
on both sides]
[Symmetrically identical
t = 3.0mm
on both sides]
t = 3.0mm
t = 2.0mm
t = 2.0mm
t = 1.6mm
t = 1.6mm
[Passenger Vehicle]
t = 4.0mm
[Symmetrically identical
on both sides]
t = 4.0mm
t = 3.0mm
t = 2.0mm
[Symmetrically identical
on both sides]
t = 2.0mm
[Symmetrically identical
on both sides]
t = 2.0mm
[Taxi]
SM7-1101
CAUTION
Cut the fusible insulators on the floor panel according to the measurements shown in the
table below.
Pressure reducing type fusible insulators
mm
G5930-89904
500 x 1,000 x 1.5t
G5930-89905
500 x 1,000 x 3.0t
G5930-89906
500 x 1,000 x 6.0t
11
2. TOUCH-UP PRODUCTS
2. Touch-up Products
2-1 Touch-up Products
When repairing the vehicle body, use only the touch-up products shown in the table below.
Item
Product Name
Part
number
Application
Type
Amount
Manufacturer
Bumper
primer
Plastic primer
934-0
Primer for bumper
painting
Can
1ℓ
BASF
GLASURIT
Electropainting primer
ZINCOT
N-50
Anti-corrosive agent
for welded surface
Aerosol
420 mℓ
Nambang
Chemistry
Nr.892-081
Anti-corrosive agent
for panel connecting
areas and welded surfaces after replacing
parts
Can
1000 mℓ
WURTH
Anti corrosion wax
Inner wax
Texture
Stone guard
coat
Nontexture
Black 1109-1240-4
Gray 1109-1240-6
Fixing stone guard
coat
Aerosol 1000 mℓ
BASF
GLASURIT
Fixing undercoat
Aerosol 1000 mℓ
WURTH
Nr.08930751
Undercoat
WURTH
Sealing
Scotch-Seal
5300
Etching primer
filler
283-150
KA38389910
Sealing for hemmed
areas of inner and
outer panels
Can
310 mℓ
Can
Base 1,
Hardener 1
Primer for
anti-corrosion
Anti-corrosion primer
Primer filler
285-16
Can
12
Base 4,
Hardener 1
3M
BASF
GLASURIT
2. TOUCH-UP PRODUCTS
2-2 Foaming Agent
1. Using form kit urethane
To fix sealing materials, use foam kit urethane.
Before performing filling service, read usage instructions for a forming agent.
2. Filling service
(1) Filling service before installing new parts
1) Remove a remaining forming agent on the vehicle.
2) When removing silicon residuals from where a part was removed, ensure that there
will be no more residual.
3) Apply a foaming agent to the wheelhouse outer side (See Picture 1).
Warning: Avoid flange sections and fill up the space between parts.
4) Install necessary parts.
Warning: Since a foaming agent will harden in 2 or 3 minutes after being exposed,
install new parts quickly.
Picture 1. Rear wheelhouse outer section (use a hole from inside)
Foaming agent
Nozzle hole
Front
(2) Filling service after installing new parts
1) Remove a remaining forming agent on the vehicle.
2) When removing silicon residuals from where a part was removed, ensure that there
will be no more residual.
3) Install necessary parts. (See Picture 2).
4) Insert the tip of the nozzle into the hole and apply the agent (See picture 1). Or fill up
gaps between parts with the agent.
Picture 2.
Avoid flange sections and
apply the foaming agent.
Foaming agent
Front
13
3. PLASTIC MATERIALS
3. Plastic Materials
3-1. Precaution with handling plastic materials
Abbreviation
Material name
Heat resisting
temperature
(°C)
Resistance to gasoline
and solvent
Other
cautions
PE
Polyethylene
80
Gasoline and most solvents are
harmless.
Flammable
Poisonous
Gasoline and most solvents are
gases are emitharmless if applied for a very short
ted when
time (wipe up quickly).
burned
PVC
Polyvinyl chloride
90
EPDM
Ethylene Propylene (diene)
rubber
120
Avoid flammable and
solvent materials
PP
Polypropylene
90
Gasoline and most solvents are
harmless
ABS
Acrylonitrile Butadiene
Styrene Dipolymer
90
Avoid gasoline and solvents
EVAC
Ethylene Vinyl Acetage
90
Gasoline and most solvents are
harmless
PMMA
Polymethylmethacrylate
90
Avoid gasoline and solvents
PUR
Poly Urethane
90
Gasoline and most solvents are
harmless
ASA
Acrylonitrile Styrene Acrylate
100
Avoid gasoline and solvents
Flammable
PPE
Poly Phenylene Ethylene
110
POM
Poly Acetal
120
Gasoline and most solvents are
harmless.
Avoid battery
acid
PC
Poly Carbonate
120
Avoid gasoline and solvents.
PA
Polyamide (nylon)
150
Gasoline and most solvents are
harmless.
PBT
Poly Butylene Terephthalate
140
Gasoline and most solvents are
harmless.
TPP
Thermo Plastic Rubber
80
Avoid gasoline and solvents.
CAUTION
Flammable
Avoid brake
fluid
Avoid brake
fluid
Avoid water
1. When repairing or painting a portion of the body adjacent to plastic parts, consider
their chemical reactions to heat and solvent. If necessary, remove them or take protective measures during the repair.
2. Plastic parts should be repaired or painted according to their chemical characteristics.
14
3. PLASTIC MATERIALS
3-2. Locations of Plastic Parts
Roof side molding
(PVC)
Windshield molding
(PVC)
Roof drop molding
(PVC + Stainless)
(
Front grille
(ABS)
Door mirror
Housing: ABS
Base: PA
)
Door outside molding
(PVC + Stainless)
Front bumper
(PP)
(
Door side molding
(PP)
Front fog lamp
Lens: glass
Housing: PBT + PSA
Side turn signal lamp
Lens: PMMA
Housing: ABS
(
)
Front turn signal lamp
Lens: PC
Housing: PC
(
(
)
Headlamp
Lens: PC
Housing: PP
)
SM7-1501
Rear window molding
(EPDM)
Rear combination signal lamp
Lens: PMMA
Housing: ABS
(
)
Door outside handle
(PC + PET)
Trunk lid finisher
(ABS)
Door side molding
(PP)
Mud guard center
(PP)
Wheel disk cap
(PC + ABS)
Personal lamp
Lens: PC
Housing: PP
(
)
)
License plate
Lens: PC
Housing: PC
(
Rear bumper
(PP)
)
SM7-1502
Center pillar garnish
(PP)
Front pillar garnish
(PP)
Map lens
Lens: PC
Finisher: PP
(
Rear pillar garnish
(PP)
)
Cluster lid
(PP)
Instrument panel
(PP)
Cluster lid
(PC + ABS)
Console lid
(PP)
Console body
(ABS)
A/T finisher
(ABS)
15
Glove box
(PP)
SM7-1503
4. BODY SEALING
4. Body Sealing
Trunk lid
Hood
Q
H
N
F
J
G
M
K
B
I
D
L
A
C E
P
O
Rear door
Front door
SM7-1601
Unit: mm
Indicates where sealing must be applied.
Section A
Front
280
30
Section B
130
50
620
100
200
300
300
500
350
460
110
180
660
Front
SM7-1602
16
SM7-1603
4. BODY SEALING
Indicates where sealing must be applied.
Unit: mm
Section C
Section D
1100
1710: Right
2020: Left
Front
Front
650
320
40
80
200
SM7-1701
Section E
SM7-1702
Section F
1720
Front
230
140
Front
200
SM7-1703
Section G
SM7-1704
Section H
Front
810
300
Front
540
400
150
SM7-1705
Section I
SM7-1706
Section J
980
1440
560
Front
190
1600
330
220
430
1670
200
550
360
650
Front
SM7-1707
17
SM7-1708
4. BODY SEALING
Indicates where sealing must be applied.
Unit: mm
Section K
Section L
200
Front
530
Front
A
300
450
Cross section A-A
160
1050
A
850
1500
1600
SM7-1801
Section M
SM7-1802
Section N
In case of a hemming section,
apply sealing on its corresponding
part during service.
460
580
1560
1150
Front
SM7-1804
SM7-1803
Section O
Section P
In case of a hemming section,
apply sealing on its corresponding
part during service.
In case of a hemming section,
apply sealing on its corresponding
part during service.
100
170
220
150
100
140
210
SM7-1807
Section Q
In case of a hemming section,
apply sealing on its corresponding
part during service.
20
20
SM7-1807
18
160
SM7-1806
5. CORROSION PROTECTION
5. Corrosion Protection
5-1. Stone Guard coating application locations
Indicates where Stone Guard coating needs to be applied.
A
A
A
A
350mm
500mm
SM7-1901
60 mm
Stone Guard coating
application area
Section A-A
SM7-1902
19
5. CORROSION PROTECTION
5-2. Undercoating application locations
Indicates where Stone Guard coating needs to be applied.
SM7-2001
CAUTION
1. Before applying undercoating, apply sealing on the vehicle body first.
CAUTION
2. Do not apply undercoating to the following areas.
• Muffler, catalytic converter or exhaust manifold which is subjected to heat
• Brake hose and tube connection areas
• ABS unit and harness installation areas
• Pipe installation areas
• Radiator rod, rear stabilizer, and parville universal joint installation areas
• Sub frame and rear suspension bolts
20
6. WHEEL ALIGNMENT
6. Wheel Alignment
(1) Measurement and adjustment with a 4-wheel alignment tester
<Type and severity of accident>
• The vehicle equipped with alignment device in suspension structure has been damaged at suspension, body structure, or inner panels.
• Customer ordered a specific repair.
• Frontal or rear impact, direct damage at front or rear wheels, staggered wheels
(2) Front wheel alignment (when unloaded)
Item
Camber
Desirable range
Lower range
Upper range
-0° ~ 20'
1° ~ 05'
0° 25'
2° ~ 50'
2° ~ 20'
3° 35'
14° ~ 40'
13° ~ 55'
15° 25'
2WD
Caster
Kingpin inclination (Reference)
2WD
Toe-in
2WD
(in) 1.7 mm ~ 0.3 mm
Side slip (Reference)
(in) 5 mm ~ 5 mm
(3) Rear wheel alignment (when unloaded)
<VQ23 engine equipped vehicle>
Item
Desirable range
Lower range
Upper range
Camber
-0° 40'
-1° 11'
0° 11'
Toe-in
(in) 4.4 mm~1.2 mm
21
7. BODY ALIGNMENT
7. Body Alignment
7-1. Projected Dimensions of Underbody (mm)
b
e
c d
a
16
k
16
70
952
952
18
932
45
61
15
1020
127
0
1330
857
02
12
857
620
1097
990
988
4
116
4
88
Front
1703
j
i
f
06
Right
h
g
I
J
K
Vehicle
center line
Left
F
A
C D
G
H
E
B
RH493, LH486
RH837, LH843
398
483
RH791, LH785
RH1320, LH1314
338
227
152
167
95
95
72
789
136
357
RH1438, LH1432
337
1052
1220
1470
Baseline
C D
c d
E
e
F
f
A
a
G
g
B
b
H
h
I
i
J
j
K
k
SM7-2201
CAUTION
Only one dimension is shown when both sides are symmetrically identical.
Unit: mm
A ~ a
[Longitudinal measures]
Measuring
points
Standard
dimensions
A ~ C
1432
1314
785
486
843
1438
1320
791
493
837
398
483
1052
1220
1470
A ~ D
A ~ E
A ~ F
A ~ G
a ~ c
a ~ d
a ~ e
a ~ f
a ~ g
B ~ G
B ~ H
B ~
I
B ~ J
B ~ K
B ~ b
D ~ d
[Width]
Measured
dimensions
Measuring
points
C ~ c
D ~ c
d
E ~ e
F ~ f
A ~ a
G ~ g
B ~ b
H ~ h
I ~ i
J ~ j
K ~ k
Centering gauge installation points
G~ g
J ~ j
[Diagonal measures]
Standard
dimensions
988
990
1097
620
857
857
1330
1020
932
952
952
Measured
dimensions
Measuring
points
Standard
dimensions
A ~ c
1703
1606
884
1202
1708
1611
888
1198
1164
1270
1545
1670
1861
A ~ d
A ~
f
A ~ g
a ~ C
a ~ D
a ~ F
a ~ G
B ~ g
B ~ h
B ~
B ~
i
j
B ~ k
22
Measured
dimensions
7. BODY ALIGNMENT
A c F f points: end of the front suspension member installation bolts
D d points: front side member base holes
E e points: center of the front thrust installation hole
Front
Front
f
E
d
c
SM7-2301
SM7-2302
a point: center of the front side member extension center base hole
G g points: center of the front side member extension rear base hole
A point: center of the front side member extension center base hole
g
a
A
Front
Front
SM7-2303
A point: center of the front side member extension center base hole
SM7-2304
I point: end of the rear suspension member installation bolt
J K points: center of the rear suspension member extension base hole
I
J
Front
K
Front
i
j
SM7-2305
J31-JA06
point: end of the rear suspension member installation bolt
k points: center of the rear suspension member extension base hole
j
Front
i
k
SM7-2307
23
7. BODY ALIGNMENT
7-2. Underbody
Straight dimensions (mm)
b
e
c d
h
g
a
j
i
k
f
Vehicle
center
line
Right
Front
Left
F
A
C D
G
E
H
I
J
K
H
h
I
i
J
j
K
k
B
Baseline
C D
c d
E
e
F
f
A
a
G
g
B
b
SM7-2401
CAUTION
Unit: mm
Only one dimension is indicated for symmetrically identical dimensions on both sides.
Centering gauge installation points
[Longitudinal measures]
Measuring
points
Standard
dimensions
A ~ C
1432
1339
487
843
1440
1347
507
837
404
483
1054
1232
1480
A ~ D
A ~ F
A ~ G
A ~ c
a ~ d
a ~ f
a ~ g
a ~ G
a ~ H
B ~
I
B ~ J
B ~ K
[Width]
Measured
dimensions
Measuring
points
C ~ c
D ~ c
d
E ~ e
F ~ f
A ~ a
G ~ g
B ~ b
H ~ h
I ~ i
J ~ j
K ~ k
[Diagonal measures]
Standard
dimensions
988
990
1097
620
857
857
1330
1020
932
952
952
Measured
dimensions
Measuring
points
A ~ c
A ~ d
A ~ g
A ~ g
a ~ C
a ~ D
a ~ F
a ~ G
B ~ g
B ~ h
B ~
i
B ~
j
B ~ k
24
Standard
dimensions
1703
1709
1627
884
888
1202
1709
1632
888
1198
1166
1271
1546
1679
1869
Measured
dimensions
7. BODY ALIGNMENT
A c F f points: end of the front suspension member installation bolts
D d points: front side member base holes
E e points: center of the front thrust installation hole
Front
Front
f
E
d
c
SM7-2501
SM7-2502
a point: center of the front side member extension center base hole
G g points: center of the front side member extension rear base hole
A point: center of the front side member extension center base hole
g
a
A
Front
Front
SM7-2503
B b points: center of the rear side member installation base hole
H h points: end of the rear suspension member installation bolt
SM7-2304
I point: end of the rear suspension member installation bolt
J K points: center of the rear suspension member extension base hole
I
J
Front
K
Front
i
j
SM7-2505
J31-JA06
point: end of the rear suspension member installation bolt
k points: center of the rear suspension member extension base hole
j
Front
i
k
SM7-2507
25
7. BODY ALIGNMENT
7-3. Engine Compartment
57
8
4746
DF_LF_0001
CAUTION Only one dimension is shown when both sides are symmetrically identical.
Unit: mm
[Longitudinal measures]
Measuring
points
Standard
dimensions
A ~ B
734
519
774
870
547
579
701
739
1455
1233
316
301
A ~ C
A ~ D
A ~ E
A ~ F
A ~ f
A ~ G
A ~ g
B ~ b
B ~ c
b ~ c
B ~ D
[Other measures]
Measured
dimensions
752
Measuring
points
B ~ e
b ~ c
e
C ~ c
D ~ d
D ~ e
E ~ e
F ~ f
G ~ g
H ~ h
H ~ i
I ~ i
Standard
dimensions
Measured
dimensions
1534
546
976
1449
245
1413
945
969
1124
1132
1124
1532
26
216
935
980
Measuring
points
Standard
dimensions
Measured
dimensions
7. BODY ALIGNMENT
A point: dash upper flange section (Vehicle center)
B b D d E e points: center of the front fender installation holes
C c points: center of the front side member base hole
C
B Left
Right
D
A
Front
E
Front
SM7-2702
SM7-2701
f point: center of the front side member measuring hole
g point: center of the engine mounting bracket installation hole
F point: center of the harness clip installation hole
G point: center of the engine mounting bracket installation hole
Front
Front
F
g
G
SM7-2704
SM7-2703
H h
I
i points: center of the bumper installation hole
H
Front
f
I
SM7-2705
27
7. BODY ALIGNMENT
7-4. Body Side
SM7-2801
CAUTION Only one dimension is shown when both sides are symmetrically identical.
Unit: mm
[Longitudinal measures]
[Rear door opening] [Other straight dimensions]
Measuring Standard
points dimensions
Measuring Standard
points dimensions
I ~ J
Measuring Standard
points dimensions
E ~ e
N ~
l
A ~ h
I ~ K
F ~
N ~
i
A ~ h
I ~ L
f
G ~ g
N ~ J
A ~
J ~ K
H ~ h
N ~
B ~ k
i
j
N ~ K
B ~
N ~ k
C ~ k
C ~ D
K ~ k
N ~ L
C ~
I
C ~ d
L ~
l
N ~
C ~
I
D ~ d
M ~ E
E ~
Measuring Standard
points dimensions
Measuring Standard
points dimensions
A ~ B
E ~ F
A ~ C
E ~ G
A ~ D
E ~ H
B ~ C
F ~ G
Measuring Standard
points dimensions
B ~ D
F ~ H
J ~ L
I ~
C ~ C
G ~ H
K ~ L
J ~
M ~ F
M ~ G
M ~ H
28
j
I
j
I
f
E ~ g
D ~ Q
E ~ h
F ~ g
C ~ Q
C ~ R
D ~ R
7. BODY ALIGNMENT
B point: ending section of the roof flange location mark (vehicle center)
C c points: front pillar end
A point : dash upper flange section (Vehicle center)
Front
B
A
C
Front
SM7-2902
SM7-2701
E e F f points: center of the front pillar indention
O o P p points: center of the door hinge installation nut hole
D d point : front pillar end
Front
E
D
O
P
Front
F
SM7-2903
SM7-2904
G g H h I i J j points: center of the front pillar indention
Q q R r points: center of the door hinge installation nut hole
K k L
K
I
G
Q
H
Front
J
Front
R
SM7-2905
L
SM7-2906
M point : center of the transmission control reinforcement base hole (vehicle center)
N point : center of the transmission control reinforcement base hole
N
M
Front
l points: end of the rear fender flange
SM7-2907
29
7. BODY ALIGNMENT
7-5. Rear Body
SM7-3001
CAUTION Only one dimension is shown when both sides are symmetrically identical.
Unit: mm
[Rear window opening measures]
Measuring
points
A ~ B
A ~ C
B ~ D
B ~ b
B ~ C
B ~ c
B ~ D
C ~ c
C ~ D
Standard
dimensions
554
874
808
1103
644
1326
993
1217
638
[Trunk room opening measures]
Measured
dimensions
Measuring
points
D ~ E
D ~ F
D ~ G
E ~ e
E ~ F
E ~ f
E ~ G
F ~ f
F ~ G
30
Standard
dimensions
501
642
530
997
404
1036
692
912
463
Measured
dimensions
7. BODY ALIGNMENT
C c points: end of rear fender
D point: end of the rear waist flange indention mark (vehicle center)
A point : end of the roof flange mark (vehicle center)
B b point : end of rear fender
Front
Front
C
b
A
D
SM7-3102
SM7-3101
E e point : end of the rear fender corner
F f point : end of the rear combination lamp base
e
G point : rear panel upper reinforcement measuring point
(vehicle center)
Front
G
Front
f
SM7-3104
SM7-3103
31
8. PARTS REPLACEMENT
8. Parts Replacement
(1) This section describes cautions necessary for replacing parts surely and efficiently. For installation or removal procedures, refer to Body Repair Manual.
(2) Symbols and numbers in brackets indicate welding methods and numbers of welding
points.
Illustration: example
Drilling a plug welding hole
on a service part according
to its body side hole
1(S/A)
3
2
Front
3
5(S)
1(S)
Indicates the welding operations at inner side
Number of welding points
Drilling a plug welding hole
on a service part
D Section
(3) Anti-corrosive wax should be coated on the welded area after panel replacement.
32
8. PARTS REPLACEMENT
(4) Symbols for cutting, welding or brazing operation
2-spot welding
2-spot welding
Spot
welding
3-spot welding
3-spot welding
MIG plug welding
MIG
welding
MIG seam welding
Brazing
(S)
Drilling a plug welding hole on a service part
(S/A)
Drilling a plug welding hole on a service part according to its corresponding body side hole
33
8-1. HOODLEDGE PANEL (REPLACEMENT)
• Installation
CAUTION
For easy installation, remove the front side member closing plate.
2(S)
Cassette hoodledge reinforcement
7
10(S/A)
4(S/A)
4(S)
1(S)
1(S/A)
3
10 (S)
Hoodledge
Extension
7(S)
1(S)
5(S/A)
6(S)
4
Front
5
2-spot
welding
3-spot
welding
Plug
welding
Section A
Arc seam
welding
Brazing
Drilling a plug welding hole
on a service part
Service part
(S)
Service part
(S/A)
[Replacing parts]
Hoodledge assembly (LH)
Hoodledge reinforcement (LH)
Front side member crossing plate (LH)
34
Hoodledge reinforcement rear (LH)
(S/A)
8-1. HOODLEDGE PANEL (REPLACEMENT)
Front
Front
3(S/A)
3(S)
Section B
6
Section C
After removing the hoodledge reinforcement
1
Front
3
1
2
2(S)
4(S)
Section D
1(S)
4(S)
2(15 mm X 2)
Front
1(S/A)
1(S/A)
4(S)
1(S)
1(S)
1(S)
2(S)
Front
Section E
1(S/two-side plug)
5
3(S)
7
Section F
35
8-2. HOODLEDGE PANEL (PARTIAL REPLACEMENT)
• Installation
CAUTION
For easy installation, remove the front side member crossing plate, which will be
reused.
6
10
4(S/A)
1
3(S/A)
3
1
1
5
1
1
5
7
6
1
4
After removing the front side member crossing plate
Front
1
Section A
2-spot
welding
3-spot
welding
Plug
welding
Arc seam
welding
Brazing
Drilling a plug welding hole
on a service part
Service part
(S)
[Replacing parts]
Hoodledge assembly (LH)
Hoodledge reinforcement (LH)
36
Service part
(S/A)
(S/A)
8-2. HOODLEDGE PANEL (PARTIAL REPLACEMENT)
1(S)
3(S)
1(S)
Front
1(S)
3(S)
5
7
Section B
Front
1(S)
1(S)
Section C
After removing the front hoodledge reinforcement front
Front
1(170 mm)
4(S)
Section D
Apply the anti-corrosive primer on the other side of an arc-welded part.
37
8-3. FRONT SIDE MEMBER (REPLACEMENT)
• Installation (after removing the hoodledge assembly and side member crossing plate)
Front
^
1
3
Front
1
_
Section B
Section A
2-spot
welding
3-spot
welding
Plug
welding
Arc seam
welding
Brazing
Drilling a plug welding hole
on a service part
Service part
(S)
[Replacing parts]
Front side member (LH)
38
Service part
(S/A)
(S/A)
8-4. FRONT SIDE MEMBER (PARTIAL REPLACEMENT)
• Installation
Front
1(S)
2(S)
4(S)
1(300 mm)
5(S)
Section A
5(S)
Front
2
6(S)
1(S)
Section B
Apply the anti-corrosive primer on the other side of an arc-welded part.
[Point] Welding points of the left front side member matching mark
Front
2-spot
welding
Front
3-spot
welding
Plug
welding
Arc seam
welding
Brazing
Drilling a plug welding hole
on a service part
Service part
(S)
[Replacing parts]
Front side member (RH)
Side member crossing plate front (RH)
39
Service part
(S/A)
(S/A)
8-5. FRONT PILLAR (REPLACEMENT)
• Installation (after removing hoodledge reinforcement)
Front pillar
upper hinge brace
Front
1(S)
1(S/A)
7(S/A)
1(S/A)
1(165 mm)
Foaming agent
Section A
8(S/A)
3(S)
3(S)
Body sealing (420 mm)
1(S/A)
1(S/A)
3(S/A)
2(S/A)
3(S/Two-side plug)
3(S/A)
1(S/A)
4
4(S/Two-side plug)
2(S/A)
1(S)
1(S/Two-side plug)
1(S/A)
2(S/A)
2(S/A)
4(S)
4(S/A)
1(190 mm)
Front pillar lower hinge brace
4(S)
Foaming agent
Front pillar lower
reinforcement
Apply the anti-corrosive primer on the other side of an arc-welded part
2-spot
welding
3-spot
welding
Plug
welding
Arc seam
welding
Brazing
Drilling a plug welding hole
on a service part
Service part
(S)
Service part
(S/A)
[Replacing parts]
Body side outer (LH)
Front pillar hinge reinforcement (LH)
Cowl top side (LH)
Dash side (LH)
40
Front pillar inner upper (LH)
(S/A)
8-5. FRONT PILLAR (REPLACEMENT)
After removing the body side outer
Front
1(120 mm)
1
1(S)
Front
Front pillar upper
hinge brace
Section B
1(S/A)
2
1(S)
2(S)
Section C
1(S)
2(S)
Front
1(S/Two-sided plug)
1(S)
2(S)
2(S)
5
Section D
After removing the body side outer
Front
1(S)
2(S)
Front
1(S/A)
1(S)
1(S)
2(S)
1(S)
1(S)
7(S)
1(S)
3(S)
Front pillar hinge brace
1(S)
Section E
Section F
Apply the anti-corrosive primer on the other side of an arc-welded part.
41
8-5. FRONT PILLAR (REPLACEMENT)
Front
Front
1(S)
4(S)
Foaming agent
Section H
Section G
Front
Front
4(S)
1(90 mm)
6(S)
2(S/Two-sided plug)
Section I
Section J
Apply the anti-corrosive primer on the other side of an arc-welded part.
42
8-6. CENTER PILLAR (REPLACEMENT)
• Installation
1(140 mm)
Front
Center pillar lower brace
After removing
the body side outer
Front
Section A
1(S)
1(S)
Foaming agent
16(S/Two-sided plug)
1(140 mm)
17(S/Two-sided plug)
Center pillar lower brace
Center pillar reinforcement
Section B
1(S/A)
1(S/A)
8(S/A)
13(S)
1(S)
1(185 mm)
1(185 mm)
2(S)
2(S)
Foaming agent
6(S)
1(S)
Center pillar inner
5(S/A)
Apply the anti-corrosive primer on the other side of an arc-welded part.
2-spot
welding
3-spot
welding
Plug
welding
Arc seam
welding
Drilling a plug welding hole
on a service part
Brazing
Service part
(S)
Service part
(S/A)
(S/A)
[Replacing parts]
Body side outer (LH)
Center pillar inner (LH)
Center pillar lower brace (LH)
43
Seal outer reinforcement (LH)
8-6. CENTER PILLAR (REPLACEMENT)
1(30 mm x 1)
Front
After removing the body side outer
1(30 mm x 1)
1(S)
Front
1(15 mm x 1)
1(15 mm x 1)
3(S/A)
Section C
1(S)
After removing the body side outer
1(S)
1(S)
4(S)
Front
1(290 mm)
Section D
1(S)
Front
1(S/A)
2(S/A)
1(S/A)
Seal outer
reinforcement
Section E
1(S)
2(S)
2(S)
Front
Section F
1(S/A)
2(S)
Front
1
2(S)
Seal outer
reinforcement
Section G
Apply the anti-corrosive primer on the other side of an arc-welded part.
Front
2(S)
Center pillar inner
Service Parts
[Point]
Because a (welded section) is not visible, install the center pillar inner
and seal outer brace first.
44
8-7. SEAL OUTER (REPLACEMENT)
• Installation
CAUTION
For easy installation, cut and remove the center pillar lower brace.
Center pillar lower brace
1(320mm)
Front pillar lower hinge brace
1(310mm)
5 (S/Two-sided plug)
1(S/A)
11(S/A)
18(S)
1(S)
5
1(S)
2(S)
Foaming
agent
5(S)
Foaming agent
10(S)
Center pillar inner
2(S/A)
Seal out
reinforcement
Center pillar lower reinforcement
Front
After removing the seal outer
Seal outer lower
hinge brace
Front
3(S)
1
2(S)
4(S)
1(S/A)
1(S)
2
1(S/A)
1(S)
1(S)
1
7
1(S/A)
3(S/A)
Section A
Section B
Apply the anti-corrosive primer on the other side of an arc-welded part.
2-spot
welding
3-spot
welding
Plug
welding
Arc seam
welding
Brazing
Drilling a plug welding hole
on a service part
Service part
(S)
Service part
(S/A)
[Replacing parts]
Seal outer (LH)
Seal outer reinforcement (LH)
45
Front pillar lower reinforcement (LH)
(S/A)
8-7. SEAL OUTER (REPLACEMENT)
After removing the seal outer and
center pillar lower brace
After removing the seal outer, center
pillar lower brace, and seal outer reinforcement
1
Front
2
Front
1
2(S)
2
3
2(S)
3(S)
3
Section C
Section D
Front
3(S)
1(S/A)
1(250 mm)
4(S)
1(S)
2(S/A)
Front
1(S)
1(S)
2(S/A)
1(S)
2(S)
Section E
1(S)
2(S)
1
1(S/A)
After removing the seal outer
1(S/A)
Section F
1(S)
1(S)
3
Front
Front
1(S/A)
1(S/A)
1(S)
3
2(S)
1(S)
Section G
4 (S/Two-sided plug)
1(S/A)
1(S/A)
1(S/A)
1(S)
Apply the anti-corrosive primer on the other side of an arc-welded part.
46
Section H
2(S/A)
8-7. SEAL OUTER (REPLACEMENT)
After removing the seal outert
2(30 mm x 2)
Front
1(270 mm)
1
Front
1
1
4
1
Section J
Section I
Front
3(S)
1(S/Two-sided plug)
1(S/A)
Foaming agent
Front
Section k
a2
Front
3(15 mm x 3)
a2
Section L
Service Part
Apply the anti-corrosive primer on the other side of an arc-welded part.
[Point]
Because a (welded section) is not visible, install the front pillar
reinforcement and seal outer reinforcement first.
Front
47
8-8. REAR FENDER (REPLACEMENT)
• Installation
3
4
3
5
7
Front
Foaming
agent
5
Foaming agent
1
4
2
Section A
1(185 mm)
6
1(S)
1
1(S)
Rear pillar upper
reinforcement
1(S)
Foaming agent
16
3(S)
Front
Front
1
7
8
1
1
1
Section B
1
Section C
1
Apply the anti-corrosive primer on the other side of an arc-welded part.
2-spot
welding
3-spot
welding
Plug
welding
Arc seam
welding
Brazing
Drilling a plug welding hole
on a service part
Service part
(S)
[Replacing parts]
Rear fender (LH)
48
Service part
(S/A)
(S/A)
8-8. REAR FENDER (REPLACEMENT)
5
Front
4
Front
3(S)
1
3(S/A)
Glue
Glue
Section E
Front
Section D
1
1(S/A)
1
Section F
Front
Front
1(S)
1
1
1
1
1(100 mm)
1
1
1(175 mm)
Section G
Section H
Apply the anti-corrosive primer on the other side of an arc-welded part.
Front
Apply a sealing agent to the arched section of the rear wheelhouse
49
8-9. REAR WHEELHOUSE OUTER (REPLACEMENT)
• Installation (After removing the rear fender assembly)
For easy installation, remove the rear pillar upper assembly.
For easy installation, remove the seal outer reinforcement.
CAUTION
1
3
3(S/A)
1
2(S)
1(S/A)
5
4
5
2
1
6(S)
9
5
1
3
1(S)
5
Seal outer reinforcement
2(S)
3
After removing the rear pillar inner reinforcement
2(S/A)
2(S/A)
Front
Front
1
2(S)
1
2(S)
1(S)
2(S)
Section A
2(S)
Section B
Apply the anti-corrosive primer on the other side of an arc-welded part.
2-spot
welding
3-spot
welding
Plug
welding
Arc seam
welding
Brazing
Drilling a plug welding hole
on a service part
Service part
(S)
[Replacing parts]
Rear wheel house outer (LH)
50
Service part
(S/A)
(S/A)
8-9. REAR WHEELHOUSE OUTER (REPLACEMENT)
After removing the seal outer reinforcement
1
Front
Front
1(20 mm x 1)
Section A
1
2(S)
Section B
1
1
1
Front
3
3
1(280 mm)
Seal outer reinforcement
Section E
1
Front
Front
4
1
3
1(S)
1
1(S/A)
2
1
1
Section G
Section F
Apply the anti-corrosive primer on the other side of an arc-welded part.
51
8-10. REAR PANEL (REPLACEMENT)
• Installation
5
1(S)
4
1
3(S)
1(S)
1(S)
1(S)
3
8(S)
4
1(S)
6(S)
4(S)
1
1(S)
1(S)
Apply the anti-corrosive primer on the other side of an arc-welded part.
2-spot
welding
3-spot
welding
Plug
welding
Arc seam
welding
Brazing
Drilling a plug welding hole
on a service part
Service part
(S)
[Replacing parts]
Rear panel upper
52
Service part
(S/A)
(S/A)
8-11. REAR FLOOR REAR (REPLACEMENT)
• Installation (After removing the rear panel)
7(S/A)(LH)
7(S)(RH)
17(S)
1(S)
8(S/A)(LH)
8(S)(RH)
4(S)
8
Front
4(S)
1(S)
Front
7
1(S)
2(S)
3
7(S)
1(S)
1(S)
1
1(S)
3
2(S)
3(S)
2(S)
1
2(S)
Section A
5
Apply the anti-corrosive primer on the other side of an arc-welded part.
5
Section B
Note: Install fusible insulators securely when they are temporarily removed.
When the insulators are heat-damaged, replace them with new ones.
2-spot
welding
3-spot
welding
Plug
welding
Arc seam
welding
Brazing
Drilling a plug welding hole
on a service part
Service part
Service part
(S)
(S/A)
[Replacing parts]
Rear floor rear
Rear floor rear side (LH)
Spare tire clamp bracket
53
(S/A)
8-12. REAR SIDE MEMBER (REPLACEMENT)
• Installation
(After removing the rear fender, rear panel, rear floor rear side, rear wheelhouse outer, rear
wheelhouse outer extension, and seal outer reinforcement)
2(20 mm x 2)
1
1
1(260 mm)
7
2
Front
7
Front
2
1
3
Section A
Rear cross member assembly
2(10 mm x 2)
Section B
Apply the anti-corrosive primer on the other side of an arc-welded part.
2-spot
welding
3-spot
welding
Plug
welding
Arc seam
welding
Drilling a plug welding hole
on a service part
Brazing
Service part
(S)
[Replacing parts]
Rear side member (LH)
54
Service part
(S/A)
(S/A)
8-12. REAR SIDE MEMBER (REPLACEMENT)
1(S)
1
2
Front
1
Front
2
1(S)
1
1(S)
1
2
2(S)
1
2
1
Section C
2
Section D
4
Front
5 (Two-sided plug)
Section E
Front
Front
2(S)
1
Section F
1
Section G
To display the hidden welding point (a), the rear floor front is removed in A Section.
Front
[Point]
Front
Because the welding point a is hidden, remove
the rear cross center member too.
For fixing the rear side member, weld the b point continuously,
as an alternative to the hidden a point.
Section A
Section B
55
8-13. REAR SIDE MEMBER EXTENSION (REPLACEMENT)
• Installation (After removing the rear panel)
7
7
Front
Front
2(S)
4(S)
2(S)
4(S)
4(S)
Section A
Section B
2-spot
welding
3-spot
welding
Plug
welding
Arc seam
welding
Drilling a plug welding hole
on a service part
Brazing
Service part
(S)
[Replacing parts]
Rear side member extension (LH)
56
Service part
(S/A)
(S/A)
8-14. ROOF PANEL (REPLACEMENT)
• Installation
16
2(S)
2(S)
3(S)
2(S)
3(S)
16
2(S)
1(S)
1(S)
1(S)
2(S)
2(S)
2(S)
Front
Front
1(S)
1
2(S)
1(S)
1(S)
Section B
1(S)
Section A
Apply the anti-corrosive primer on the other side of an arc-welded part.
2-spot
welding
3-spot
welding
Plug
welding
Arc seam
welding
Brazing
Drilling a plug welding hole
on a service part
Service part
(S)
[Replacing parts]
Roof
57
Service part
(S/A)
(S/A)
Zinc-treated and high strength steel plate
High strength steel plate
SM7-5801
9. SERVICE PARTS
9. Service Parts
9-1. Underbody
58
16 Transmission control reinforcement
17 2nd cross member
18 4th cross member
19 Seal inner
20 Rear floor front extension
21 Rear floor front
22 Rear floor belt anchor reinforcement
23 2nd seat mounting bracket
24 Rear seat back support
25 Rear floor rear
26 Spare tire clamp bracket
27 Rear tie down hook
28 Rear floor rear side
29 Front side member
30 Front side member corner
1 Hoodledge assembly
2 Hoodledge lower front
3 Harness mounting connector bracket
4 Hoodledge extension
5 Cassette hoodledge reinforcement
6 Hoodledge reinforcement
7 Hoodledge reinforcement rear
8 Air box assembly
9 Cowl top side
10 Dash lower
11 Dash side
12 Front floor
13 Dash lower rear
14 Cable mounting bracket
15 Center floor member
43 Rear side member extension
42 Seal inner reinforcement rear
41 Seal inner extension
40 Rear side member
39 Rear cross center member assembly
38 Rear seat cross member
37 Front side member extension rear
36 Jack-up point bracket
35 Front side member rear side
34 Front side member extension front
33 Dash lower cross member
32 Crossing plate side member front
31 Crossing plate side member
9. SERVICE PARTS
59
Zinc-treated and high strength steel plate
High strength steel plate
Zinc-treated steel plate
SM7-6001
9. SERVICE PARTS
9-2. Body Side & Roof
60
16 Rear wheelhouse inner extension
17 Rear seat back side
18 Parcel shelf side
19 Rear inner pillar
20 Rear pillar upper reinforcement
21 Rear pillar inner lower
22 Roof assembly
23 Front roof rail
24 Roof bow No. 1
25 Roof bow No. 2
26 Roof reinforcement center
27 Roof bow No. 3
28 Roof bow No. 4
29 Rear roof rail
30 Rear fender assembly
1 Hood
2 Front fender
3 Body side pillar hinge assembly
4 Front pillar hinge reinforcement’
5 Roof side rail outer reinforcement
6 Center pillar lower plate
7 Front pillar inner upper
8 Center pillar inner
9 Front pillar lower reinforcement
10 Seal outer reinforcement
11 Rear wheelhouse outer
12 Rear wheelhouse outer extension
13 Rear wheelhouse inner
14 Seal crossing plate
15 Rear wheelhouse inner reinforcement
44 Trunk lid
43 Rear door
42 Front door
41 Rear bumper fascia bracket
40 Rear bumper upper retainer center
39 Rear panel assembly
38 Child seat anchor reinforcement
37 Parcel shelf side reinforcement
36 Rear waist
35 Parcel shelf full waist
34 Pillar lead
33 Rear bumper bracket side
32 Rear combination lamp base
31 Rear fender extension
9. SERVICE PARTS
61