Professional Documents
Culture Documents
E
CONTENTS
VEHICLE INFORMATION ............................. 3 Hoodledge (RHD Models) .......................................44 F
Hoodledge (LHD Models) ........................................45
BODY EXTERIOR PAINT COLOR ..................... 3 Hoodledge (RHD Models Partial Replacement) ......46
Body Exterior Paint Color .......................................... 3 Hoodledge (LHD Models Partial Replacement) .......48 G
Front Side Member (2WD, RHD Models) ................50
PRECAUTION ............................................... 5 Front Side Member (2WD, LHD Models) .................53
Front Side Member (4WD, RHD Models) ................56
REPAIRING HIGH STRENGTH STEEL .............. 5 H
Front Side Member (4WD, LHD Models) .................58
High Strength Steel (HSS) ...................................... 5
Front Side Member (2WD Models Partial Replace-
Handling of Ultra High Strength Steel Plate Parts...... 8
ment) .......................................................................60
Front Side Member (4WD Models Partial Replace- I
PREPARATION ............................................ 9
ment) .......................................................................62
REPAIRING MATERIAL ..................................... 9 Front Pillar (RHD Models) .......................................64
Foam Repair ............................................................. 9 Front Pillar (LHD Models) ........................................67 J
Center Pillar (2WD Models) .....................................71
BODY COMPONENT PARTS ............................11 Center Pillar (4WD Models) .....................................73
Underbody Component Parts (2WD Models) .......... 11 Outer Sill (Partial Replacement) ..............................75
Underbody Component Parts (4WD Models) .......... 13 BRM
Outer Sill (RHD Models) ..........................................76
Body Component Parts (2WD Models) ................... 15 Outer Sill (LHD Models) ...........................................79
Body Component Parts (4WD Models) ................... 18 Inner Sill ...................................................................81
Rear Fender (2WD Models) ....................................84 L
REMOVAL AND INSTALLATION ............... 21 Rear Fender (4WD Models) ....................................87
CORROSION PROTECTION .............................21 Rear Fender Extension (2WD Models) ....................90
Rear Fender Extension (4WD Models) ....................91 M
Description .............................................................. 21
Rear Pillar Reinforcement .......................................91
Anti-corrosive Wax .................................................. 21
Outer Rear Wheelhouse (2WD Models) ..................92
Undercoating (2WD Models) ................................... 22
Outer Rear Wheelhouse (4WD Models) ..................94 N
Undercoating (4WD Models) ................................... 23
Inner Rear Wheelhouse (2WD Models) ...................96
Body Sealing (2WD RHD Models) .......................... 24
Inner Rear Wheelhouse (4WD Models) ...................97
Body Sealing (2WD LHD Models) ........................... 28
Rear Panel (2WD Models) .......................................99
Body Sealing (4WD RHD Models) .......................... 31 O
Rear Panel (4WD Models) ..................................... 100
Body Sealing (4WD LHD Models) ........................... 34
Inner Rear Pillar ..................................................... 100
BODY CONSTRUCTION ....................................37 Rear Floor Rear (2WD Models) ............................. 101
Body Construction (RHD Models) ........................... 37 Rear Floor Rear (4WD Models) ............................. 102 P
Body Construction (LHD Models) ............................ 39 Rear Side Member (4WD Models Partial Replace-
Rear Fender Hemming Process .............................. 40 ment) ..................................................................... 103
Rear Side Member Extension (2WD Models) ........ 104
REPLACEMENT OPERATIONS ........................42 Rear Side Member Extension (4WD Models) ........ 105
Description .............................................................. 42 Roof ....................................................................... 107
Radiator Core Support ............................................ 44 Roof Rail ................................................................ 108
BRM-1
SERVICE DATA AND SPECIFICATIONS Engine Compartment (4WD LHD Models) ............ 118
(SDS) .......................................................... 109 Underbody (2WD Models) .................................... 120
Underbody (4WD Models) .................................... 122
BODY ALIGNMENT ......................................... 109 Passenger Compartment ...................................... 125
Body Center Marks (RHD Models) ........................109 Rear Body ............................................................ 127
Body Center Marks (LHD Models) .........................110
Description .............................................................111 LOCATION OF PLASTIC PARTS .................... 129
Engine Compartment (2WD RHD Models) ............111 Precautions for Plastics ........................................ 129
Engine Compartment (2WD LHD Models) .............114 Location of Plastic Parts ....................................... 130
Engine Compartment (4WD RHD Models) ............116
BRM-2
BODY EXTERIOR PAINT COLOR
< VEHICLE INFORMATION >
VEHICLE INFORMATION A
BODY EXTERIOR PAINT COLOR
Body Exterior Paint Color INFOID:0000000006482807
B
JSKIA2126ZZ
H
Color code B326 BKAD BKAX BKY0 BNAH BRAQ BZ11
Description White Gray Dark Gray Silver Red Dark Blue Black
Component Paint type Note Solid M PM M PM M PM I
Hard clear
− × × × × × ×
coat
Grille Material color − − − − − − − J
Front
1 Chromium
grille Molding Cr Cr Cr Cr Cr Cr Cr
plate
2 Front bumper fascia Body color B326 BKAD BKAX BKY0 BNAH BRAQ BZ11 BRM
3 Front fillet molding Material color − − − − − − −
Body color B326 BKAD BKAX BKY0 BNAH BRAQ BZ11
4 Door outside mirror L
Material color − − − − − − −
5 Back door finisher Body color B326 BKAD BKAX BKY0 BNAH BRAQ BZ11
6 Rear bumper fascia Body color B326 BKAD BKAX BKY0 BNAH BRAQ BZ11 M
7 Rear fillet molding Material color − − − − − − −
8 Center mudguard Material color − − − − − − −
N
Front door outside Body color B326 BKAD BKAX BKY0 BNAH BRAQ BZ11
9
handle Material color − − − − − − −
Rear door outside O
10 Material color − − − − − − −
handle
NOTE:
• S: Solid P
• 2S: Solid + Clear
• CS: Color clear solid
• M: Metallic
• P: 2-Coat pearl
• 3P: 3-Coat pearl
• FPM: Iron oxide pearl
• RPM: Multi flex color
BRM-3
BODY EXTERIOR PAINT COLOR
< VEHICLE INFORMATION >
• TM: Micro titanium metallic
• PM: Pearl metallic
JSKIA2126ZZ
Front door outside Body color BB20 BKAD BKAX BKY0 BNAH BRAQ BQX1
9
handle Material color − − − − − − −
Rear door outside
10 Material color − − − − − − −
handle
NOTE:
• S: Solid
• 2S: Solid + Clear
• CS: Color clear solid
• M: Metallic
• P: 2-Coat pearl
• 3P: 3-Coat pearl
• FPM: Iron oxide pearl
• RPM: Multi flex color
• TM: Micro titanium metallic
• PM: Pearl metallic
BRM-4
REPAIRING HIGH STRENGTH STEEL
< PRECAUTION >
PRECAUTION A
REPAIRING HIGH STRENGTH STEEL
High Strength Steel (HSS) INFOID:0000000006482809
B
High strength steel is used for body panels in order to reduce vehicle weight.
Accordingly, precautions in repairing automotive bodies made of high strength steel are described below:
C
FOR 2WD MODELS
BRM-5
REPAIRING HIGH STRENGTH STEEL
< PRECAUTION >
PIIA0115E
PIIA0116E
BRM-6
REPAIRING HIGH STRENGTH STEEL
< PRECAUTION >
PIIA0117E
D
JSKIA0082GB
H
• Spot welding on HSS panels is harder than that of an ordinary
steel panel.
Therefore, when cutting spot welds on a HSS panel, use a low I
speed high torque drill (1,000 to 1,200 rpm) to increase drill bit
durability and facilitate the operation.
J
BRM
PIIA0145E
PIIA0146E
O
BRM-7
REPAIRING HIGH STRENGTH STEEL
< PRECAUTION >
• The panel surfaces must fit flush to each other, leaving no
gaps.
PIIA0147E
BRM-8
REPAIRING MATERIAL
< PREPARATION >
PREPARATION A
REPAIRING MATERIAL
Foam Repair INFOID:0000000006482811
B
During factory body assembly, foam insulators are installed in certain body panels and locations around the
vehicle. Use the following procedure(s) to replace any factory-installed foam insulators.
C
URETHANE FOAM APPLICATIONS
Use commercially available Urethane foam for sealant (foam material) repair of material used on vehicle.
D
<Urethane foam for foaming agent> 3M™ Automix™ Flexible Foam 08463 or equiva-
lent
Read instructions on product for fill procedures. E
Example of foaming agent filling operation procedure
1. Fill procedures after installation of service part.
a. Eliminate foam material remaining on vehicle side. F
b. Clean area after eliminating form insulator and foam material.
c. Install service part.
G
d. Insert nozzle into hole near fill area and fill foam material or fill enough to close gap with the service part.
BRM
L
JSKIA0129GB
1. Urethane foam
A. Nozzle insert hole
M
: Vehicle front
BRM-9
REPAIRING MATERIAL
< PREPARATION >
1. Urethane foam
A. Fill while avoiding flange area
: Vehicle front
NOTE:
Fill enough to close gap with service part while avoiding flange
area.
d. Install service part.
NOTE: JSKIA0130GB
Refer to label for information on working times.
BRM-10
BODY COMPONENT PARTS
< PREPARATION >
BODY COMPONENT PARTS
A
Underbody Component Parts (2WD Models) INFOID:0000000006482812
BRM
JSKIA2127ZZ
BRM-11
BODY COMPONENT PARTS
< PREPARATION >
BRM-12
BODY COMPONENT PARTS
< PREPARATION >
Underbody Component Parts (4WD Models) INFOID:0000000006482813
BRM
P
JSKIA2128ZZ
BRM-13
BODY COMPONENT PARTS
< PREPARATION >
BRM-14
BODY COMPONENT PARTS
< PREPARATION >
Body Component Parts (2WD Models) INFOID:0000000006482814
BRM
P
JSKIA2129ZZ
A. Right side
: Both sided anti-corrosive precoated steel sections
: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections
BRM-15
BODY COMPONENT PARTS
< PREPARATION >
3. Front side member front assembly (RH & LH) Under 440 ×
4. Front fender (RH & LH) Under 440 ×
5. Inner side roof rail (RH & LH) 590 —
6. Upper inner front pillar (RH & LH) 780 —
7. Inner center pillar (RH & LH) 590 ×
8. Outer side roof rail reinforcement (RH & LH) 590 —
9. Lower center pillar brace (RH & LH) 590 —
10. Front pillar brace (RH & LH) 590 —
11. Lower front pillar hinge brace (RH & LH) 590 —
12. Outer front side body (RH & LH) Under 440 ×
13. Front fender bracket assembly (RH & LH) Under 440 ×
14. Outer sill reinforcement (RH & LH) 780 ×
15. Outer sill (RH & LH) Under 440 ×
16. Front door (RH & LH) Under 440 ×
17. Outer front door panel (RH & LH) Under 440 ×
18. Rear door (RH & LH) Under 440 ×
19. Outer rear door panel (RH & LH) Under 440 ×
20. Inner rear pillar reinforcement (RH & LH) 450 —
21. Rear pillar reinforcement (RH & LH) Under 440 —
22. Inner rear pillar (RH & LH) Under 440 —
23. Inner rear wheelhouse (RH & LH) 450 ×
24. Outer rear wheelhouse (RH & LH) Under 440 ×
25. Outer rear wheelhouse extension (RH & LH) Under 440 ×
26. Roof Under 440 —
27. Front roof rail 780 —
28. Roof bow No.1 Under 440 —
29. Roof bow No.2 590 —
30. Roof bow No.3 Under 440 —
31. Rear roof rail Under 440 —
32. Rear fender (RH & LH) Under 440 ×
33. Rear fender extension (RH & LH) Under 440 —
34. Rear fender corner (RH & LH) Under 440 ×
35. Striker retainer (RH & LH) Under 440 —
36. Fuel filler base Under 440 —
37. Fuel filler lid Under 440 ×
38. Back door Under 440 ×
39. Upper rear panel Under 440 ×
40. Upper rear bumper retainer Under 440 ×
41. Rear side bumper bracket Under 440 ×
BRM-16
BODY COMPONENT PARTS
< PREPARATION >
Tensile strength Both sided anti-corrosive
No. Parts name
(MPa) precoated steel sections A
42. Rear bumper stay (RH & LH) 590 ×
T=1.2 mm
43. Inner center rear bumper reinforcement
(0.047 in) 1310caution — B
NOTE:
• For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with.
• Tensile strength column shows the largest strength value of a part in the component part.
C
BRM
BRM-17
BODY COMPONENT PARTS
< PREPARATION >
Body Component Parts (4WD Models) INFOID:0000000006482815
JSKIA2130ZZ
A. Right side
: Both sided anti-corrosive precoated steel sections
: High strength steel (HSS) sections
: Both sided anti-corrosive steel and HSS sections
BRM-18
BODY COMPONENT PARTS
< PREPARATION >
18. Outer front door panel (RH & LH) Under 440 ×
19. Rear door (RH & LH) Under 440 ×
I
20. Outer rear door panel (RH & LH) Under 440 ×
21. Inner rear pillar reinforcement (RH & LH) 440 —
22. Rear pillar reinforcement (RH & LH) Under 440 — J
23. Inner rear pillar (RH & LH) Under 440 —
24. Inner rear wheelhouse (RH & LH) 440 ×
BRM
25. Outer rear wheelhouse (RH & LH) Under 440 ×
26. Outer rear wheelhouse extension (RH & LH) Under 440 ×
27. Roof Under 440 — L
28. Front roof rail 780 —
29. Roof bow No.1 Under 440 —
M
30. Roof bow No.2 590 —
31. Roof bow No.3 Under 440 —
32. Rear roof rail Under 440 — N
33. Rear fender (RH & LH) Under 440 ×
34. Rear fender extension (RH & LH) Under 440 —
35. Rear fender corner (RH & LH) Under 440 ×
O
BRM-19
BODY COMPONENT PARTS
< PREPARATION >
NOTE:
• For the parts without a number described in the figure, it is supplied only with the assembly part that the part is included with.
• Tensile strength column shows the largest strength value of a part in the component part.
BRM-20
CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION A
CORROSION PROTECTION
Description INFOID:0000000006482816
B
To provide improved corrosion prevention, the following anti-corrosive measures have been implemented in
NISSAN production plants. When repairing or replacing body panels, it is necessary to use the same anti-cor-
rosive measures. C
SIIA2294E
G
Nissan Genuine Service Parts are fabricated from galvannealed steel. Therefore, it is recommended that
GENUINE NISSAN PARTS or equivalent be used for panel replacement to maintain the anti-corrosive perfor-
H
mance built into the vehicle at the factory.
PHOSPHATE COATING TREATMENT AND CATIONIC ELECTRODEPOSITION PRIMER
A phosphate coating treatment and a cationic electrodeposition I
primer, which provide excellent corrosion protection, are employed
on all body components.
CAUTION:
Confine paint removal during welding operations to an absolute J
minimum.
BRM
PIIA0095E L
Nissan Genuine Service Parts are also treated in the same manner. Therefore, it is recommended that GENU-
INE NISSAN PARTS or an equivalent be used for panel replacement to maintain anti-corrosive performance M
built into the vehicle at the factory.
Anti-corrosive Wax INFOID:0000000006482817
N
To improve corrosion resistance, anti-corrosive wax is applied inside the body sill and inside other closed sec-
tions. Accordingly, when replacing these parts, be sure to apply anti-corrosive wax to the appropriate areas of
the new parts. Select an excellent anti-corrosive wax which will penetrate after application and has a long shelf
O
life.
DOOR
P
BRM-21
CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
JSKIA2131ZZ
The underside of the floor and wheelhouse are undercoated to prevent rust, vibration, noise and stone chip-
ping. Therefore, when such a panel is replaced or repaired, apply undercoating to that part. Use an undercoat-
ing which is rust resistant, soundproof, vibration-proof, shock-resistant, adhesive, and durable.
PRECAUTIONS IN UNDERCOATING
1. Never apply undercoating to any place unless specified (such as the areas above the muffler and three-
way catalyst that are subjected to heat).
2. Never undercoat the exhaust pipe or other parts that become hot.
3. Never undercoat rotating parts.
4. Apply bitumen wax after applying undercoating.
5. After putting seal on the vehicle, put undercoating on it.
BRM-22
CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
H
JSKIA2132ZZ
: Undercoated areas
: Sealed portions
I
J
The underside of the floor and wheelhouse are undercoated to prevent rust, vibration, noise and stone chip-
ping. Therefore, when such a panel is replaced or repaired, apply undercoating to that part. Use an undercoat-
ing which is rust resistant, soundproof, vibration-proof, shock-resistant, adhesive, and durable.
BRM
PRECAUTIONS IN UNDERCOATING
1. Never apply undercoating to any place unless specified (such as the areas above the muffler and three-
way catalyst that are subjected to heat). L
2. Never undercoat the exhaust pipe or other parts that become hot.
3. Never undercoat rotating parts.
4. Apply bitumen wax after applying undercoating. M
5. After putting seal on the vehicle, put undercoating on it.
BRM-23
CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
JSKIA2133ZZ
: Undercoated areas
: Sealed portions
The following figure shows the areas that are sealed at the factory. Sealant that is applied to these areas
should be smooth and free from cuts or gaps. Care should be taken not to apply an excess amount of sealant
and not to allow other unaffected parts to come into contact with the sealant.
BRM-24
CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2002ZZ
: Vehicle front O
: Sealed portions
BRM-25
CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
JSKIA2134ZZ
BRM-26
CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
BRM
JSKIA2135ZZ
P
: Vehicle front
: Sealed portions
BRM-27
CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
Body Sealing (2WD LHD Models) INFOID:0000000006486722
The following figure shows the areas that are sealed at the factory. Sealant that is applied to these areas
should be smooth and free from cuts or gaps. Care should be taken not to apply an excess amount of sealant
and not to allow other unaffected parts to come into contact with the sealant.
JSKIA2136ZZ
: Vehicle front
: Sealed portions
BRM-28
CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
BRM
JSKIA2137ZZ
P
T. HR16DE Engine models U. MR16DDT and K9K Engine models
: Vehicle front
: Sealed portions
BRM-29
CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
JSKIA2135ZZ
: Vehicle front
: Sealed portions
BRM-30
CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
Body Sealing (4WD RHD Models) INFOID:0000000006482892
A
The following figure shows the areas that are sealed at the factory. Sealant that is applied to these areas
should be smooth and free from cuts or gaps. Care should be taken not to apply an excess amount of sealant
and not to allow other unaffected parts to come into contact with the sealant. B
BRM
JSKIA2138ZZ
P
: Vehicle front
: Sealed portions
BRM-31
CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
JSKIA2139ZZ
: Vehicle front
: Sealed portions
BRM-32
CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
BRM
JSKIA2140ZZ
P
: Vehicle front
: Sealed portions
BRM-33
CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
Body Sealing (4WD LHD Models) INFOID:0000000006486723
The following figure shows the areas that are sealed at the factory. Sealant that is applied to these areas
should be smooth and free from cuts or gaps. Care should be taken not to apply an excess amount of sealant
and not to allow other unaffected parts to come into contact with the sealant.
JSKIA2141ZZ
: Vehicle front
: Sealed portions
BRM-34
CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
BRM
JSKIA2142ZZ
P
: Vehicle front
: Sealed portions
BRM-35
CORROSION PROTECTION
< REMOVAL AND INSTALLATION >
JSKIA2140ZZ
: Vehicle front
: Sealed portions
BRM-36
BODY CONSTRUCTION
< REMOVAL AND INSTALLATION >
BODY CONSTRUCTION
A
Body Construction (RHD Models) INFOID:0000000006482825
BRM
JSKIA2006ZZ
1. Outer side body 2. Outer front pillar reinforcement 3. Upper inner front pillar
4. Lower dash 5. Hoodledge reinforcement 6. Lower front pillar hinge brace
7. Weld nut 8. Side dash 9. Upper hinge plate
BRM-37
BODY CONSTRUCTION
< REMOVAL AND INSTALLATION >
10. Lower hinge plate 11. Inner front pillar reinforcement 12. Inner front sill reinforcement
13. Inner sill 14. Front floor reinforcement 15. Front floor
16. Front outrigger 17. Outer sill reinforcement 18. Plate nut
19. Inner center pillar 20. Center pillar reinforcement 21. Center pillar hinge brace
22. Center sill reinforcement 23. Inner sill extension 24. Inner rear wheelhouse
25. Outer rear wheelhouse 26. Rear roof rail brace 27. Inner rear pillar reinforcement
28. Rear fender extension 29. Inner rear pillar 30. Inner rear wheelhouse reinforce-
ment
BRM-38
BODY CONSTRUCTION
< REMOVAL AND INSTALLATION >
Body Construction (LHD Models) INFOID:0000000006482826
BRM
P
JSKIA2143ZZ
1. Outer side body 2. Outer front pillar reinforcement 3. Upper inner front pillar
4. Lower dash 5. Hoodledge reinforcement 6. Lower front pillar hinge brace
7. Weld nut 8. Side dash 9. Upper hinge plate
10. Lower hinge plate 11. Inner front pillar reinforcement 12. Inner front sill reinforcement
13. Inner sill 14. Front floor reinforcement 15. Front floor
BRM-39
BODY CONSTRUCTION
< REMOVAL AND INSTALLATION >
16. Front outrigger 17. Outer sill reinforcement 18. Plate nut
19. Inner center pillar 20. Center pillar reinforcement 21. Center pillar hinge brace
22. Center sill reinforcement 23. Inner sill extension 24. Inner rear wheelhouse
25. Outer rear wheelhouse 26. Rear roof rail brace 27. Inner rear pillar reinforcement
28. Rear fender extension 29. Inner rear pillar 30. Inner rear wheelhouse reinforce-
ment
31. Upper inner front pillar reinforcement
1. A wheel arch is to be installed and hemmed over the left and right outer wheel houses.
2. In order to hem the wheel arch, it is necessary to repair any damaged or defaced parts around outer
wheel house.
CAUTION:
Ensure that the area that is to be glued around the outer wheelhouse is undamaged or defaced.
PROCEDURE OF THE HEMMING PROCESS
• Peel off old bonding material on the surface of the outer wheel-
house and clean thoroughly.
• Peel off a primer coat in the specified area where new adhesive is
to be applied on rear fender (the replacing part).
• Apply new adhesive to both specified areas of the outer wheel-
house and rear fender.
• Bend the welded part starting from the center of the wheel arch
gradually with a hammer and a dolly. (Also hem the end of the
flange.)
• Hemming with a hammer is conducted to an approximate angle of
80 degrees.
SIIA2245E
• Starting from the center, hem the wheel arch gradually, using slight
back and forth motion with a hemming tool.
SIIA2246E
BRM-40
BODY CONSTRUCTION
< REMOVAL AND INSTALLATION >
• Seal up the area around the hemmed end of the flange.
A
JSKIA0137GB
BRM
BRM-41
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
REPLACEMENT OPERATIONS
Description INFOID:0000000006482827
• This section is prepared for technicians who have attained a high level of skill and experience in repairing
collision-damaged vehicles and also use modern service tools and equipment. Persons unfamiliar with body
repair techniques should not attempt to repair collision-damaged vehicles by using this section.
• Technicians are also encouraged to read the Body Repair Manual (Fundamentals) in order to ensure that the
original functions and quality of the vehicle are maintained. The Body Repair Manual (Fundamentals) con-
tains additional information, including cautions and warnings, that are not including in this manual. Techni-
cians should refer to both manuals to ensure proper repair.
• Please note that this information is prepared for worldwide usage, and as such, certain procedures might not
apply in some regions or countries.
The symbols used in this section for welding operations are shown below.
Symbol marks Description
2-spot welds
JSKIA0049ZZ
JSKIA0053ZZ
3-spot welds
JSKIA0050ZZ
JSKIA0054ZZ
MIG plug weld
For 3 panels plug weld method
JSKIA0051ZZ
JSKIA0055ZZ
JSKIA0052ZZ JSKIA0056ZZ
BRM-42
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
• Front pillar butt joint can be determined anywhere within shaded
area as shown in the figure. The best location for the butt joint is at A
position A due to the construction of the vehicle.
PIIA0150E
D
• Determine cutting position and record distance from the locating
indent. Use this distance when cutting the service part. Cut outer
front pillar over 60 mm (2.36 in) above the inner front pillar cut E
position.
G
JSKIA0104GB
• Prepare a cutting jig to make outer pillar easier to cut. Also, this will H
permit the service part to be accurately cut at the joint position.
BRM
JSKIA0105GB
PIIA0153E
O
BRM-43
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Radiator Core Support INFOID:0000000006482828
JSKIA2008ZZ
: Vehicle front
Replacement parts
z Side radiator core support (LH Up- z Side radiator core support (LH Low- z Hoodledge connector (LH)
per) er)
BRM-44
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2009ZZ
: Vehicle front O
Replacement parts
z Front strut housing (LH) z Hoodledge reinforcement (LH)
P
View B: Before installing hoodledge reinforcement
Hoodledge (LHD Models) INFOID:0000000006517470
BRM-45
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2157ZZ
: Vehicle front
Replacement parts
z Front strut housing (LH) z Hoodledge reinforcement (LH)
BRM-46
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2158ZZ
: Vehicle front O
Replacement parts
z Upper hoodledge (RH) z Lower front hoodledge (RH) z Hoodledge reinforcement (RH)
P
View B: Before installing hoodledge reinforcement
BRM-47
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2034GB
Unit: mm (in)
: Vehicle front
BRM-48
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2158ZZ
: Vehicle front O
Replacement parts
z Upper hoodledge (RH) z Lower front hoodledge (RH) z Hoodledge reinforcement (RH)
P
View B: Before installing hoodledge reinforcement
BRM-49
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2159GB
Unit: mm (in)
: Vehicle front
BRM-50
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2160ZZ
: Vehicle front O
: Weld the parts onto the back of the component part.
Replacement parts
z Front side member assembly (LH) z Front suspension mounting bracket z Engine mounting reinforcement P
(LH Front)
z Front side member reinforcement z Tie down hook reinforcement z Front side member closing plate as-
assembly sembly (LH)
z Front towing hook reinforcement z Add on frame bracket (LH) z Front tie down hook
z Sensor harness bracket (LH) z Front brake hose bracket (LH) z Front suspension mounting bracket
(LH Rear)
BRM-51
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2161ZZ
: Vehicle front
: Weld the parts onto the back of the component part.
BRM-52
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2162GB
Unit: mm (in) O
: Vehicle front
: Weld the parts onto the back of the component part.
P
View M: Before installing front suspension mounting bracket (Rear)
Front Side Member (2WD, LHD Models) INFOID:0000000006517471
BRM-53
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2160ZZ
: Vehicle front
: Weld the parts onto the back of the component part.
Replacement parts
z Front side member assembly (LH) z Front suspension mounting bracket z Engine mounting reinforcement
(LH Front)
z Front side member reinforcement z Tie down hook reinforcement z Front side member closing plate as-
assembly sembly (LH)
z Front towing hook reinforcement z Add on frame bracket z Front tie down hook
z Sensor harness bracket (LH) z Front brake hose bracket (LH) z Front suspension mounting bracket
(LH Rear)
BRM-54
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2163ZZ
: Vehicle front O
: Weld the parts onto the back of the component part.
BRM-55
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2162GB
Unit: mm (in)
: Vehicle front
: Weld the parts onto the back of the component part.
BRM-56
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2011ZZ
: Vehicle front O
: Weld the parts onto the back of the component part.
Replacement parts
z Front side member assembly (LH) z Front side member closing plate as- z Front suspension mounting bracket P
sembly (LH) (LH Rear)
BRM-57
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2164ZZ
: Vehicle front
: Weld the parts onto the back of the component part.
BRM-58
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2165ZZ
: Vehicle front O
: Weld the parts onto the back of the component part.
Replacement parts
z Front side member assembly (LH) z Front side member closing plate as- z Front suspension mounting bracket P
sembly (LH) (LH Rear)
BRM-59
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2164ZZ
: Vehicle front
: Weld the parts onto the back of the component part.
BRM-60
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2166ZZ
: Vehicle front O
: Weld the parts onto the back of the component part.
Replacement parts
z Front suspension mounting bracket z Add on frame bracket (RH) P
(RH Front)
POINT
The front side member on the left can also be replaced partially by butt welding.
BRM-61
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2167GB
Unit: mm (in)
: Vehicle front
Replacement parts
z Front side member assembly (LH) z Front side member closing plate as-
sembly (LH)
NOTE:
For welding method and the number of welding points, refer to BRM-50, "Front Side Member (2WD, RHD Models)" or BRM-53, "Front
Side Member (2WD, LHD Models)".
BRM-62
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2013ZZ
: Vehicle front O
: Weld the parts onto the back of the component part.
Replacement parts
z Front suspension mounting bracket z Add on frame bracket (RH) P
(RH Front)
POINT
The front side member on the left can also be replaced partially by butt welding.
BRM-63
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2014GB
Unit: mm (in)
: Vehicle front
Replacement parts
z Front side member assembly (LH) z Front side member closing plate as-
sembly (LH)
NOTE:
For welding method and the number of welding points, refer to BRM-56, "Front Side Member (4WD, RHD Models)" or BRM-58, "Front
Side Member (4WD, LHD Models)".
BRM-64
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2015GB
1. Body sealing O
Unit: mm (in)
: Vehicle front
Replacement parts P
z Outer front side body (LH) z Front pillar brace (LH) z Side dash (LH)
z Upper inner front pillar (LH) z Front fender bracket assembly (LH)
View A: Before installing outer front side body, front fender bracket assembly, and front pillar brace
BRM-65
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2016ZZ
1. Urethane foam
: Vehicle front
: Drill φ9 mm (0.35 in) hole for the plug welding hole (ultra high strength steel plate).
: Weld the parts onto the back of the component part.
View E: Before installing outer front side body and front fender bracket assembly
View G: Before installing outer front side body, front fender bracket assembly, and front pillar brace
BRM-66
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2017GB
Unit: mm (in) O
: Vehicle front
BRM-67
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2168GB
1. Body sealing
Unit: mm (in)
: Vehicle front
Replacement parts
z Outer front side body (LH) z Front pillar brace (LH) z Side dash (LH)
z Upper inner front pillar (LH) z Front fender bracket assembly (LH)
View A: Before installing outer front side body, front fender bracket assembly, and front pillar brace
BRM-68
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2169ZZ
1. Urethane foam O
: Vehicle front
View E: Before installing outer front side body and front fender bracket assembly
P
BRM-69
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2170GB
Unit: mm (in)
: Vehicle front
: Drill φ9 mm (0.35 in) hole for the plug welding hole (ultra high strength steel plate).
: Weld the parts onto the back of the component part.
View G: Before installing outer front side body, front fender bracket assembly, and front pillar brace
View M: Before installing outer front side body
BRM-70
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Center Pillar (2WD Models) INFOID:0000000006482835
BRM
JSKIA2171GB O
1. Outer sill reinforcement 2. Lower center pillar brace 3. Inner center pillar
Unit: mm (in) P
: Vehicle front
Replacement parts
z Outer front side body (LH) z Lower center pillar brace (LH) z Inner center pillar (LH)
BRM-71
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2172GB
BRM-72
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Center Pillar (4WD Models) INFOID:0000000006517509
BRM
JSKIA2018GB O
1. Outer sill reinforcement 2. Lower center pillar brace 3. Inner center pillar
Unit: mm (in) P
: Vehicle front
Replacement parts
z Outer front side body (LH) z Lower center pillar brace (LH) z Inner center pillar (LH)
BRM-73
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2172GB
BRM-74
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Outer Sill (Partial Replacement) INFOID:0000000006482838
BRM
JSKIA2020GB O
Unit: mm (in)
: Vehicle front P
Replacement parts
z Outer sill (LH) z Outer sill reinforcement (LH)
BRM-75
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Outer Sill (RHD Models) INFOID:0000000006527930
JSKIA2173GB
BRM-76
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2174GB
1. Hemming portion O
Unit: mm (in)
: Vehicle front
P
View J: Before installing outer sill
POINT
BRM-77
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
• Perform the hemming to the flange of wheelarch after applying the
adhesive.
• Apply the sealing to the flange end.
• Refer to BRM-40, "Rear Fender Hemming Process".
BRM-78
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Outer Sill (LHD Models) INFOID:0000000006527931
BRM
JSKIA2175GB O
BRM-79
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2174GB
1. Hemming portion
Unit: mm (in)
: Vehicle front
BRM-80
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
• Perform the hemming to the flange of wheelarch after applying the
adhesive. A
• Apply the sealing to the flange end.
• Refer to BRM-40, "Rear Fender Hemming Process".
B
1. Outer rear wheelhouse
2. Rear fender
3. Adhesive C
4. Sealant
JSKIA0204GB
D
Inner Sill INFOID:0000000006482843
BRM
BRM-81
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2176GB
BRM-82
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2177GB
Unit: mm (in) O
: Vehicle front
: Weld the parts onto the back of the component part.
P
View D: Before installing lower front pillar hinge brace
BRM-83
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Rear Fender (2WD Models) INFOID:0000000006527932
JSKIA2206GB
BRM-84
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2207GB
1. Adhesive O
Unit: mm (in)
: Vehicle front
: Weld the parts onto the back of the component part. P
View F: Before installing rear fender
View H: Right side rear fender
POINT
BRM-85
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
• Perform the hemming to the flange of wheelarch after applying the
adhesive.
• Apply the sealing to the flange end.
• Refer to BRM-40, "Rear Fender Hemming Process".
BRM-86
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Rear Fender (4WD Models) INFOID:0000000006527933
BRM
JSKIA2178GB O
BRM-87
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2179GB
1. Adhesive
Unit: mm (in)
: Vehicle front
: Weld the parts onto the back of the component part.
BRM-88
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
• Perform the hemming to the flange of wheelarch after applying the
adhesive. A
• Apply the sealing to the flange end.
• Refer to BRM-40, "Rear Fender Hemming Process".
B
1. Outer rear wheelhouse
2. Rear fender
3. Adhesive C
4. Sealant
JSKIA0204GB
BRM
BRM-89
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Rear Fender Extension (2WD Models) INFOID:0000000006517610
JSKIA2025ZZ
1. Body sealing
Replacement parts
z Rear fender corner (LH)
BRM-90
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Rear Fender Extension (4WD Models) INFOID:0000000006517607
BRM
JSKIA2180ZZ O
1. Body sealing
Replacement parts P
z Rear fender corner (LH)
BRM-91
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2181GB
Unit: mm (in)
: Vehicle front
: Weld the parts onto the back of the component part.
Replacement parts
z Inner rear pillar reinforcement (LH)
BRM-92
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2026ZZ
BRM-93
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2027GB
BRM-94
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2182ZZ
BRM-95
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2027GB
Work after rear fender, outer sill reinforcement, and outer rear wheelhouse are removed.
BRM-96
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2183GB
Unit: mm (in) O
: Vehicle front
Replacement parts
z Inner rear wheelhouse (LH) P
Work after rear fender, outer sill reinforcement, and outer rear wheelhouse are removed.
BRM-97
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2184GB
Unit: mm (in)
: Vehicle front
Replacement parts
z Inner rear wheelhouse (LH)
BRM-98
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Rear Panel (2WD Models) INFOID:0000000006482861
BRM
JSKIA2028GB O
Unit: mm (in)
: Vehicle front P
: Welding method and the number of welding points apply to both side of the vehicle.
Replacement parts
z Upper rear panel
BRM-99
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Rear Panel (4WD Models) INFOID:0000000006482862
JSKIA2185GB
Unit: mm (in)
: Vehicle front
: Welding method and the number of welding points apply to both side of the vehicle.
Replacement parts
z Upper rear panel
Work after rear fender and inner rear pillar reinforcement are removed.
BRM-100
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2186ZZ
: Vehicle front O
: Weld the parts onto the back of the component part.
Replacement parts
z Inner rear pillar (LH) z Rear pillar reinforcement (LH) P
BRM-101
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2029ZZ
: Vehicle front
: Welding method and the number of welding points apply to both side of the vehicle.
: Weld the parts onto the back of the component part.
Replacement parts
z Rear floor rear z Spare tire clamp bracket z Rear towing hook bracket
z Muffler mounting bracket
BRM-102
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2187ZZ
: Vehicle front O
: Welding method and the number of welding points apply to both side of the vehicle.
Replacement parts
z Rear floor rear z Spare tire clamp bracket z Jack mounting bracket P
z Canister bracket
Work after rear panel and rear floor rear are removed.
BRM-103
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2188GB
Unit: mm (in)
: Vehicle front
: Weld the parts onto the back of the component part.
Replacement parts
z Rear side member assembly (LH)
BRM-104
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
BRM
N
JSKIA2032ZZ
: Vehicle front O
: Weld the parts onto the back of the component part.
Replacement parts
z Rear side member extension (LH) P
BRM-105
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
JSKIA2189ZZ
: Vehicle front
: Weld the parts onto the back of the component part.
Replacement parts
z Rear side member extension (LH)
BRM-106
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Roof INFOID:0000000006482869
BRM
JSKIA2190ZZ O
1. Body sealing
: Vehicle front P
: Welding method and the number of welding points apply to both side of the vehicle.
: Sealing portion apply to both side of the vehicle.
Replacement parts
z Roof z Roof bow No. 1 z Roof bow No. 2
z Roof bow No. 3
BRM-107
REPLACEMENT OPERATIONS
< REMOVAL AND INSTALLATION >
Roof Rail INFOID:0000000006482870
JSKIA2191ZZ
1. Adhesive
: Vehicle front
: Welding method and the number of welding points apply to both side of the vehicle.
: Adhesive portion apply to both side of the vehicle.
Replacement parts
z Front roof rail z Rear roof rail
BRM-108
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
BODY ALIGNMENT
Body Center Marks (RHD Models) INFOID:0000000006482872
B
A mark is placed on each part of the body to indicate the vehicle center. When repairing the vehicle frame
(members, pillars, etc.) damaged by an accident which it enables more accurate and effective repair by using
these marks together with body alignment specifications. C
BRM
JSKIA1988ZZ
O
: Vehicle front
P
Unit: mm (in)
Points Portion Marks
A Front roof Embossment
B Cowl top Embossment
C Upper dash Hole φ7 (0.28)
D Trans control reinforcement Hole φ16 (0.63)
BRM-109
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
Points Portion Marks
E Parking brake reinforcement Hole φ12 (0.47)
F Rear panel Indent
G Rear roof Embossment
A mark is placed on each part of the body to indicate the vehicle center. When repairing the vehicle frame
(members, pillars, etc.) damaged by an accident which it enables more accurate and effective repair by using
these marks together with body alignment specifications.
JSKIA2144ZZ
: Vehicle front
Unit: mm (in)
Points Portion Marks
A Front roof Embossment
B Cowl top Embossment
BRM-110
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
Points Portion Marks
A
C Upper dash Embossment
D Trans control reinforcement Hole φ16 (0.63)
E Parking brake reinforcement Hole φ12 (0.47) B
F Rear panel Indent
G Rear roof Embossment
C
Description INFOID:0000000006482873
BRM
JSKIA0073GB
M
MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.
N
BRM-111
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
JSKIA2145GB
Unit: mm (in)
«The others»
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo Point Dimension Memo
A-C 721 (28.39)* B-E 298 (11.73)* D-d 1429 (56.26) G-h 1192 (46.93)*
A-D 723 (28.46)* B-e 1233 (48.54)* E-e 1037 (40.83) J-j 965 (37.99)
A-F 802 (31.57)* C-c 1441 (56.73) F-f 1366 (53.78)
MEASUREMENT POINTS
BRM-112
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
BRM
L
JSKIA2146ZZ
: Vehicle front M
Unit: mm (in)
BRM-113
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
Engine Compartment (2WD LHD Models) INFOID:0000000006482894
MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.
JSKIA2147GB
Unit: mm (in)
«The others»
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo Point Dimension Memo
A-C 729 (28.70)* A-J 673 (26.50) C-c 1441 (56.73) F-f 1366 (53.78)
A-D 729 (28.70)* B-E 298 (11.73)* D-d 1429 (56.26) G-h 1192 (46.93)*
A-F 798 (31.42)* B-e 1233 (48.54)* E-e 1037 (40.83) J-j 965 (37.99)
MEASUREMENT POINTS
BRM-114
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
BRM
L
JSKIA2148ZZ
: Vehicle front M
Unit: mm (in)
BRM-115
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
Engine Compartment (4WD RHD Models) INFOID:0000000006482875
MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.
JSKIA2149GB
Unit: mm (in)
«The others»
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo Point Dimension Memo
A-C 721 (28.39)* B-E 298 (11.73)* D-d 1429 (56.26) G-h 1192 (46.93)*
A-D 723 (28.46)* B-e 1233 (48.54)* E-e 1037 (40.83) J-j 958 (37.72)
A-F 802 (31.57)* C-c 1441 (56.73) F-f 1366 (53.78)
MEASUREMENT POINTS
BRM-116
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
BRM
L
JSKIA2150ZZ
: Vehicle front M
Unit: mm (in)
BRM-117
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
Engine Compartment (4WD LHD Models) INFOID:0000000006482895
MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.
JSKIA2151GB
Unit: mm (in)
«The others»
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo Point Dimension Memo
A-C 729 (28.70)* B-E 298 (11.73)* D-d 1429 (56.26) G-h 1192 (46.93)*
A-D 729 (28.70)* B-e 1233 (48.54)* E-e 1037 (40.83) J-j 958 (37.72)
A-F 798 (31.42)* C-c 1441 (56.73) F-f 1366 (53.78)
MEASUREMENT POINTS
BRM-118
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
BRM
L
JSKIA2152ZZ
: Vehicle front M
Unit: mm (in)
BRM-119
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
Underbody (2WD Models) INFOID:0000000006482876
MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.
The following figure shows a bottom view and a side view of the vehicle.
JSKIA1991GB
BRM-120
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm (in) A
: Vehicle front
: Vehicle left side
MEASUREMENT POINTS B
BRM
N
JSKIA2153ZZ
: Vehicle front
O
Unit: mm (in)
Coordinates Coordinates
Points Remarks Points Remarks
X Y Z X Y Z P
473.5 −557.0 293.0 ±482.3 2374.2 348.3
A Hole φ11 (0.43) H, h Hole φ12 (0.47)
(18.642) (−21.929) (11.535) (±18.988) (93.472) (13.713)
−491.0 −557.0 301.9 499.5 2448.0 378.0
a Hole φ11 (0.43) J Hole φ21 (0.83)
(−19.331) (−21.929) (11.886) (19.665) (96.378) (14.882)
472.4 −455.0 328.9 −487.5 2448.0 378.0
B Hole φ18 (0.71) j Hole φ21 (0.83)
(18.598) (−17.913) (12.949) (−19.193) (96.378) (14.882)
BRM-121
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
Coordinates Coordinates
Points Remarks Points Remarks
X Y Z X Y Z
−489.7 −455.0 328.9 498.0 2743.0 378.0 Hole 17×16
b Hole φ18 (0.71) K
(−19.279) (−17.913) (12.949) (19.606) (107.992) (14.882) (0.67×0.63)
±410.0 547.0 190.2 −487.5 2743.0 378.0 Hole 17×16
C, c Hole φ16 (0.63) k
(±16.142) (21.535) (7.488) (−19.193) (107.992) (14.882) (0.67×0.63)
±410.0 815.0 184.0 498.0 2970.0 375.4
D, d Hole φ12 (0.47) M Hole φ16 (0.63)
(±16.142) (32.087) (7.244) (19.606) (116.929) (14.779)
±410.0 1173.0 170.1 Hole 14×2 −485.1 2965.8 375.4
E, e m Hole φ16 (0.63)
(±16.142) (46.181) (6.697) (0.55×0.47) (−19.098) (116.764) (14.779)
±633.0 2032.3 318.0 ±583.6 6.6 868.2
F, f Hole φ16 (0.63) N, n Hole φ98 (3.86)
(±24.921) (80.012) (12.520) (±22.976) (0.261) (34.181)
±350.0 2253.0 390.4 ±575.4 2569.2 734.4
G, g Hole 16 (0.63) O, o Hole φ20 (0.79)
(±13.780) (88.701) (15.370) (±22.653) (101.149) (28.913)
MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the
vehicle.
The following figure shows a bottom view and a side view of the vehicle.
BRM-122
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
BRM
JSKIA2154GB
P
Unit: mm (in)
: Vehicle front
: Vehicle left side
MEASUREMENT POINTS
BRM-123
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
JSKIA2155ZZ
: Vehicle front
Unit: mm (in)
Coordinates Coordinates
Points Remarks Points Remarks
X Y Z X Y Z
473.5 −557.0 293.0 ±515.1 2318.6 357.2
A Hole φ11 (0.43) G, g Hole φ12 (0.47)
(18.642) (−21.929) (11.535) (±20.279) (91.283) (14.063)
−491.0 −557.0 301.9 ±330.0 2339.7 419.0 Hole 33×30
a Hole φ11 (0.43) H, h
(−19.331) (−21.929) (11.886) (±12.992) (92.114) (16.496) (1.30×1.18)
472.4 −455.0 328.9 ±482.0 2648.0 422.2 Hole 20×6
B Hole φ18 (0.71) J, j
(18.598) (−17.913) (12.949) (±18.976) (104.252) (16.622) (0.79×0.63)
−489.7 −455.0 328.9 ±300.0 2815.0 417.2 Hole 18×6
b Hole φ18 (0.71) K, k
(−19.279) (−17.913) (12.949) (±11.811) (110.827) (16.425) (0.71×0.63)
±410.0 547.0 190.2 ±482.7 2910.5 421.4
C, c Hole φ16 (0.63) M, m Hole φ23 (0.91)
(±16.142) (21.535) (7.488) (±19.004) (114.586) (16.591)
±410.0 815.0 184.0 ±583.6 6.6 868.2
D, d Hole φ12 (0.47) N, n Hole φ98 (3.86)
(±16.142) (32.087) (7.244) (±22.976) (0.261) (34.181)
BRM-124
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
Coordinates Coordinates
Points Remarks Points Remarks A
X Y Z X Y Z
±410.0 1173.0 170.1 Hole 14×2 ±558.8 2568.4 734.4
E, e O, o Hole φ20 (0.79)
(±16.142) (46.181) (6.697) (0.55×0.47) (±22.000) (101.118) (28.913)
B
±601.8 2016.4 315.0
F, f Hole φ15 (0.59)
(±23.693) (79.386) (12.402)
MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the D
vehicle.
BRM
M
JSKIA1996GB
Unit: mm (in)
N
«The others»
O
BRM-125
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm (in)
Point Dimension Memo Point Dimension Memo Point Dimension Memo Point Dimension Memo
A-E 724 (28.50)* H-h 1406 (55.35) N-n 1423 (56.02) R-J 1394 (54.88)*
B-E 1028 (40.47)* H-j 1829 (72.01)* N-o 1585 (62.40)* R-K 1072 (42.20)*
C-d 1290 (50.79)* H-k 1663 (65.47)* N-p 1554 (61.18)* S-M 1094 (43.07)*
C-e 1423 (56.02)* J-j 1257 (49.49) N-q 1506 (59.29)* S-N 786 (30.94)*
F-f 1222 (48.11) J-k 1463 (57.60)* O-o 1326 (52.20) S-O 1248 (49.13)*
F-h 1569 (61.77)* K-k 1425 (56.10) O-q 1518 (59.76)* S-P 1126 (44.33)*
F-j 1386 (54.57)* M-m 1248 (49.13) P-p 1397 (55.00) S-Q 905 (35.63)*
F-k 1519 (59.80)* M-n 1451 (57.13)* Q-q 1444 (56.85) T-V 1128 (44.41)*
G-g 1359 (53.50) M-o 1441 (56.73)* R-F 1104 (43.46)* T-W 1105 (43.50)*
G-j 1630 (64.17)* M-p 1486 (58.50)* R-G 885 (34.84)* U-V 1204 (47.40)*
G-k 1616 (63.62)* M-q 1578 (62.13)* R-H 720 (28.35)* U-W 1091 (42.95)*
MEASUREMENT POINTS
JSKIA1997ZZ
BRM-126
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
: Vehicle front A
Unit: mm (in)
MEASUREMENT
Dimensions marked with ″*″ indicate symmetrically identical dimensions on both the right and left hand of the G
vehicle.
BRM
P
JSKIA1998GB
Unit: mm (in)
MEASUREMENT POINTS
BRM-127
BODY ALIGNMENT
< SERVICE DATA AND SPECIFICATIONS (SDS)
JSKIA1999ZZ
: Vehicle front
BRM-128
LOCATION OF PLASTIC PARTS
< SERVICE DATA AND SPECIFICATIONS (SDS)
LOCATION OF PLASTIC PARTS
A
Precautions for Plastics INFOID:0000000006698764
B
Heat resisting
Abbre- Resistance to gasoline and
Material name temperature Other cautions
viation solvents
°C (°F)
C
Gasoline and most solvents are
PE Polyethylene 60 (140) harmless if applied for a very Flammable
short time (wipe out quickly).
ABS Acrylonitrile Butadiene Styrene 80 (176) Avoid gasoline and solvents. — D
Gasoline and most solvents are
EPM/ Ethylene Propylene (Diene) co-
80 (176) harmless if applied for a very Flammable
EPDM polymer
short time (wipe out quickly). E
PS Polystyrene 80 (176) Avoid solvents. Flammable
Gasoline and most solvents are
Poisonous gas is emitted
PVC Poly Vinyl Chloride 80 (176) harmless if applied for a very F
when burned.
short time (wipe out quickly).
TPO Thermoplastic Olefine 80 (176) ↑ Flammable
AAS Acrylonitrile Acrylic Styrene 85 (185) Avoid gasoline and solvents. — G
PMMA Poly Methyl Methacrylate 85 (185) ↑ —
EVAC Ethylene Vinyl Acetate 90 (194) ↑ —
H
Gasoline and most solvents are
Flammable, avoid bat-
PP Polypropylene 90 (194) harmless if applied for a very
tery acid.
short time (wipe out quickly).
I
PUR Polyurethane 90 (194) Avoid gasoline and solvents. —
UP Unsaturated Polyester 90 (194) ↑ Flammable
ASA Acrylonitrile Styrene Acrylate 100 (212) ↑ Flammable J
PPE Poly Phenylene Ether 110 (230) ↑ —
TPU Thermoplastic Urethane 110 (230) ↑ —
PBT+ Poly Butylene Terephthalate +
BRM
120 (248) ↑ Flammable
PC Polycarbonate
PC Polycarbonate 120 (248) ↑ —
L
POM Poly Oxymethylene 120 (248) ↑ Avoid battery acid.
Avoid immersing in wa-
PA Polyamide 140 (284) ↑
ter.
M
PBT Poly Butylene Terephthalate 140 (284) ↑ —
PAR Polyarylate 180 (356) ↑ —
PET Polyethylene terephthalate 180 (356) ↑ — N
PEI Polyetherimide 200 (392) ↑ —
CAUTION:
• When repairing and painting a portion of the body adjacent to plastic parts, consider their characteristics (influence of heat O
and solvent) and remove them if necessary or take suitable measures to protect them.
• Plastic parts should be repaired and painted using methods suiting the materials, characteristics.
P
BRM-129
LOCATION OF PLASTIC PARTS
< SERVICE DATA AND SPECIFICATIONS (SDS)
Location of Plastic Parts INFOID:0000000006482882
JSKIA2000ZZ
BRM-130
LOCATION OF PLASTIC PARTS
< SERVICE DATA AND SPECIFICATIONS (SDS)
H
JSKIA2001ZZ
BRM-131