TO INDEX

C REPLACEMENT PROCEDURE FOR BODY PANELS

RADIATOR SUPPORT UPPER-------------- C - 1

REPLACEMENT ------------------------------ C - 1
RADIATOR SUPPORT SIDE ----------------- C - 4
REPLACEMENT ------------------------------ C - 4
FRONT FENDER APRON FRONT --------- C - 6
REPLACEMENT ------------------------------ C - 6
FRONT FENDER APRON------------------- C - 10
REPLACEMENT ---------------------------- C - 10
FRONT SIDE MEMBER---------------------- C - 14
REPLACEMENT (CUTTING) ------------ C - 14
REPLACEMENT ---------------------------- C - 18
COWL TOP SIDE PANEL ------------------- C - 20
REPLACEMENT ---------------------------- C - 20
FRONT BODY PILLAR ----------------------- C - 22
REPLACEMENT ---------------------------- C - 22
CENTER BODY PILLAR --------------------- C - 26
REPLACEMENT ---------------------------- C - 26
ROCKER PANEL OUTER ------------------- C - 29
REPLACEMENT (CUTTING) ------------ C - 29
REPLACEMENT ---------------------------- C - 31
QUARTER PANEL----------------------------- C - 33
REPLACEMENT ---------------------------- C - 33
QUARTER WHEEL HOUSE PANEL
OUTER ------------------------------------------- C - 37
REPLACEMENT ---------------------------- C - 37
QUARTER PANEL EXTENSION REAR - C - 41
REPLACEMENT ---------------------------- C - 41
BODY LOWER BACK PANEL-------------- C - 43
REPLACEMENT (CUTTING) ------------ C - 43
REPLACEMENT (CUTTING ON ONE
SIDE) ------------------------------------------- C - 47
REAR FLOOR CROSS MEMBER
REINFORCEMENT NO.2-------------------- C - 52
REPLACEMENT ---------------------------- C - 52
REAR FLOOR SIDE PANEL
EXTENSION FRONT ------------------------- C - 54
REPLACEMENT ---------------------------- C - 54
REAR FLOOR PAN --------------------------- C - 56
REPLACEMENT (CUTTING) ------------ C - 56
REPLACEMENT ---------------------------- C - 59
REAR FLOOR CROSS MEMBER NO.2- C - 62
REPLACEMENT ---------------------------- C - 62
REAR FLOOR MOUNTING BRACKET
NO.2 ----------------------------------------------- C - 64
REPLACEMENT ---------------------------- C - 64
ROOF PANEL----------------------------------- C - 68
REPLACEMENT ---------------------------- C - 68
C–1
1 RADIATOR SUPPORT UPPER
1-1 REPLACEMENT
1-1-1 REMOVAL PROCEDURES

4)S

1)S

2)S

T11B9001S30
 C–2
1-1-2 INSTALLATION PROCEDURES

4)P

1)P

2)P

T11B9002S30

1.Remove the part or component to be exchanged from the service parts and install to the vehicle.
C–3

1,230 mm

1,040 m
m
m
55m

T11B9003S40

The figures are reference values.

2.Measure dimensions of the head lamp mounting hole before installing replacement parts.
 C–4
2 RADIATOR SUPPORT SIDE
2-1 REPLACEMENT
2-1-1 REMOVAL PROCEDURES

4)S

2)S 2)S 5)S

T11B9004S40
C–5
2-1-2 INSTALLATION PROCEDURES

4)P

2)P 2)P 5)P

T11B9005S40
 C–6
3 FRONT FENDER APRON FRONT
3-1 REPLACEMENT
3-1-1 OPERATION BEFORE REMOVAL
1.Remove the part or component to be exchanged from the radiator support upper.
3-1-2 REMOVAL PROCEDURES

[RH]
1)S

2)S

7)S

3)S

3)S
2)S 1)S

[LH]

1)S
2)S

8)S

1)S
5)S

T11B9006S40
C–7

1)S

1)S

T11B9007S30
 C–8
3-1-3 INSTALLATION PROCEDURES

[RH] 1)P
2)P

7)P

3)P

3)P
1)P
2)P

[LH]

1)P
2)P

8)P

1)P
5)P

T11B9008S40

1.Remove the part or component to be exchanged from the service parts and install to the vehicle.
C–9

1)P

1)P

2)P

[A]

T11B9009S40

[A] Front fender mounting bracket

3-1-4 OPERATION AFTER INSTALLATION
1.Install the radiator support upper.
 C–10
4 FRONT FENDER APRON
4-1 REPLACEMENT
4-1-1 OPERATION BEFORE REMOVAL
1.Remove the part or component necessary to remove the radiator support upper.
2.Remove the part or component necessary to remove the cowl top side panel.
4-1-2 REMOVAL PROCEDURES

[RH]

3)S 3)S

2)S 7)S

[LH]

12)S

T11B9010S40
C–11

4)S

1)S

5)S

2)S

1)S

7)S

T11B9011S40
 C–12
4-1-3 INSTALLATION PROCEDURES

[RH]

[A]

3)P 3)P

2)P 7)P

[LH]

[A]

12)P

T11B9012S40

[A] Front fender mounting bracket

C–13

1)P

4)P

2)P

5)P

1)P

7)P

2)P

[A]

T11B9013S40

[A] Front fender mounting bracket

4-1-4 OPERATION AFTER INSTALLATION
1.Install the cowl top side panel.
2.Install the radiator support upper.
 C–14
5 FRONT SIDE MEMBER
5-1 REPLACEMENT
5-1-1 OPERATION BEFORE REMOVAL
1.Remove the necessary part or component of the radiator support side.
5-1-2 REMOVAL PROCEDURES

[LH]

40 m
m

[A]

4)S

T11B9014S30

[A] Front side member plate No.2

1.Remove [A] together.
C–15
[RH]

m
30m

[A]

4)S

T11B9015S30

[A] Front side member plate No.2

2.Remove [A] together.
 C–16
5-1-3 INSTALLATION PROCEDURES
[LH]

4)P

Butt welding
Fillet welding(15mm)
[B]

5)P

4)P

3)P

5)P
[A]

Fillet welding(15mm)

[B]
2)P

T11B9016ES40

[A] Front side member plate No.2

[B] Front bumper arm
C–17
[RH]

4)P
Butt welding
Fillet welding(15mm)
5)P
[B]

4)P

3)P

5)P
[A]

Fillet welding(15mm)

[B]

2)P

T11B9017ES40

[A] Front side member plate No.2

[B] Front bumper arm
5-1-4 OPERATION AFTER INSTALLATION
1.Install the radiator support side.
 C–18
5-2 REPLACEMENT
5-2-1 OPERATION BEFORE REMOVAL
1.Remove the necessary part or component of the radiator support side.
2.Remove the necessary part or component of the front fender apron.
5-2-2 REMOVAL PROCEDURES

2)S

9)S
5)S 4)S

6)S

T11B9018S30

1.Replace the front side member while retaining the rear section of it on the vehicle side.
C–19
5-2-3 INSTALLATION PROCEDURES

4)P 9)P

6)P

2)P

Fillet welding(15mm)
[A]

5)P
5)P

3)P 4)P

5)P

Fillet welding(15mm)
T11B9019ES40

[A] Front side member plate No.2

1.Remove the part or component to be exchanged from the replacement parts and install to the vehicle.
5-2-4 OPERATION AFTER INSTALLATION
1.Install the front fender apron.
2.Install the radiator support side.
 C–20
6 COWL TOP SIDE PANEL
6-1 REPLACEMENT
6-1-1 REMOVAL PROCEDURES

Perform grinding,
using a cut grinder or the like.

9)S

11)S

T11B9020ES40
C–21
6-1-2 INSTALLATION PROCEDURES

Fillet welding(15mm)4)

9)P

11)P

T11B9021ES40
 C–22
7 FRONT BODY PILLAR
7-1 REPLACEMENT
7-1-1 OPERATION BEFORE REMOVAL
1.Remove the necessary part or component of the cowl top side panel.
7-1-2 REMOVAL PROCEDURES

2)S

mm

mm
50

100
2)S
3)S

2)S
5)S

3)S

1)S
1)S

1)S Perform grinding,

using a cut grinder or the like.
7)S

2)S
2)S
5)S 240 mm
30 mm

5)S 1)S

1)S

1)S

72mm

T11B9022ES40
C–23

5)S

Perform grinding,
using a cut
grinder or the like.

3)S

6)S

2)S
T11B9023ES30
 C–24
7-1-3 INSTALLATION PROCEDURES

mm
50
110 mm
mm
65

[A]

2)P
[E]

[C]

12)S
Fillet welding(15mm)4) 1)P
8)S
1)P
1)P

4)S
15)S
[D]
4)P 17)S

1)P
2)P
[B] 2)P

2)P 4)P

1)P
3)S 11)S 4)P

T11B9024ES40

[A] Rocker panel reinforcement

[B] Front pillar reinforcement lower
[C] Front pillar upper inner
[D] Front pillar inner
[E] Outer panel
1.Provide the specified number of welds to [A], [B], [C], [D], and [E] before the replacement parts are
temporarily installed.
C–25

5)P
2)P

2)P
4)S Fillet welding(15mm)2)
3)P
2)P Butt welding

7)S Butt welding

3)P
1)P 6)P
1)P
1)P
Fillet welding(15mm)

7)P

2)P 2)P
5)P

1)P
5)P Butt welding

1)P

1)P 2)P

Butt welding

T11B9025ES40

7-1-4 OPERATION AFTER INSTALLATION

1.Install the cowl top side panel.
 C–26
8 CENTER BODY PILLAR
8-1 REPLACEMENT
8-1-1 REMOVAL PROCEDURES

1)S
100 mm 1)S
45 mm 3)S
*1 1)S

16)S

6)S 6)S 8)S

4)S
4)S 18)S 210 mm

Perform grinding,
using a cut grinder or the like.

30 mm
35 mm

m
45 m

T11B9026ES40

*1 is reused.
C–27
8-1-2 INSTALLATION PROCEDURES

[A] 200mm

13)S

[B]

9)P

6)P

28)S
28)S

[C]

4)P

T11B9027S30

[A] Rocker panel reinforcement

[B] Center pillar reinforcement
[C] Center pillar inner
1.Provide the specified number of welds to [A], [B], and [C] before the replacement parts are temporar-
ily installed.
 C–28

Butt welding

[B]

13)P

2)P

5)P 10)S 2)P 7)S

3)P 8)S 5)P 8)S

1)P Butt welding 1)P
[A]
3)P

[C]

1)P Butt welding

1)P

[D]

29)P 4)P
34)P

Fillet welding(15mm)2)
Butt welding Butt welding

6)P

4)P 24)P

T11B9028ES40

[A] Rocker panel reinforcement

[B] Center pillar reinforcement
[C] Center pillar inner
[D] Outer panel
2.Weld [A], [B], and [C] to the vehicle and then install [D].
C–29
9 ROCKER PANEL OUTER
9-1 REPLACEMENT
9-1-1 REMOVAL PROCEDURES

5)S

5)S
210 mm 530 mm

T11B9029S30
 C–30
9-1-2 INSTALLATION PROCEDURES

Butt welding

5)P

5)P

T11B9030ES30
C–31
9-2 REPLACEMENT
9-2-1 REMOVAL PROCEDURES

Adhesive application
range

;;;;
a(a

16)S 17)S
a
a
4)S

34)S Adhesive application range

80mm

T11B9031ES40
 C–32
9-2-2 INSTALLATION PROCEDURES

Butt welding

16)P 17)P
a
;;;; a
4)P

34)P
Butt welding Adhesive application range

Adhesive application range

a(a

T11B9032ES30
C–33
10 QUARTER PANEL
10-1 REPLACEMENT
10-1-1 REMOVAL PROCEDURES

180mm
Adhesive application
range

16)S

a(a
; a

; a
1)S

Adhesive application range

T11B9033ES30
 C–34

12)S

5)S

T11B9034S30
C–35
10-1-2 INSTALLATION PROCEDURES

Body sealer
application range

b
Body sealer application range

3)P [B]
[A]

b(b
b

Adhesive application
range

3)P

[C]

[D]

T11B9035ES30

[A] Quarter lock pillar reinforcement

[B] Fuel inlet box
[C] Fuel filler opening lid
[D] Waterproofing rivet
1.Apply the body sealer before the replacement parts are temporarily installed.
 C–36

Adhesive application
Butt welding range

21)S
Adhesive application range
a a(a

Butt welding
13)S
;;
a
1)P

*1

Butt welding

12)P

3mm [E]

7)S

5mm

*2

T11B9036ES40

[E] Spot tip

2.As the flange width is narrow, work and adjust the end portion of [E] as in *2 when spot welding the
section *1.
C–37
11 QUARTER WHEEL HOUSE PANEL OUTER
11-1 REPLACEMENT
11-1-1 OPERATION BEFORE REMOVAL
1.Remove the necessary part or component of the quarter panel.
2.Remove the necessary part or component of the quarter panel extension rear.
11-1-2 REMOVAL PROCEDURES
[LH]

4)S [A]

13)S 3)S
4)S

2)S
Adhesive application range
6)S

210 mm [B]

4)S 7)S
2)S
3)S

8)S

2)S
9)S 3)S

3)S

1)S 1)S
T11B9037ES30

[A] Rocker panel outer

[B] Quarter wheel house gusset inner
1.Remove [A] and [B] to remove the replacement parts.
 C–38

[RH]

[A] 4)S

4)S 3)S

6)S

Adhesive application 2)S

range 210 mm 13)S

[B]

6)S 4)S 4)S

2)S

1)S

4)S
2)S
6)S 9)S

3)S

1)S
1)S

T11B9038ES40

[A] Rocker panel outer

[B] Quarter wheel house gusset inner
2.Remove [A] and [B] to remove the replacement parts.
C–39
11-1-3 INSTALLATION PROCEDURES
[LH]

4)P 7)P
3)S
3)P

[D]

8)P
[C]

4)P 3)P
12)S

4)S

1)P

1)P

[A]

[B]

Butt welding 4)P

4)P

13)P 3)P

6)P Adhesive application

2)P
range

T11B9039ES30

[A] Rocker panel outer

[B] Quarter wheel house gusset inner
[C] Belt anchor to quarter reinforcement inner lower
[D] Rear seat back set retainer
1.Install the replacement parts, and then install [A] and [B].
 C–40

[RH]

4)P 4)P
3)S

6)P
[E] [C]

1)P
4)P

4)P
6)P 12)S

4)S

1)P

1)P

[A]

[B]

Butt welding
4)P

4)P
3)P 13)P

Adhesive application range

2)P 6)P

T11B9040ES40

[A] Rocker panel outer

[B] Quarter wheel house gusset inner
[C] Belt anchor to quarter reinforcement inner lower
[E] Rear seat back set retainer
2.Install the replacement parts, and then install [A] and [B].
11-1-4 OPERATION AFTER INSTALLATION
1.Install the quarter panel extension rear.
2.Install the quarter panel.
C–41
12 QUARTER PANEL EXTENSION REAR
12-1 REPLACEMENT
12-1-1 OPERATION BEFORE REMOVAL
1.Remove the necessary part or component of the quarter panel.
12-1-2 REMOVAL PROCEDURES

1)S

1)S 2)S

1)S

3)S

1)S

1)S
6)S
3)S

9)S

T11B9041S30
 C–42
12-1-3 INSTALLATION PROCEDURES

1)P 1)P

1)P
1)P

1)P 2)P

7)S

3)P

4)P

6)P
3)P

T11B9042S30

1.Remove the part or component to be exchanged from the replacement parts and install to the vehicle.
12-1-4 OPERATION AFTER INSTALLATION
1.Install the quarter panel.
C–43
13 BODY LOWER BACK PANEL
13-1 REPLACEMENT
13-1-1 REMOVAL PROCEDURES

5)S

5)S

150 mm

[A]

T11B9043S30

[A] Body lower back reinforcement

1.Remove [A] before starting the work.
 C–44

20)S

40mm

6)S 6)S

T11B9044S40
C–45
13-1-2 INSTALLATION PROCEDURES

5)S

4)S

140mm

[A]

2)S

40mm

4)S 4)S

T11B9070S40

[A] Body lower back reinforcement

1.Remove the part or component to be exchanged from the replacement parts and install to the vehicle.
2.Remove [A] before starting the work.
 C–46

Butt welding Butt welding

20)P

6)P 6)P

Butt welding Butt welding

5)P

5)P

Butt welding

T11B9045ES44
C–47
13-2 REPLACEMENT
13-2-1 OPERATION BEFORE REMOVAL
1.Remove the necessary part or component of the quarter panel extension rear.
13-2-2 REMOVAL PROCEDURES

[A]
5)S

5)S

150mm

16)S

40mm

T11B9046S40

[A] Body lower back reinforcement

1.Remove [A] before starting the work.
 C–48

2)S

1)S 2)P

5)S
3)S

8)S

2)S

Adhesive application range

1)S

6)S

T11B9047ES40
C–49
13-2-3 INSTALLATION PROCEDURES

5)S

4)S

140mm

[A]

2)S

40mm

4)S

T11B9071S40

[A] Body lower back reinforcement

1.Remove the part or component to be exchanged from the replacement parts and install to the vehicle.
2.Remove [A] before starting the work.
 C–50

Butt welding
16)P

2)P

1)P 2)P

5)P
3)P

8)P

2)P
Adhesive application range

1)P

T11B9048ES40
C–51

6)P

Butt welding

5)P

5)P

Butt welding

T11B9049ES40

13-2-4 OPERATION AFTER INSTALLATION

1.Install the quarter panel extension rear.
 C–52
14 REAR FLOOR CROSS MEMBER REINFORCEMENT NO.2
14-1 REPLACEMENT
14-1-1 REMOVAL PROCEDURES

5)S

5)S

8)S

5)S
6)S

T11B9050S30
C–53
14-1-2 INSTALLATION PROCEDURES

5)P

5)P

8)P

6)P

5)P

T11B9051S30
 C–54
15 REAR FLOOR SIDE PANEL EXTENSION FRONT
15-1 REPLACEMENT
15-1-1 REMOVAL PROCEDURES

18)S

12)S

3)S

2)S
16)S *1
1)S

14)S

T11B9052S30

*1 is LH only.
C–55
15-1-2 INSTALLATION PROCEDURES

18)P

12)P

3)P

2)P
16)P *1
1)P

14)P

T11B9053S30

*1 is LH only.
 C–56
16 REAR FLOOR PAN
16-1 REPLACEMENT
16-1-1 OPERATION BEFORE REMOVAL
1.Remove the necessary part or component of the body lower back panel.
16-1-2 REMOVAL PROCEDURES

2)S

3)S
2)S
10)S
*1
1)S

12
7)S

0m
m
140
mm

[A]

[B]

a(a

T11B9054S40

*1is LH only.
[A] Rear floor side panel extension front
[B] Rear floor cross member No.2
C–57
16-1-3 INSTALLATION PROCEDURES

Body sealer application range

[B]

*1

b(b
260mm

[C]*2

4)P

16)P

T11B9513ES30

*2 is only for vehicles that have a compact tire as the spare tire.
[B] Rear floor cross member No.2
[C] Jack support bracket
1.Remove the part or component to be exchanged from the replacement parts and install to the vehicle.
2.Cut off the replacement part where it overlaps with the cut end by approx. 30mm.
3.Plug weld the overlapped portions of *1, and apply the body sealer on both sides.
 C–58

2)P
3)P

Body sealer application range

2)P
10)P *1
1)P

7)P
[A]

Butt welding

T11B9056ES30

*1 is LH only.
[A] Rear floor side panel extension front
16-1-4 OPERATION AFTER INSTALLATION
1.Install the body lower back panel.
C–59
16-2 REPLACEMENT
16-2-1 OPERATION BEFORE REMOVAL
1.Remove the necessary part or component of the body lower back panel.
2.Remove the necessary part or component of the rear floor cross member reinforcement No.2.
3.Remove the necessary part or component of the rear floor side panel extension front.
16-2-2 REMOVAL PROCEDURES
19)S

14)S

15)S

17)S

16)S

1)S
2)S
2)S 2)S
11)S 1)S
4)S
1)S
1)S
4)S
7)S
1)S

6)S
1)S
1)S
1)S
2)S 1)S

1)S

T11B9057S30
 C–60
16-2-3 INSTALLATION PROCEDURES

[B] [B] 3)P 3)P

6)P 4)P

[A] 4)P

[C]

3Vehicles that have a compact tire as the spare tire5 3Vehicles that have a standard tire as the spare tire5

19)P

14)P

15)P

17)P

16)P

T11B9510ES40

[A] Jack support bracket

[B] Spare wheel clamp bracket
[C] Spare wheel carrier bracket No.1
C–61

2)P

11)P

6)P

1)P
2)P
2)P
1)P
4)P 1)P

1)P
4)P
7)P 1)P

1)P
1)P
1)P
1)P
2)P

1)P

T11B9059S30

16-2-4 OPERATION AFTER INSTALLATION

1.Install the rear floor side panel extension front.
2.Install the rear floor cross member reinforcement No.2.
3.Install the body lower back panel.
 C–62
17 REAR FLOOR CROSS MEMBER NO.2
17-1 REPLACEMENT
17-1-1 REMOVAL PROCEDURES

17)S

16)S

6)S

T11B9060S30
C–63
17-1-2 INSTALLATION PROCEDURES

17)P

16)P

6)P

T11B9061S30
 C–64
18 REAR FLOOR MOUNTING BRACKET NO.2
18-1 REPLACEMENT
18-1-1 OPERATION BEFORE REMOVAL
1.Remove the necessary part or component of the body lower back panel.
2.Remove the necessary part or component of the rear floor cross member No.2.
18-1-2 REMOVAL PROCEDURES

[LH]
3)S

[A]
4)S

7)S

2)S 2)S

4)S

5)S

2)S

2)S

4)S

3)S

T11B9064S40

[A] Rear shock absorber bracket

1.Remove [A] together.
C–65
[RH]

3)S

[A]

2)S
8)S

2)S 2)S

4)S

5)S

2)S

2)S

1)S 4)S
1)S

1)S
1)S

T11B9065S40

[A] Rear shock absorber bracket

2.Remove [A] together.
 C–66
18-1-3 INSTALLATION PROCEDURES

[LH]

3)P

[A]

4)P

14)P 2)P 2)P

4)P

5)P

2)P

2)P

4)P

3)P

T11B9066S40

[A] Rear shock absorber bracket

C–67
[RH]

3)P

[A]

2)P

2)P 2)P 16)P

4)P

5)P

2)P

2)P

1)P 4)P
1)P

1)P 1)P

T11B9067S40

[A] Rear shock absorber bracket

18-1-4 OPERATION AFTER INSTALLATION
1.Install the rear floor cross member No.2.
2.Install the body lower back panel.
 C–68
19 ROOF PANEL
19-1 REPLACEMENT
19-1-1 REMOVAL PROCEDURES

27)S

27)S

18)S

3)S 3)S
7)S 7)S

6)S
2)S 2)S

T11B9068S30
C–69
19-1-2 INSTALLATION PROCEDURES

27)P

4)P
27)P

13)S

4)P

3)P 3)P
7)P 7)P

8)S
2)P 2)P

T11B9069S30

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