FOREORD

This Body Repair Manual contains information and instructions for repairing the body structure of
the 2005 SM3 CF model. In order to achieve reliable repair work and ensure customer satisfaction,
the technician should study this manual and become familiar with appropriate sections before start-
ing repair and rebuilding work.

All information in this manual is based on the latest product information at the time of publication.
The right is reserved to make changes in specifications and methods at any time without notice.

Relevant Materials

1. SM3 CF Introduction Manual

2. SM3 CF Service Manual
3. Sheet Metal Training Manual
4. Painting Training Manual
5. Color Combination Chart

1
 CONTANTS

1. Body Construction..........................................................................................................4
2. Touch-up Products .......................................................................................................12
3. Plastic Materials............................................................................................................13
4. Body Sealing .................................................................................................................15
5. Corrosion Protection ....................................................................................................19
6. Wheel Alignment...........................................................................................................22
7. Body Alignment ............................................................................................................23
8. Parts Replacement........................................................................................................33
8-1. Radiator Core Support (Replacement)........................................................................................ 35
8-2. Radiator Core Support (Partial Replacement) ............................................................................ 36
8-3. Hoodledge Panel (Replacement) ................................................................................................ 37
8-4. Hoodledge Panel (Partial Replacement).....................................................................................39
8-5. Front Side Member (Replacement)............................................................................................. 41
8-6. Front Side Member (Partial Replacement).................................................................................. 42
8-7. Front Pillar (Replacement) .......................................................................................................... 44
8-8. Center Pillar (Replacement)........................................................................................................ 46
8-9. Seal Outer (Replacement) .......................................................................................................... 48
8-10. Rear Fender (Replacement) ..................................................................................................... 50
8-11. Rear Wheelhouse Outer (Replacement) ................................................................................... 52
8-12. Rear Panel (Replacement)........................................................................................................ 54
8-13. Rear Floor Rear (Replacement)................................................................................................ 55
8-14. Rear Side Member (Replacement) ........................................................................................... 57
8-15. Rear Side member extension, LH (Replacement) .................................................................... 59
8-16. Rear Side member extension, RH (Replacement).................................................................... 60
8-17. Roof Panel (Replacement)........................................................................................................ 61
9. Service Parts .................................................................................................................62
9-1. Underbody................................................................................................................................... 62
9-2. Body Side & Roof........................................................................................................................ 66

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 1. BODY CONSTRUCTION

1. Body Construction
1-1. Body Construction

Body side outer Dash side Front pillar

Cowl top side inner upper

Front filler drip

Front pillar inner upper

Body side outer Front pillar upper

Front pillar upper
hinge reinforcement
hinge reinforcement
Section A-A Section B-B

Front pillar lower

Dash side Front pillar lower
Hinge plate lower hinge reinforcement
reinforcement

Body side Body side

outer outer
Seal inner
Seal outer front
reinforcement
Front pillar lower
hinge reinforcement

Section C-C Section D-D

4
 1. BODY CONSTRUCTION

Body side outer Center pillar inner

Center pillar
Center pillar inner hinge reinforcement

Seal inner

Body side Center pillar

Seal outer outer hinge reinforcement
front reinforcement
Section E-E Section F-F

Center pillar
Center pillar inner reinforcement inner Center pillar inner Center pillar lower reinforcement

Body side
outer

Center pillar Body side Center pillar hinge reinforcement

hinge reinforcement Center pillar reinforcement outer

Section G-G Section H-H

Body side outer

Seal inner Rear wheel house inner
extension
Rear wheel house outer

Rear fender Rear fender

Wheel house outer
extension

Section I-I Section J-J

Rear pillar inner lower

Rear pillar inner upper
Rear pillar inner upper

Rear fender
Parcel shelf side
reinforcement LH
Parcel shelf side

Rear wheel house outer

Rear fender
drip Rear fender Rear pillar inner reinforcement

RH

Section K-K Section L-L

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 1. BODY CONSTRUCTION

1-2. Body Center Marks

A mark has been placed on each part of the body to indicate the vehicle center.
When repairing parts damaged by an accident which might affect the vehicle frame (members,
pillars, etc.) more accurate, effective repair will be possible by using these marks together with
body alignment data.

Hole
Hole

Embossing

Upper radiator core support Cowl top Front roof Rear roof

Elongated
hole
Embossing

Embossing
Elongated
hole
Front

Rear waist panel Rear panel crossmember Front floor Rear floor

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 1. BODY CONSTRUCTION

1-3. Panel Parts Matching Marks

A mark has been placed on each body panel to indicate the parts matching positions. When
repairing parts damaged by an accident which might affect the vehicle frame (members, pil-
lars, etc.) more accurate, effective repair will be possible by using these marks together with
body alignment data.

Type A (Hole ~ Hole) Type D (Hole ~ Embossing)

Type B (Indention ~ Hole) Type E (Indention ~ Indention)

Type C (Indention ~ Embossing)

(1) Front section

(2) Rear section

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 1. BODY CONSTRUCTION

1-4. Measurement
Hood

8
 1. BODY CONSTRUCTION

Door

9
 1. BODY CONSTRUCTION

Trunk Lid

Bolts (left: 2, right: 2)

Bolts (2)

Correcting the step difference (striker section) Trunk lid

Rear fender corner

Trunk lid
Rear fender Bumper

Rear fender Trunk lid

Section A-A Section B-B Section C-C
Unit : mm
: N.m {kgf-m}

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 1. BODY CONSTRUCTION

1-5. Location of Fusible Insulator

Fusible insulators (melt sheet) are installed on the floor surface and inside of dash panel to re-
duce the noise and dust and to block the exhaust heat.

: indicate the fusible insulator portions.

*1 t = 1.6mm
*1 t = 1.6mm
*1 t = 3.2mm
*1 t = 3.2mm

*1 t = 5.0mm *1 t = 3.2mm

t = 3.2mm

*2 DLS 4.0mm

t = 3.2mm

t = 3.2mm

t = 3.2mm
*1 : Symmetrically identical dimensions on both sides
*2 DLS : Double Layer Sheet

CAUTION Cut the fusible insulator on floor panel according to the measurements shown in table.

Pressure reducing type insulator mm

G5930-89904 1,000 x 800 x 1.6t
G5930-89905 1,000 x 800 x 3.0t
G5930-89906 500 x 800 x 6.0t

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 2. TOUCH-UP PRODUCTS

2. Touch-up Products
When repairing the vehicle body, use only the touch-up products shown in table.

Part
Product Name Application Type Capacity Manufacturer
number

Bumper Priming for bumper BASF

Plastic primer 934-0 Can 1ℓ
primer painting GLASURIT

Electropaint- Anti-corrosive agent Nambang

ZINCOT N-50 Aerosol 420 mℓ
ing primer for welding surface chemistry

Anti-corrosive agent
for panel connecting
Anti corro-
Inner wax Nr.892-081 area and welding sur- Can 1000 mℓ WURTH
sive wax
face after replacing
the service products

Texture Black 1109-1240-4

Stone guard Correction for stone BASF
Aerosol 1000 mℓ
coat Non- guard coat GLASURIT
Gray 1109-1240-6
texture

Nr.08930751
Correction for under-
Undercoat WURTH Aerosol 1000 mℓ WURTH
KA383- coat
89910

Sealing for hemming

area of hood and
Sealing Scotch-Seal 5300 door/connecting area Can 310 mℓ 3M
of outer and inner
panels

Base 1,
Etching primer
283-150 Can Hard-
filler
ener 1
Anti-corro- Priming for BASF
sion primer anti-corrosion GLASURIT
Base 4,
Primer filler 285-16 Can Hard-
ener 1

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 3. PLASTIC MATERIALS

3. Plastic Materials
3-1. Handling Precautions for Plastic

Heat resisting
Abbre- Resistance to gasoline Other
Material name temperature
viation and solvent cautions
(°C)
Gasoline and most solvents are
PE Polyethylene 80 Flammable
harmless.
Gasoline and most solvents are Poison gas is
PVC Polyvinyl chloride 90 harmless if applied for a very short emitted when
time (wipe up quickly). burned.
EPM/ Ethylene Propylene Terpoly-
80 K Flammable
EPDM mers
Gasoline and most solvents are
PP Polypropylene 90 K
harmless
Acrylonitrile Butadiene Avoid brake
ABS 90 Avoid gasoline and solvents.
Styrene Dipolymer fluid
Acrylonitrile Ethylene
AES 90 K K
Styrene Dipolymer
PMMA Polymethylmethacrylate 90 K K
Gasoline and most solvents are
PUR Poly Urethane 90 K
harmless.
Acrylonitrile Acryl Rubber
AAS 95 Avoid gasoline and solvents. K
Styrene Dipolymer
Acrylonitrile Styrene
AS 85 K K
Dipolymer
ASA Acrylonitrile Styrene Acrylate 100 K Flammable
PPE Poly Phenylene Ethylene 110 K
PPO Poly Phenylene Oxide 110 K
Gasoline and most solvents are Avoid battery
POM Poly Acetal 120
harmless. acid
PC Poly Carbonate 120 Avoid gasoline and solvents.
Gasoline and most solvents are Avoid immers-
PA Polyamide 150
harmless. ing in water.
Fiberglass Reinforcement
FRP 170 K
Plastics
PPC Polypropylene Compound 115 K Flammable
PBT Poly Butylene Terephthalate 140 K
PET Poly Butylene Terephthalate 180 K
TPP Thermo Plastic Rubber 80 Avoid gasoline and solvents.
TPE Thermo Plastic Elastomer 80 K

CAUTION 1. When repairing and painting a portion of the body adjacent to plastic parts, consider
their characteristics (influence of heat and solvent) and remove them if necessary or
take suitable measures to protect them.
2. Plastic parts should be repaired and painted using methods suiting the materials char-
acteristics.

13
 3. PLASTIC MATERIALS

3-2. Locations of Plastic Parts

2 Headlamps Window shield molding

(Lens: PC, Housing: PPC) (PVC+Stainless)
4 Headlamps Door mirror
(Lens: Glass, Housing: PP) (Housing: ABS, Base: PA)

Front grille (ABS)

Side guard molding (PP)

Front bumper fascia

(Body: PP, Molding: PP) Side turn signal lamp
(Lens: PMMA, Housing: ABS)
Fog lamp
(Lens: Glass,
Housing: PET)
Rear window molding (PVC)

Door outside molding

(PVC+Stainless)

License plate lamp

(Lens: PC, Housing: PC)

Door outside molding

(Handle: PC+ABS, Rear combination lamp outer lens: PMMA
Housing: PPE+PA) Inner lens (Tail, Strap): PC
Outer housing: PC+PET
Pull cover for disc wheel (PA+PPE) Inner housing: PBT+PET
Half cover for disc wheel (PC+ABS)

Center pillar Armrest

garnish (PPC) (TPO) Front pillar garnish (PPC)
Door finisher (PPC)

Rear pillar finisher (PPC) Cluster lid A (PPC)

Instrument panel
(Panel: PPC, Pad: TPO)

Cup holder (EPDM)

Glove box (PPC)

Center console (PPC)

Kicking plate (PPC)

14
 4. BODY SEALING

4. Body Sealing

Hood

Trunk lid

Rear door

Front door

: Indicates the sealing coated portion. Unit : mm

Section A Apply the sealing on the hemming portion Section B
of service parts

15
 4. BODY SEALING

: Indicates the sealing coated portion. Unit : mm

Section C Section D

Section E Section F

Section A-A Section B-B

Section G Section H

Section A-A

Section I

16
 4. BODY SEALING

: Indicates the sealing coated portion. Unit : mm

Section J Section K Apply the sealing on the hemming portion
of service parts

1350(RH)
1570(LH)

Section L Apply the sealing on the hemming portion Section M

of service parts

Section N Section O

Section A-A

17
 4. BODY SEALING

: Indicates the sealing coated portion. Unit : mm

Section P Section Q

Section R Section S Apply the sealing on the hemming portion

of service parts

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 5. CORROSION PROTECTION

5. Corrosion Protection
5-1. Anti-corrosive Primer Coated Portion
(1) Material
Product: Nr. 892-081 (WURTH)

(2) Coating area and wax nozzle inserting point

Rear fender

Wax nozzle inserting point

Over 50 mm
O
ve
r50
Over 10 mm

m
m

Section D-D Front

(3) Amount of coating

Anti-corrosive primer: Half a container per panel

(4) Coating procedures

1. Immerse the wax nozzle into warm water (45°C) bath so that it could be straightened.
2. Attach the wire for guiding at the point of 200mm from nozzle end.
3. Insert the wax nozzle into the aerosol container.
4. Insert the wax nozzle into an inserting point and carefully apply the wax.
5. Apply the wax until any bubble at the nozzle end is invisible. Clean the leaked wax with
a shop cloth.

CAUTION In cold weather, immerse the aerosol container into warm water (40°C) for
5 minutes before use.

19
 5. CORROSION PROTECTION

5-2. Stone Guard Coat

: Indicates the stone guard coated portion.

Stone guard coated portion

Section A-A

20
 5. CORROSION PROTECTION

5-3. Undercoating

: Indicates the undercoated portion.

CAUTION Do not apply undercoating to the following area.

• Muffler, catalytic converter and exhaust manifold which are subjected to heat
• Brake hose and tube connection area
• ABS unit and harness installation area
• Pipe installation area
• Radiator rod, rear stabilizer and parville universal joint installation area
• Sub frame and rear suspension bolts

Product: Nr. 08930751 (WURTH)

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 6. WHEEL ALIGNMENT

6. Wheel Alignment
(1) Measurement and adjustment by 4-wheel alignment tester
• The wheel alignment for 4 wheel independent suspension is based on rear wheels and a
part of body maintenance procedures.
The measurement and adjustment by 4-wheel alignment tester should be performed ac-
cording to the type and severity of accident even when the body alignment is correct.
• Using by 4-wheel alignment tester lowers the necessity of repeated repairs.

<Type and severity of accident>

• The vehicle equipped with alignment device in suspension structure has been dam-
aged 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)

Engine 15DE

Toe-in (mm) 1 (in) ~ 3 (out)

Camber (°) -0° 20' ± 45°

Caster (°) 1° 25' ± 45°

King pin inclination (°) 14° 40' ± 45°

Side slip (reference) (mm) 5 (in) ~ 3 (out)

(3) Rear wheel alignment (when unloaded)

Toe-in (mm) 5 (in) ~ 3 (out)

Camber (°) -1° 00' ± 45°

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 7. BODY ALIGNMENT

7. Body Alignment
7-1. Projected Dimensions of Underbody (mm)

Body
RH
center
line
Front

LH

Base line

CAUTION Only one dimension is indicated for symmetrically identical dimensions on both sides.
Unit: mm Centering gauge installation points

[Longitudinal] [Width] [Diagonal]

Point Dimension Point Dimension Point Dimension

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 7. BODY ALIGNMENT

Radiator core support lower base hole Front strap mounting hole
Front side member base hole
Front suspension member mounting bolt end

Front

Front

Front side member base hole Rear suspension mounting bolt end
Front suspension member mounting bolt end Rear strap mounting hole
Front side member extension base hole
Front floor measuring hole

Front

Front

Lateral link mounting hole Rear side member base hole

Rear side member reinforcement base hole
Rear side member extension base hole
Front

Front

Rear side member reinforcement base hole

Rear side member extension base hole

Front

24
 7. BODY ALIGNMENT

7-2. Straight Dimensions of Underbody (mm)

Body
RH
center
line
Front

LH

Base line

CAUTION Only one dimension is indicated for symmetrically identical dimensions on both sides.
Unit: mm Centering gauge installation points

[Longitudinal] [Width] [Diagonal]

Point Dimension Point Dimension Point Dimension

25
 7. BODY ALIGNMENT

Radiator core support lower base hole Front strap mounting hole
Front side member base hole
Front suspension member mounting bolt end

Front

Front

Front side member base hole Rear suspension mounting bolt end
Front suspension member mounting bolt end Rear strap mounting hole
Front side member extension base hole
Front floor measuring hole

Front

Front

Lateral link mounting hole Rear side member base hole

Rear side member reinforcement base hole
Rear side member extension base hole
Front

Front

Rear side member reinforcement base hole

Rear side member extension base hole

Front

26
 7. BODY ALIGNMENT

7-3. Engine Compartment

CAUTION Only one dimension is indicated for symmetrically identical dimensions on both sides.
Unit: mm

[Engine compartment] [Radiator core]

Point Dimension Point Dimension Point Dimension

27
 7. BODY ALIGNMENT

Cowl top base hole (body center point) Hoodledge front reinforcement measuring hole
Front strut mounting hole
Front fender mounting hole

Front

Front fender mounting hole Radiator core support upper measuring hole
Radiator core support side base hole (body center point)
Hood lock mounting hole

Front Front

ABS mounting hole Front side member measuring hole

Battery bracket mounting hole Engine bracket mounting hole

Front Front

Radiator core support lower base hole

Hood lock stay measuring hole
(body center point)

Front

28
 7. BODY ALIGNMENT

7-4. Side Body

CAUTION Only one dimension is indicated for symmetrically identical dimensions on both sides.
Unit: mm

[Front window opening] [Front door opening] [Rear door opening] [Other straight dimensions not shown in drawing]

Point Dimension Point Dimension Point Dimension Point Dimension Point Dimension Point Dimension

29
 7. BODY ALIGNMENT

Cowl top base hole (body center point) Roof flange end (body center point)
Front pillar end

Front pillar end Front pillar indention center

Door hinge mounting nut hole

Center pillar indention Rear fender indention center

center
Door hinge mounting nut hole Door hinge mounting nut hole

Second crossmember positioning mark (body center point)

Rear floor fuel tank cover mounting hole (body center point)

30
 7. BODY ALIGNMENT

7-5. Rear Body

CAUTION Only one dimension is indicated for symmetrically identical dimensions on both sides.
Unit: mm

Point Dimension Point Dimension

31
 7. BODY ALIGNMENT

Roof flange mark end (body center point) Rear fender end
Rear fender end

Front pillar end Corner rear fender end

Rear panel lock mounting hole flange end (body center point)

32
 8. PARTS REPLACEMENT

8. Parts Replacement
(1) This section describes the cautions for parts replacement to improve the working proce-
dures. For installation order, refer to Body Repair Manual.
(2) The symbol and number in bracket indicates the welding type and numbers of welding
points.

Drilling a plug welding hole

on service part according to body side hole

1 (S/A)
3

Front 2

1 (S) 5 (S)
Number
of welding points Indicates the welding operations at inner side.

Drilling a plug welding hole

on service part

(3) Anti-corrosive cationic electrodeposition primer should be applied on the welded area after
panel replacement.

33
 8. PARTS REPLACEMENT

(4) Symbols for cutting and welding/brazing operations

2-spot welds
2-spot welds

Spot weld

3-spot welds

3-spot welds

MIG plug weld

MIG weld

MIG seam weld

Brazing

(S)
Drilling a plug welding hole on service
part

(S/A)
Drilling a plug welding hole on service
part according to body side hole

34