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1-1

GROUP 1

BODY
CONSTRUCTION
CONTENTS

BODY COMPONENTS. . . . . . . . . . . . 1-2 SIDE BODY . . . . . . . . . . . . . . . . . . . . . . . . . 1-13


REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 1-15
BODY MAIN CROSS-SECTIONAL ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
VIEWS . . . . . . . . . . . . . . . . . . . . . . . . 1-4 UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 1-16
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
MAINTENANCE,
SERVICEABILITY . . . . . . . . . . . . . . . 1-6 SILENCER APPLICATION
LOCATIONS . . . . . . . . . . . . . . . . . . . . 1-21
BODY CONSTRUCTION
CHARACTERISTICS . . . . . . . . . . . . . 1-8 URETHANE FOAM USAGE
FRONT BODY. . . . . . . . . . . . . . . . . . . . . . . 1-8 LOCATIONS . . . . . . . . . . . . . . . . . . . . 1-23
1-2 BODY CONSTRUCTION
BODY COMPONENTS

BODY COMPONENTS
M4010001002238

24 28
22

20 59* 26
27
19 21 25*
23 29
17 61
58* 60*
18 66*
88*
30
68
57*
62
16 76*
56* 69 31
67
65* 32
15
80
81 33
14 34
82
55 53* 35
13 54 36
77* 63
79* 37
12 87
10 75* 78* 38
74* 52* 72* 39
11 64**
45 44 83
9 51
49
86* 41
8* 43
40*
6 42
7*
70* 84
4 5 85*
71*
3 47
4 73**
3 50
2 46*
48*

1
NOTE:
: Anti-corrosion steel panels
: High-tensile steel panels (*: Indicates 590MPa-high-tensile steel panels.)
(**: Indicates 980MPa-ultra-high-tensile steel panels.) ABC00328AB

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BODY CONSTRUCTION 1-3
BODY COMPONENTS

1. Front panel crossmember lower 45. Rear floor rear seat under crossmember
2. Front bumper reinforcement 46. Front floor side sill inner
3. Headlight support panel 47. Front floor sidemember
4. Headlight support bracket 48. Front sidemember reinforcement rear
5. Headlight support panel upper 49. Front floor
6. Front sidemember plate 50. Front fender
7. Front inner sidemember 51. Front floor sidemember
8. Front outer sidemember 52. Front floor sidemember rear
9. Engine mounting gusset 53. Front pillar reinforcement lower inner
10. Fender shield frame upper inner 54. Front deck frame upper outer
11. Front inner wheel house 55. Front fender bracket
12. Dash panel crossmember 56. Front pillar reinforcement upper
13. Dash panel 57. Front lower inner pillar
14. Cowl top panel 58. Front upper inner pillar
15. Front deck crossmember 59. Roof side rail inner
16. Hood inner panel 60. Center inner pillar
17. Hood outer panel 61. Rear pillar reinforcement
18. Front door panel inner 62. Rear pillar brace
19. Front door side door beam 63. Front fender bracket
20. Front door panel outer 64. Side sill reinforcement
21. Rear door panel inner 65. Center pillar reinforcement
22. Rear door panel outer 66. Roof side rail reinforcement center
23. Roof rail front 67. Side sill rear end plate
24. Roof panel 68. Rear wheel house inner panel
25. Roof bow 69. Quarter panel lower inner
26. Roof rail rear 70. Side inner sill rear
27. Liftgate inner panel 71. Rear seat crossmember reinforcement
28. Liftgate outer panel 72. Rear floor crossmember reinforcement
29. Gate pillar reinforcement 73. Front floor front crossmember
30. Rear inner pillar 74. Front sidemember reinforcement rear lower
31. Quarter panel extension upper outer 75. Dash side brace
32. Quarter panel extension lower outer 76. Rear door hinge reinforcement
33. Fuel filler lid 77. Side sill bulkhead
34. Side outer panel 78. Side sill reinforcement outer support
35. Rear end panel outer 79. Side sill reinforcement support front
36. Rear end panel inner 80. Center pillar reinforcement lower
37. Spare tire bracket 81. Side sill reinforcement support rear
38. Rear towing hook bracket 82. Side sill support rear
39. Rear floor stay 83. Canister bracket
40. Rear floor sidemember reinforcement 84. Side sill reinforcement inner
41. Rear floor sidemember extension 85. Side sill inner reinforcement
42. Rear floor sidemember 86. Rear floor sidemember reinforcement upper
43. Rear floor 87. Rear seat pan reinforcement
44. Rear floor crossmember 88. Rail roof side support

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1-4 BODY CONSTRUCTION
BODY MAIN CROSS-SECTIONAL VIEWS

BODY MAIN CROSS-SECTIONAL VIEWS


M4010002001380

B
D

E
A

C
F
ABB00524AB

A D
Cowl top
outer panel Roof panel
Roof side rail
Cowl top stay reinforcement
center
Rail roof side
Cowl top support
inner panel
Dash panel Roof side rail
ABB00614AB inner Side outer panel ABC00323AB

B Roof panel E Center pillar seat belt


reinforcement
Center inner Center pillar
pillar upper reinforcement

Side outer
panel
Front roof
reinforcement rail
Roof front rail inner

ABC00322AB ABB00618AB

C Front pillar F Side sill Side outer panel


reinforcement lower
reinforcement
Front inner support front
pillar lower
Side sill
Side outer reinforcement
panel
Front floor
side sill inner

Side sill
reinforcement
ABB00616AB outer support ABC00324AB

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BODY CONSTRUCTION 1-5
BODY MAIN CROSS-SECTIONAL VIEWS

K
G

L
ABB00525 AB

G Front pillar reinforcement upper J

Front inner pillar


upper
Rear wheel house
inner panel
Quarter panel
lower inner
Side outer panel Side outer
panel
ABB00620AB ABB00623AB

H Center pillar Rear door hinge K


reinforcement reinforcement
Center inner
pillar upper
Roof panel

Side outer
panel
Roof rear rail inner

ABC00129 AB ABB00624AB

Gate pillar inner L


I upper extension
Rear pillar Gate pillar Quarter outer
reinforcement reinforcement upper A extension Rear end
outer panel
Side outer Gate pillar
panel inner panel
Rear end
inner panel

ABB00622AB ABB00625AB

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1-6 BODY CONSTRUCTION
MAINTENANCE, SERVICEABILITY

MAINTENANCE, SERVICEABILITY
M4010003001145

FENDER SHIELD
A positioning hole and cut-out have been added on
the front sidemember inner and the dash crossmem-
ber to improve assembling workability when replac-
ing the panel.

ABB00389AB

SIDE STRUCTURE
A panel positioning notch has been added on the
door opening to improve assembling workability
when replacing the panel.

Panel positioning notch AB201388AB

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BODY CONSTRUCTION 1-7
MAINTENANCE, SERVICEABILITY

ABB00467AB

SIDE OUTER PANEL


The extra parts are supplied in 4 different cut forms
as a result of employing the integrated side-frame
side outer panel.

Center outer pillar

Front outer pillar

Quarter panel outer

Front floor side sill outer

ABB00600AB

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1-8 BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS

BODY CONSTRUCTION CHARACTERISTICS


FRONT BODY
M4010010001750

HEADLIGHT SUPPORT • The bolt-on headlight support panel is used to


• The crush box structure has been adopted to the improve maintainability.
front end of the front sidemember to improve the
maintainability at a minor collision and the char-
acteristics at a minor frontal collision.
ABB00350
7.0 ± 3.0 N·m
62 ± 26 in-lb

10 ± 4 N·m
5
89 ± 35 in-lb

3
7.0 ± 3.0 N·m
62 ± 26 in-lb 4

26 ± 6 N·m 3
19 ± 4ft-lb

2
26 ± 6 N·m
19 ± 4ft-lb A 7.0 ± 3.0 N·m
62 ± 26 in-lb

1
ABC00325AB

1. Front panel crossmember lower


A
2. Front bumper reinforcement
3. Headlight support bracket
4. Headlight support panel
5. Headlight support panel upper

Crush box

ABD00021AB

A crash box has been established in order to effi-


ciently absorb energy upon impact.

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BODY CONSTRUCTION 1-9
BODY CONSTRUCTION CHARACTERISTICS

FENDER SHIELD
(Right side)
4
3
2

5
1

23 ± 9 N·m
17 ± 6 ft-lb

ABB00351AB

(Left side)
3 2

23 ± 9 N·m
4 17 ± 6 ft-lb

7
5
23 ± 9 N·m
17 ± 6 ft-lb

ABB00352 AB

1. Engine mounting gusset FRONT SIDEMEMBER REINFORCEMENT


2. Fender shield frame upper inner The 590-MPa class high tensile strength steel panels
3. Front spring house gusset have been adopted for the front sidemember outer,
4. Spring house bracket front sidemember reinforcement rear lower, front
5. Front spring house panel floor sidemember rear and front sidemember inner to
6. Front sidemember
improve the crash safety.
7. Transmission mounting gusset

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1-10 BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS

(Right side) 7
9*
4
8*
5

6
3*

10
2
12 11

13
1
14*
NOTE: *: Indicates 590MPa-high-tensile steel panels. ABB00353 AB

2
5

14 6 8
10

13
12
ABB00418AB

1. Front sidemember plate 8. Front sidemember reinforcement rear lower


2. Engine mounting bulkhead 9. Front floor sidemember rear
3. Front sidemember outer 10. Front sidemember rear A
4. Brake hose bracket 11. Dash crossmember lower
5. Front sidemember bulkhead front 12. Front suspension crossmember plate rear
6. Front sidemember reinforcement front 13. Front suspension crossmember bracket rear
7. Front sidemember brace lower 14. Front sidemember inner

A 14 B 8

10
2

13
3
ABB00419 AB 12 ABB00420AB

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BODY CONSTRUCTION 1-11
BODY CONSTRUCTION CHARACTERISTICS

(Left side)
4
3*
7* 8
6

2* 5

14 1
9
12
13

NOTE: *: Indicates 590MPa-high-tensile steel panels.


11* 10
ABB00354 AB

6 9 11

5
B

1 3

13
12
ABB00421AB

1. Front sidemember rear A 8. Brake hose bracket


2. Front floor sidemember rear 9. Transmission mounting bulkhead
3. Front sidemember reinforcement rear lower 10. Front sidemember plate
4. Front sidemember brace lower 11. Front sidemember inner
5. Front sidemember reinforcement front 12. Front suspension crossmember plate rear
6. Front sidemember bulkhead front 13. Front suspension crossmember bracket rear
7. Front sidemember outer 14. Dash crossmember lower

A B 3
11

1
9

13
7
ABB00422 AB 12 ABB00423AB

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1-12 BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS

FRONT DECK
The padding structure of the cowl top is designed to
have a crushable structure in order to efficiently
absorb energy upon impact, thus improving the
pedestrian protection capability.
ABB00355

4
5
1
6
7

8 ABC00181AB

1. Cowl top inner panel 5. Wiper center bracket


2. Heater B bracket 6. Wiper A bracket
3. Cowl top outer panel 7. Heater A bracket
4. Cowl top stay 8. Harness bracket

DASH PANEL
The 590-MPa class high tensile strength steel panels
has been adopted for the dash side brace to improve
the crash safety.
ABB00356
8* 9 4 5

6
7

2 9
8*
3

1
10
NOTE: *: Indicates 590MPa-high-tensile steel panels. ABC00182AB

1. Dash panel crossmember 6. Brake reinforcement


2. Canister bracket 7. Clutch pedal reinforcement <M/T>
3. Dash panel 8. Dash side brace
4. Accelerator pedal bracket 9. Heater bracket lower
5. Deck crossmember stay bracket 10. Flare nut holder

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BODY CONSTRUCTION 1-13
BODY CONSTRUCTION CHARACTERISTICS

SIDE BODY
M4010011001708

SIDE STRUCTURE
The 590-MPa class high tensile strength steel panels
or 980-MPa class ultra high tensile strength steel
panels have been adopted for the front pillar, center
pillar, side sill, and roof side rail to improve the body
rigidity.

9*
13
6
12
16
5 14
11
10 ± 4 N·m 4*
89 ± 35 in-lb 17
8*
23 15
10 18 19 24
22 25
3 7*
21
50*
44*
2
1* 27
26 28
43*
45*
20 29

46* 51*
52* 30
42
41 53 32
38* 37**
40 47*

49*

39
33
36 48* 31

35
NOTE:
34 23 ± 9 N·m
*: Indicates 590MPa-high-tensile steel panels.
17 ± 6 ft-lb
**: Indicates 980MPa-ultra-high-tensile steel panels. ABC00326AB

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1-14 BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS

1. Front inner pillar lower 28. Rear light housing


2. Instrument panel side bracket 29. Quarter outer lower A extension
3. Wiper side bracket 30. Quarter outer lower B extension
4. Front inner pillar upper 31. Side outer panel
5. Sunvisor bracket 32. Rear door striker reinforcement
6. Front roof rail brace 33. Front fender bracket
7. Center inner pillar lower 34. Upper outer frame
8. Center inner pillar upper 35. Front fender bracket
9. Roof side rail inner 36. Hood hinge reinforcement
10. Seat belt retractor bracket 37. Side sill reinforcement
11. Center pillar seat belt lower reinforcement 38. Front pillar reinforcement lower
12. Center pillar seat belt reinforcement 39. Front pillar bulkhead hinge lower
13. Rear pillar reinforcement 40. Checker bracket front pillar
14. Gate pillar inner upper extension 41. Front pillar bulkhead hinge upper
15. Gate pillar inner panel 42. Deck crossmember bracket
16. Gate pillar reinforcement 43. Front pillar reinforcement upper
17. Seat belt reinforcement 44. Roof side rail reinforcement center
18. Rear seat striker reinforcement 45. Center pillar reinforcement
19. Gate pillar brace 46. Rear door hinge reinforcement
20. Side sill rear end plate 47. Side sill bulkhead
21. Rear wheel house inner panel 48. Side sill reinforcement outer support
22. Rear wheel house inner extension 49. Side sill reinforcement support front
23. Absorber reinforcement 50. Rail roof side support
24. Quarter panel lower inner 51. Center pillar reinforcement lower
25. Filler neck bracket (Left side) 52. Side sill reinforcement support rear
26. Quarter outer upper B extension 53. Side sill support rear
27. Quarter outer upper A extension

SIDE STRUCTURE REINFORCEMENT


The ring structure of the side structure reinforcement
has been adopted to improve the collision character-
istics and the rigidity of the whole vehicle.
Gate pillar
Roof side rail reinforcement
reinforcement center

Front pillar Gate pillar brace


reinforcement upper

Center pillar reinforcement

Front pillar Side sill reinforcement


reinforcement lower ABC00334AB

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BODY CONSTRUCTION 1-15
BODY CONSTRUCTION CHARACTERISTICS

REAR BODY
M4010012000991

REAR END PANEL


5 7
6
8
3
2

ABB00357 AB

1. Rear end inner panel 5. Rear end outer panel


2. Bumper bracket lower 6. Rear bumper reinforcement
3. Liftgate lock reinforcement 7. Rear license light bracket
4. Nut plate 8. Garage Jack reinforcement

ROOF
M4010013001834
The 590-MPa class high tensile strength steel panels
has been adopted for the roof bow to improve the
body strength.

7 4
5
8

6* 4

2
1
NOTE: *: Indicates 590MPa-high-tensile steel panels. 2 ABC00327AB

1. Roof front rail inner 5. Roof rear rail inner


2. Holder bracket 6. Roof bow
3. Roof panel 7. Roof bow center reinforcement
4. Liftgate hinge reinforcement 8. Front roof reinforcement rail

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1-16 BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS

UNDER BODY
M4010014001718

FRONT FLOOR
The 590-MPa class high tensile strength steel panels
have been adopted for the front sidemember rein-
forcement rear and front floor side sill inner and the
980-MPa class ultra high tensile strength steel pan-
els for the front floor front crossmember to improve
the body strength.
2
5
6

4 5
4
7
3
10

11
14**
8

9
15* 18
8

16
17
13*
12
NOTE:
*: Indicates 590MPa-high-tensile steel panels.
**: Indicates 980MPa-ultra-high-tensile steel panels. ABC00313AB

1. Backbone panel 10. Front seat side bracket rear


2. Parking lever reinforcement 11. Jack bracket
3. ECU bracket 12. Front floor sidemember
4. Nut plate 13. Front floor side sill inner
5. Front seat center bracket rear 14. Front floor front crossmember
6. Parking cable bracket 15. Front sidemember reinforcement rear
7. Backbone reinforcement 16. Backbone crossmember
8. Front floor side pan 17. Backbone crossmember front
9. Fuel reinforcement tank support 18. Front floor crossmember front reinforcement

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BODY CONSTRUCTION 1-17
BODY CONSTRUCTION CHARACTERISTICS

REAR FLOOR
The 590-MPa class high tensile strength steel panels
have been adopted for the rear seat crossmember
reinforcement and rear floor crossmember reinforce-
ment to improve the body strength.
ABB00360
11
18 10

9
19
8

12

7 13

6*
3 14 15
7
5
2
4*
1 17
16
3

1
NOTE: *: Indicates 590MPa-high-tensile steel panels. ABC00314 AB

1. Fuel tank protector 11. Spare tire bracket


2. Rear seat crossmember 12. Rear seat reinforcement center
3. Tie down reinforcement 13. Rear seat plate center
4. Rear seat crossmember reinforcement 14. Rear seat back reinforcement side
5. Rear floor crossmember 15. Rear floor sidemember
6. Rear floor crossmember reinforcement 16. Side sill reinforcement inner
7. Rear seat bracket 17. Side sill reinforcement inner support
8. Rear floor pan 18. Rear seat pan reinforcement
9. Rear floor stay 19. Canister bracket
10. Rear towing hook bracket

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1-18 BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS

REAR FLOOR SIDEMEMBER


REINFORCEMENT
The 590-MPa class high tensile strength steel panels
has been adopted for the side inner sill rear to
improve the body strength.
3
2

3
1 9*

8* 4

1
5

NOTE: *: Indicates 590MPa-high-tensile steel panels. 7* 6* ABC00315AB

B
A 1 3

9
8

ABC00331AB

1. Rear floor sidemember 6. Side sill inner rear reinforcement


2. Muffler hanger A bracket (Right side) 7. Side inner sill rear
3. Rear floor sidemember extension 8. Rear floor sidemember reinforcement
4. Spring seat 9. Rear floor sidemember reinforcement upper
5. Torsion arm support bracket

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BODY CONSTRUCTION 1-19
BODY CONSTRUCTION CHARACTERISTICS

A B
8
1

1 7

9
6 ABC00332 AB 8 ABC00333AB

DOOR
M4010015001119

(Front door)

12 6
2
1 4

11

3
9
10

7
8 ABB00362 AB

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1-20 BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS

(Rear door)

17
14

16 18
13 24

15 23
22

21

20
19 ABB00363 AB

1. Front door panel outer 13. Rear door panel outer


2. Front door window front sash 14. Rear door window front sash
3. Front door hinge reinforcement 15. Rear door hinge reinforcement
4. Front door beltline outer reinforcement 16. Rear door beltline outer reinforcement
5. Front door glass guide 17. Rear door glass rear guide
6. Glass stopper 18. Glass stopper
7. Front door panel inner 19. Rear door panel inner
8. Nut plate 20. Nut plate
9. Front door side door beam 21. Rear door outer lower stiffener
10. Front door outer front stiffener 22. Rear door outer upper front stiffener
11. Front door outer rear stiffener 23. Rear door outer upper rear stiffener
12. Front door latch reinforcement 24. Rear door latch reinforcement

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BODY CONSTRUCTION
SILENCER APPLICATION LOCATIONS
1-21
SILENCER APPLICATION LOCATIONS
M4010005002627
• In order to suppress noise, a silencer (melting • A silencer (melting sheet) has been affixed on the
sheet) has been adhered on the cowl top outer upper surface of the floor for vibration dampening.
panel.
• In order to suppress noise, a front pillar silencer
(damping sheet) has been adhered on the front
inner pillar lower.

Silencer

(Left side) (Right side)

Front pillar
silencer Front pillar
silencer

NOTE:
: 1.5 mm (0.06 in) thick melting sheet (Place a melting sheet.)
: 2.0 mm (0.08 in) thick damp sheet (Place two melting sheet one on top of another.)
( ) indicates the number of 1.6 mm (0.06 in) melting sheets that are used for repair.
ABC00126AB

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BODY CONSTRUCTION
SILENCER APPLICATION LOCATIONS
1-22

NOTE:
: 1.6 mm (0.06 in) thick melting sheet (Place a melting sheet.)
: 3.2 mm (0.13 in) thick damp sheet (Place two melting sheet one on top of another.)
( ) indicates the number of 1.6 mm (0.06 in) melting sheets that are used for repair.
ABD00276AB

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BODY CONSTRUCTION
URETHANE FOAM USAGE LOCATIONS
1-23

URETHANE FOAM USAGE LOCATIONS


M4010007000661
• A front door inner panel pad (urethane foam) is • In order to suppress noise, a center pillar pad
inserted in the front door sash to reduce the (urethane foam) has been filled in the bottom of
transfer of noises to the interior. the center pillar.

Front door inner


panel pad

ABB00801AB

Center pillar pad

ABC00223AB

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