12.1 Warning and precaution ................................2626 
12.1.1 Warning and precaution .............................2626
12.2 Front -end of body ..........................................2627 
12.2.1 Specification .................................................2627 
12.2.1.1 Fastener specifications................................2627 
12.2.2 Part position .................................................2627 
12.2.2.1 Component position....................................2627 
12.2.3 Dismantle and install ...................................2628 
12.2.3.1 Engine hood lock cable assembly 

replacement...............................................................2628 
12.2.3.2 Engine hood lock replacement....................2630 
12.2.3.3 Engine hood and hinge replacement........... 2632 
12.2.3.4 Front fender replacement............................ 2634 
12.3 Rear end of body............................................. 2640 
12.3.1 Specification ................................................. 2640 
12.3.1.1 Fastener specifications................................ 2640 
12.3.2 Part position ................................................. 2640 
12.3.2.1 Component position.................................... 2640 
12.3.3 Dismantle and install ................................... 2641 
12.3.3.1 Back-door and back-door hinge replacement

.................................................................................. 2641 

12.3.3.2 Back-door gas spring replacement.............. 2643 
12.3.3.3 Back-door open replacement ...................... 2644 
12.3.3.4 Filler cap assembly replacement................. 2646 
12.3.3.5 Filler cap open handle and cable replacement

.................................................................................. 2647 

12.3.3.6 Back-door cylinder core replacement ......... 2649 
12.4 Bumper ............................................................ 2651 
12.4.1 Specification ................................................. 2651 
12.4.1.1 Fastener specifications................................ 2651 
12.4.2 Part position ................................................. 2651 
12.4.2.1 Component position.................................... 2651 
12.4.3 Dismantle and install ................................... 2652 
12.4.3.1 Front bumper replacement.......................... 2652 
12.4.3.2 Front cross beam replacement .................... 2656 
12.4.3.3 Rear bumper replacement ........................... 2658 
12.4.3.4 Rear cross beam replacement ..................... 2662 

12.5 Door ................................................................. 2664 
12.5.1 Specification................................................. 2664 
12.5.1.1 Fastener specifications ............................... 2664 
12.5.2 Dismantle and install................................... 2665 
12.5.2.1 Door and hinge replacement....................... 2665 
12.5.2.2 Door limiter replacement............................ 2667 
12.5.2.3 Front door outer opening handle replacement

.................................................................................. 2668 

12.5.2.4 Inner open handle replacement of front door

.................................................................................. 2670 

12.5.2.5 Front door lock cylinder replacement......... 2671 
12.6 Frame and body bottom................................. 2676 
12.6.1 Specification................................................. 2676 
12.6.1.1 Fastener specifications ............................... 2676 
12.6.2 Description and operation .......................... 2676 
12.6.2.1 Bottom of frame and body.......................... 2676 
12.6.3 Diagnostic information and steps............... 2676 
12.6.3.1 Diagnostic Information and Procedures ..... 2676 
12.6.4 Dismantle and install................................... 2677 
12.6.4.1 Maintenance of frame................................. 2677 
12.6.4.2 Front suspension cross beam assembly 

replacement .............................................................. 2677 
12.6.4.3 Front suspension longitudinal beam 

replacement .............................................................. 2679 
12.6.4.4 Front subframe replacement....................... 2681 
12.6.4.5 Rear subframe replacement ........................ 2688 
12.7 Seat .................................................................. 2691 
12.7.1 Specification................................................. 2691 
12.7.1.1 Fastener specifications ............................... 2691 
12.7.2 Disassemble drawings ................................. 2692 
12.7.2.1 Disassemble drawings ................................ 2692 
12.7.3 Dismantle and install................................... 2693 
12.7.3.1 Front row seat headrest replacement .......... 2693 
12.7.3.2 Front row seat replacement ........................ 2693 
12.7.3.3 Rear row seat headrest replacement ........... 2693 
12.7.3.4 Intermediate row seat replacement............. 2694 
12.7.3.5 Rear row seat washer replacement ............. 2698 

2623

12.7.3.6 Intermediate row right side, replace seat side 

trim plate................................................................... 2701 
12.7.3.7 Intermediate row left side, replace seat side 

trim plate................................................................... 2702 
12.7.3.8 Replacement of Rock Row of Right Seat 

Rear Fixing Lock...................................................... 2703 
12.7.3.9 Middle row left side seat lower sliding rail 

replacement............................................................... 2705 
12.8 Instrument desk and control console ............ 2706 
12.8.1 Specification ................................................. 2706 
12.8.1.1 Fastener specifications................................ 2706 
12.8.2 Part position ................................................. 2706 
12.8.2.1 Component position.................................... 2706 
12.8.3 Dismantle and install ................................... 2707 
12.8.3.1 Instrument desk replacement ...................... 2707 
12.8.3.2 Auxiliary instrument panel replacement..... 2714 
12.8.3.3 Grove box of instrument desk replacement 2720 
12.8.3.4 Cross beam of instrument panel replacement

.................................................................................. 2721 

12.9 Interior trim .................................................... 2733 
12.9.1 Dismantle and install ................................. .2733 
12.9.1.1 Left /right front doorsill inner trim plate 

assembly replacement.............................................. 2733 
12.9.1.2 Left/right front post trim plate assembly 

replacement.............................................................. 2735 
12.9.1.3 Middle post trim plate replacement ........... 2736 
12.9.1.4 Indoor side seal strip and seal part 

replacement.............................................................. 2740 
12.9.1.5 Rear post lower trim plate replacement ..... 2742 
12.9.1.6 Rear post upper trim plate assembly 

replacement.............................................................. 2746 
12.9.1.7 Left front door interior trim plate replacement

................................................................................. 2748 

12.9.1.8 Right front door interior trim plate 

replacement.............................................................. 2751 
12.9.1.9 Rear door interior trim plate replacement.. 2752 
12.9.1.10 back-door trim plate replacement ............ 2754 
12.9.1.11 Top cover interior trim plate replacement

................................................................................. 2757 

12.9.1.12 Indoor carpet replacement .......................2764 
12.10 Exterior trim ............................................... .2765 

12.10.1 Dismantle and install............................... 2765 
12.10.1.1 Front/rear logo front/rear replacement . 2765 
12.10.1.2 Engine hood sound insulation cushion 

replacement ............................................................ 2766 
12.10.1.3 Venting cover plate replacement ............ 2767 
12.10.1.4 Engine hood strip replacement ............... 2771 
12.10.1.5 Back-door strip replacement................... 2773 
12.10.1.6 Triangular outer trim plate replacement of 

rear door ................................................................. 2776 
12.10.1.7 Top cover trim plate replacement........... 2778 
12.10.1.8 Right guard plate replacement under the 

engine ..................................................................... 2779 
12.10.1.9 Front fender lining plate replacement..... 2781 
12.10.1.10 Replacement of Rear Fender Liner....... 2783 
12.10.1.11 Doorsill lower trim plate replacement.. 2785 
12.10.1.12 Replacement of Door Sealing Strip...... 2787 
12.10.1.13 Luggage frame replacement ................. 2789 
12.11 information and maintenance of plastic panel

................................................................................ 2795 

12.11.1 Description and Operation ..................... 2795 
12.11.1.1 Description and operation....................... 2795
12.11.2 Dismantle and install............................... 2795 
12.11.2.1 Maintenance precaution of plastic par. 2795 
12.11.2.2  Maintenance  of  thermosetting  plastic  pit 
173 12.11.2.3 Scratch maintenance of thermosetting 

plastic ..................................................................... 2796 
12.11.2.4 Crack maintenance of thermosetting plastic 

(Length is below 100 mm) ..................................... 2796 
12.12 Collision maintenance ................................ 2797 
12.12.1 Specification............................................. 2797 
12.12.1.1 Collision maintenance material .............. 2797 
12.12.1.2 Clearance and face differential of body 

surface .................................................................... 2799 
12.12.1.3 Body size ................................................ 2802 
12.12.2 Description and operation ...................... 2813
12.12.2.1 Precautions of Safety.............................. 2813 
12.12.2.2 State of Components .............................. 2813 
12.12.2.3 Description of Varieties of Welding....... 2813 
12.12.2.4 Anti-corrosion Treatment ....................... 2814 

2624

12.12.2.5 Environmentally Friendly Disposal 

Approach for Scrapped Components...................... 2814 
12.12.3 Disassemble drawings.............................. 2814 
12.12.3.1 Vehicle body assembly........................... 2814 
12.12.3.2 Front Floor.............................................. 2815 
12.12.3.3 Rear floor of body................................... 2816 
12.12.3.4 Heating insulation cushion of floor ........ 2817 
12.12.3.5 Front windshield ..................................... 2818 
12.12.3.6 Front Panel.............................................. 2819 
12.12.3.7 Engine cabin ........................................... 2820 
12.12.3.8 Install the engine bottom guard plate...... 2821 
12.12.3.9 Engine hood............................................ 2822 
12.12.3.10 Front Fender ......................................... 2823 
12.12.3.11 Side frame............................................. 2824 
12.12.3.12 Front post of body................................. 2825 
12.12.3.13 Intermediate post of body ..................... 2826 
12.12.3.14 Rear post of body.................................. 2827 
12.12.3.15 Rear mud guard..................................... 2828 
12.12.3.16 Rear wall............................................... 2829 
12.12.3.17 Back-door glass .................................... 2830 
12.12.3.18 Back-door ............................................. 2831 
12.12.3.19 Roof ...................................................... 2832 

12.12.4 Diagnostic Information and Procedures 2833 

12.12.4.1 Diagnostic Information and Procedures .2833 

12.12.5 Dismantlement and Installation ............. 2834 
12.12.5.1 Dismantlement and Installation .............. 2834 

12.13 Paint/Coatings............................................. 2835 
12.13.1 Specifications ........................................... 2835 
12.13.1.1 Specifications ......................................... 2835 
12.13.2 Description and operation ...................... 2835 
12.13.2.1 Paint Coating Description....................... 2835 
12.13.2.2 Routine Vehicle Paint Maintenance ....... 2836 
12.13.2.3 Warnings and Precautions in the Paint 

Mixing and Spray Paint Operations ....................... 2837 
12.13.2.4 Precautions on Clear Coats Repair and 

Maintenance ........................................................... 2838 
12.13.2.5 Precautions on Anti-corrosion Treatment2838 
12.13.3 Diagnostic information and procedures  2839 
12.13.3.1 Common Defects Example and Treatment 

for Paint Surface..................................................... 2839 
12.13.4 Removal and installation ........................ 2841 
12.13.4.1 Common Coating Film Defect Treatment 

Process Example .................................................... 2841 
12.13.4.2 Conventional Grind and Polishing 

Treatment Process Example ................................... 2842 
12.13.4.3 Deep Polishing Treatment Process Example

................................................................................ 2843 

12.13.4.4 Spray Paint Process of Rigid Surface..... 2844 
12.13.4.5 Spray Paint Procedure on the Repaired 

Rigid Sheet Metal Surface...................................... 2851 
12.13.4.6 Patching Procedure for Painted Surface of 

Plastic Parts Surface ............................................... 2851 

2625

 
 

12.1 Warning and precaution 

12.1.1 Warning and precaution 

Warning for collision cutting 

Warning! 

Only cut in the recommended part. Failure to do so may compromise the structural integrity of the vehicle and 
cause personal injury if the vehicle is in a collision. 

Warning for window crack   

Warning! 

If part of glass for vehicle window is cracked but still intact, crisscross the glass for vehicle window with masking 
tape in order to reduce the risk of damage or personal injury. 

Glass and Sheet Metal Handling Warning 

Warning! 

When handling any types of glass or metal plate with sharp edges or burrs, please wear permissive safety goggles 
and gloves to reduce the personal injury risk. 

Warning relating to safety goggles and compressed air 

Warning! 

Wear the safety goggles in the course of the use of the compressor air in order to avoid from damaging eyes. 

Precautions of dismantling external logo 

Notes: 

Dismantle the brand plate/name plate with a plastic flat blade tool to avoid damaging the paint. 

Important precaution on Machined Surface Damage 

Notes: 

Be sure not to carve, scratch or damage the sealing surface. The sealing surface is a machined surface. Damage to 
the machined surface can cause leakage. 

Important precaution on Sealant 

Notes: 

Do not have the sealant which hardens at room temperature enter the tapped blind hole. RTV sealant that is 
allowed to enter a blind threaded hole can cause hydraulic lock of the fastener when the fastener is tightened. 
Hydraulic lock of a fastener can lead to damage to the fastener and/or the components. Hydraulic lock of a 
fastener can also prevent the proper clamping loads to be obtained when the fastener is tightened. Improper 
clamping loads can prevent proper sealing of the components allowing leakage to occur. Preventing proper 
fastener tightening can allow the components to loosen or separate leading to extensive engine damage. 

Important precaution on Window Edge Damage 

Notes: 

Avoid an impacting object from damaging the window due to the exposed edge. The window must be 1mm 
(0.025in) lower than the metal plate surface to avoid the window from being damaged. 

2626