12 Body, Sheet Metal and Painting

12.1 Warnings and Notices.................12-4

12.1.1 Warnings and Notices.......................................12-4

12.2 Body Front End...........................12-5

12.2.1 Specifications.......................................12-5

12.2.1.1 Fastener Tightening Specifications................12-5

12.2.2 Component Locator..............................12-6

12.2.2.1 Component Views..........................................12-6

12.2.3 Removal and Installation......................12-7

12.2.3.1 Hood Latch Release Cable Replacement......12-7
12.2.3.2 Hood Latch Replacement...............................12-8
12.2.3.3 Hood and Hinge Replacement.......................12-9
12.2.3.4 Front Fender Replacement..........................12-11

12.3 Body Rear End..........................12-13

12.3.1 Specifications.....................................12-13

12.3.1.1 Fastener Tightening Specifications..............12-13

12.3.2 Component Locator............................12-14

12.3.2.1 Component Views........................................12-14

12.3.3 Removal and Installation....................12-15

12.3.3.1 Rear Compartment Lid Replacement (Sedan). 12-
15
12.3.3.2  Rear  Compartment  Lid  Torsion  Spring
Replacement (Sedan)................................................12-16
12.3.3.3  Hatchback  and  Hatchback  Hinge  Replacement
(Hatchback)................................................................12-19
12.3.3.4 Hatchback Strut Replacement (Hatchback).....12-
21
12.3.3.5  Emergency  Exit  Open  Handle  Assembly
Replacement (Sedan)................................................12-22
12.3.3.6  Hatchback  Release  Handle  Replacement
(Hatchback)................................................................12-23
12.3.3.7 Fuel Tank Filler Door Replacement..............12-24
12.3.3.8 Fuel Filler Cap Release Handle Replacement. 12-
25
12.3.3.9 Hatchback Latch Replacement....................12-26

12.4 Bumpers....................................12-27

12.4.1 Specifications.....................................12-27

12.4.1.1 Fastener Tightening Specifications..............12-27

12.4.2 Component Locator............................12-28

12.4.2.1 Component Views........................................12-28

12.4.3 Removal and Installation....................12-29

12.4.3.1 Front Bumper Replacement.........................12-29
12.4.3.2 Rear Bumper Replacement (Hatchback).....12-31
12.4.3.3 Rear Bumper Replacement (Sedan)............12-33
12.4.3.4 Front Impact Bar Replacement....................12-35
12.4.3.5 Rear Impact Bar Replacement.....................12-36

12.5 Doors.........................................12-38

12.5.1 Specifications.....................................12-38

12.5.1.1 Fastener Tightening Specifications..............12-38

12.5.2 Removal and Installation....................12-39

12.5.2.1 Front Door Hinge Replacement....................12-39
12.5.2.2 Front Door Check Link Replacement...........12-40
12.5.2.3 Front Door Outside Handle Replacement........12-
41
12.5.2.4 Front Door Inside Handle Replacement.......12-42
12.5.2.5 Front Door Lock Cylinder Replacement.......12-43

12.6 Frame and Underbody..............12-44

12.6.1 Specifications.....................................12-44

12.6.1.1 Fastener Tightening Specifications..............12-44

12.6.2 Description and Operation..................12-45

12.6.2.1 Frame and Underbody.................................12-45

12.6.3 Diagnostic Information and Procedures. 12-
46

12.6.3.1 Diagnostic Information and Procedures.......12-46

12.6.4 Removal and Installation....................12-47

12.6.4.1 Frame Repair...............................................12-47
12.6.4.2 Subframe Replacement................................12-47
12.6.4.3 Cross Member Replacement........................12-52

12.7 Seats.........................................12-53

12.7.1 Specifications.....................................12-53

12.7.1.1 Fastener Tightening Specifications..............12-53

12.7.2 Disassemble View..............................12-54

12.7.2.1 Disassemble View........................................12-54

Body, Sheet Metal and Painting

Table of Contents

12-1

12.7.3 Removal and Installation....................12-56

12.7.3.1 Front Seat Head Restraint Replacement.....12-56
12.7.3.2 Front Seat Replacement..............................12-56
12.7.3.3 Rear Seat Head Restraint Replacement......12-56
12.7.3.4 Rear Seat Cushion Replacement.................12-57
12.7.3.5 Rear Seat center Armrest Replacement......12-58
12.7.3.6 Rear Seat Armrest Assembly Replacement.....12-
58
12.7.3.7 Rear Seat Back Replacement......................12-59

12.8 Instrument Panel, Gages and Console
..........................................................12-61

12.8.1 Specifications.....................................12-61

12.8.1.1 Fastener Tightening Specifications..............12-61

12.8.2 Component Locator............................12-62

12.8.2.1 Component Views........................................12-62

12.8.3 Removal and Installation....................12-63

12.8.3.1 Instrument Panel Replacement....................12-63
12.8.3.2 Glove Box Replacement...............................12-67
12.8.3.3 Instrument Panel Carrier Replacement........12-67

12.9 Interior Trim...............................12-70

12.9.1 Removal and Installation....................12-70

12.9.1.1 Headliner Replacement................................12-70
12.9.1.2 Left and Right Door Sill Nameplate Replacement.
12-75
12.9.1.3 Windshield Garnish Molding Replacement......12-
77
12.9.1.4 Center Pillar Trim Panel Replacement.........12-79
12.9.1.5  Rear  Quarter  Upper  Trim  Panel  Replacement
(Sedan).......................................................................12-81
12.9.1.6  Rear  Quarter  Upper  Trim  Panel  Replacement
(Hatchback)................................................................12-82
12.9.1.7 Rear Parcel Shelf Replacement (Sedan).....12-84
12.9.1.8 Rear Parcel Shelf Replacement (Hatchback)...12-
85
12.9.1.9 Rear Compartment Trim Panel Replacement. .12-
87
12.9.1.10  Rear  Compartment  Trim  Panel  Replacement
(Hatchback)................................................................12-88
12.9.1.11  Passenger  Compartment  Floor  Carpet
Replacement..............................................................12-90
12.9.1.12 Front Side Door Trim Panel Replacement.....12-
91

12.9.1.13 Rear Side Door Trim Panel Replacement......12-
92
12.9.1.14  Rear  Compartment  Lid  Inner  Trim  Panel
Replacement..............................................................12-93
12.9.1.15  Hatchback  Inner  Trim  Panel  Replacement
(Hatchback)................................................................12-94
12.9.1.16 Vehicle Inner Side Seal Replacement........12-95

12.10 Exterior Trim............................12-97

12.10.1 Removal and Installation..................12-97

12.10.1.1 Front and Rear Emblem Replacement.......12-97
12.10.1.2 Hood Sound Insulation Pad Replacement.....12-
98
12.10.1.3 Air Inlet Grille Panel Replacement.............12-98
12.10.1.4 Rear Compartment Lid Applique Replacement...
12-101
12.10.1.5 Hatchback Outside ornament Panel replacement
(Hatchback)..............................................................12-102
12.10.1.6 Roof Ornament Panel Replacement........12-103
12.10.1.7  Left  and  Right  Engine  Bottom  Shield
Replacement............................................................12-104
12.10.1.8 Front Wheelhouse Liner Replacement.....12-105
12.10.1.9 Rocker Panel Molding Replacement........12-106
12.10.1.10 Vehicle Inner Side Seal Replacement..........12-
107

12.11 Plastic Panel Information and Repair
........................................................12-109

12.11.1 Description and Operation..............12-109

12.11.1.1 Description and Operation........................12-109

12.11.2 Removal and Installation................12-110

12.11.2.1 Plastic Repair Notices..............................12-110
12.11.2.2 Thermosetting Plastic Dent Repair...........12-110
12.11.2.3 Thermosetting Plastic Scratch Repair......12-110
12.11.2.4 Thermosetting Plastic Crack Repair (length less
than 100 mm)...........................................................12-111

12.12 Collision Repair.....................12-112

12.12.1 Specifications.................................12-112

12.12.1.1 Collision Repair Materials.........................12-112
12.12.1.2 Body Surface Clearance and Tolerance (Sedan)
12-113
12.12.1.3  Body  Surface  Clearance  and  Tolerance
(Hatchback)..............................................................12-118
12.12.1.4 Body Dimensions.....................................12-121

12-2

Table of Contents

Body, Sheet Metal and Painting

12.12.2 Description and Operation..............12-137

12.12.2.1 Safety Instructions....................................12-137
12.12.2.2 The State of Parts....................................12-137
12.12.2.3 Welding Types Description.......................12-137
12.12.2.4 Anti-Corrosion Treatment.........................12-137
12.12.2.5 Scrapped Components Environmentally Friendly
Disposal Approach...................................................12-137

12.12.3 Disassemble View..........................12-138

12.12.3.1 Front Floor................................................12-138
12.12.3.2 Body Rear Floor (Sedan).........................12-139
12.12.3.3 Body Rear Floor (Hatchback)...................12-140
12.12.3.4 Firewall.....................................................12-141
12.12.3.5 Engine Compartment...............................12-142
12.12.3.6 Front Fender.............................................12-143
12.12.3.7 Body Side Outer Panel (Sedan)...............12-144
12.12.3.8 Body Side Outer Panel (Hatchback)........12-145
12.12.3.9 Body Front Pillars.....................................12-146
12.12.3.10 Body Middle Pillars (Sedan)...................12-147
12.12.3.11 Body Middle Pillars (Sedan)...................12-148
12.12.3.12 Body Rear Pillars (Sedan)......................12-149
12.12.3.13 Body Rear Pillars (Hatchback)...............12-150
12.12.3.14 Body Rear End (Sedan).........................12-151
12.12.3.15 Body Rear End (Hatchback)...................12-152
12.12.3.16 Rear Parcel Shelf Panel (Sedan)...........12-153

12.12.4 Diagnostic Information and Procedures12-
154

12.12.4.1 Diagnostic Information and Procedures.........12-
154

12.12.5 Removal and Installation................12-155

12.12.5.1 Removal and Installation..........................12-155

12.13 Paint/Coatings.......................12-157

12.13.1 Specifications.................................12-157

12.13.1.1 Specifications...........................................12-157

12.13.2 Description and Operation..............12-158

12.13.2.1 Paint Coating Description.........................12-158
12.13.2.2 Routine Vehicle Paint Maintenance.........12-158
12.13.2.3  Warnings  and  Notices  in  the  Paint  Mixing  and
Spray Paint Operations............................................12-159
12.13.2.4 Clear coats Maintenance and Repair Notices 12-
159
12.13.2.5 Anti-Corrosion Treatment Notices............12-159

12.13.3 Diagnostic Information and Procedures12-
161

12.13.3.1 Common Paint Defects and Treatment..........12-
161

12.13.4 Removal and Installation................12-163

12.13.4.1  Common  Coating  Film  Defect  Treatment
Example...................................................................12-163
12.13.4.2  Conventional  Grind  and  Polishing  Treatment
Example...................................................................12-164
12.13.4.3 Deep Polishing Treatment Example.........12-165
12.13.4.4 Rigid Surface Spray Paint Process..........12-166
12.13.4.5 Spray Paint on the Repaired Rigid Sheet Metal
Surface Procedure...................................................12-172
12.13.4.6 Plastic Surface Paint Repair Process.......12-173

Body, Sheet Metal and Painting

Table of Contents

12-3

12.1 Warnings and Notices

12.1.1 Warnings and Notices

Collision Sectioning Warning

Warning!

Warning:  Sectioning  should  be  performed  only  in  the
recommended areas. Failure to do so may compromise
the structural integrity of the vehicle and cause personal
injury if the vehicle is in a collision.

Cracked Window Warning

Warning!

Warning: If a window is cracked but still intact, crisscross
the window with masking tape in order to reduce the risk
of damage or personal injury.

Glass and Sheet Metal Handling Warning

Warning!

Warning: When working with any type of glass or sheet
metal  with  exposed  or  rough  edges,  wear  approved
safety glasses and gloves in order to reduce the chance
of personal injury.

Safety Glasses and Compressed Air Warning

Warning!

Warning: Wear safety glasses when using compressed
air in order to prevent eye injury.

Exterior Trim Emblem Removal Notice

Note

Notice:  Use  a  plastic,  flat-bladed  tool  to  prevent  paint
damage when removing an emblem/name plate.

Machined Surface Damage Notice

Note

Notice:  Do  not  nick,  scratch  or  damage  the  sealing
surface.  The  sealing  surface  is  a  machined  surface.
Damage to the machined surface can cause leakage.

Sealant Notice

Note

Notice: Do not allow the RTV sealant to enter any blind
threaded  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.

Window Edge Damage Notice

Note

Avoid damage to the window from impacting objects due
to an exposed edge. The window must be 1 mm (0.025
in) below the surface of the sheet metal to avoid window
damage.

12-4

Warnings and Notices

Body, Sheet Metal and Painting