:  Sep 29, 2004



Body Repairs - Tolerance Checks

Measurements shown are in millimetres and inches. The measurements shown in brackets are in inches.

Point-to-Point Dimensional Information

Point-to-point measurements are actual distances between two points. These points can be holes or intersections points. Where holes are taken, the point of measurement is always from the hole centres.



Front end dimensions



Item From To Length
A Hood latch panel, lower LH outer fixing Hood latch panel, lower RH outer fixing 1503.2 (59.18)
B Hood latch panel, LH locator slot Hood latch panel, RH locator slot 900 (35.43)
C Hood latch panel, LH locator dowel Hood latch panel, RH locator dowels 1540.4 (60.64)
D Fender, front LH fixing Fender, front RH fixing 1617.8 (63.69)
E Fender, front RH fixing Fender, rear LH fixing 1780.2 (70.08)
F Fender, rear LH fixing Fender, rear RH fixing 1620 (63.77)
G Fender, front fixing Hood latch panel, locator dowel 114.23 (4.49)

Front end dimensions



Item From To Length
A LH hood hinge, middle fixing hole RH windshield side upper finisher, fixing hole 1827 (71.92)
B LH windshield side upper finisher, fixing hole RH windshield side upper finisher, fixing hole 1431.5 (56.35)

Side view dimensions



Item From To Length
A Front door top hinge, top fixing hole Rear door top hinge, top fixing hole 1078.9 (42.47)
B Front door top hinge, top fixing hole Rear door bottom hinge, top fixing hole 1138.3 (44.81)
C Front door bottom hinge, top fixing hole Rear door top hinge, top fixing hole 1174.4 (46.23)
D Front door bottom hinge, top fixing hole Rear door bottom hinge, top fixing hole 1078.9 (42.47)
E Rear door top hinge, top fixing hole D pillar striker fixing hole 983.5 (38.72)
F Rear door bottom hinge, top fixing hole D pillar striker fixing hole 1069.9 (42.12)

Internal dimensions



Item From To Length
A LH safety belt anchorage, top fixing RH safety belt retractor, lower fixing 1743.6 (68.64)
B RH inner rear wheelarch, lower safety belt retractor fixing LH inner rear wheelarch, lower safety belt retractor fixing 1518.2 (59.77)

Rear view dimensions



Item From To Length
A Liftgate, RH alignment fixing Tailgate, LH striker fixing 1222.1 (48.11)
B Liftgate, RH alignment fixing Liftgate, LH alignment fixing 1186.6 (46.71)
C Tailgate, LH hinge cover, fixing hole Rear header, RH location hole 1184.3 (46.62)



Underbody Dimensional Information



Front integral body frame dimensions



Item From To Length
A Body Mount 1 (front) Body Mount 3 2113 (83.12)
B Body Mount 1 (front) Body Mount 2 1139 (44.84)
C Body Mount 3 (LH) Body Mount 3 (RH) 1275 (50.196)
D Body Mount 1 (LH front) Body Mount 1 (RH front) 1015 (39.96)
E Body Mount 2 (LH) Body Mount 2 (RH) 1258 (49.53)
F Datum Line (Z) Body Mount 3 136.5 (5.374)
G Datum Line (Z) Body Mount 2 105.5 (4.15)
H Datum Line (Z) Body Mount 1 78.8 (3.102)

Front integral body frame dimensions



Item From To Length
A Body Mount 1 (LH front) Damper Mounting (RH) 1063.1 (41.85)
B Body Mount 1 (LH front) Body Mount 2 (RH) 1609 (63.34)
C Body Mount 1 (LH front) Body Mount 3 (RH) 24.3.3 (94.61)
D Body Mount 2 (LH front) Body Mount 3 (RH) 1597.7 (62.90)
E Body Mount 1 (LH front) Body Mount 2 (LH) 1139 (44.84)

Front integral body frame dimensions



Item From To Length
A Front Bumper Mount (L/H) Front Bumper Mount (R/H) 810 (31.8)
B Lower Arm (L/H front) Lower Arm (R/H front) 635.7 (25.02)
C Steering Gear (L/H) Steering Gear (R/H) 520 (20.4)
D Upper Arm (L/H front) Upper Arm R/H front) 748.7 (29.47)
E Upper Arm (L/H rear) Upper Arm (R/H rear) 836.8 (32.9)
F Lower Arm ((L/H rear) Lower Arm ((L/H rear) 678.6 (26.71)

Front integral body frame dimensions



Item From To Length
A Datum Line (Z) Front Bumper Mount 37.81 (1.488)
B Datum Line (Z) Lower Arm 249.22 (9.811)
C Datum Line (Z) Steering Gear 201.84 (7.946)
D Datum Line (Z) Upper Arm front 170.09 (6.696)
E Datum Line (Z) Upper Arm Rear 134.17 (5.282)
F Datum Line (Z) Lower Arm Rear 236.37 (5.282)

Rear integral body frame dimensions



Item From To Length
A Body Mount 4 (LH) Body Mount 4 (RH) 806 (31.732)
B Body Mount 5 ( rear) Damper Mounting 533.5 (21.00)
C Body Mount 5 ( rear) Body Mount 4 882.8 (34.755)
D Body Mount 5 (LH rear) Body Mount 5 (RH rear) 1114 (43.858)
E Body Mount 5 ( rear) Rear Crossmember 332 (13.07)
F Datum Line (Z) Body Mount 5 (rear) 127.5 (5.01)
G Datum Line (Z) Body Mount 4 61.2 (2.40)

Rear integral body frame dimensions



Item From To Length
A Body Mount 5 (LH rear) Body Mount 4 (RH) 1304.2 (51.34)
B Body Mount 5 (LH rear) Rear Damper Mounting (RH) 1156 (45.51)
C Body Mount 5 (LH rear) Rear Damper Mounting (LH) 533.5 (21.00)

Rear integral body frame dimensions



Item From To Length
A Damper (L/H) Damper (R/H) 937.1 (36.9)
B Upper Arm (L/H rear) Upper Arm (R/H rear) 757.4 (29.81)
C Lower Arm (L/H front) Lower Arm (R/H front) 818.4 (32.2)
D Upper Arm (L/H front) Upper Arm (R/H front) 946.5 (37.2)
E Toe Link (L/H) Toe Link (R/H) 439 (17.2)
F Lower Arm (L/H rear) Lower Arm (R/H rear) 508.4 (20.01)

Rear integral body frame dimensions



Item From To Length
A Datum Line (Z) Damper 169.97 (6.691)
B Datum Line (Z) Upper Arm Rear 32.27 (1.270)
C Datum Line (Z) Lower Arm Front 161.04 (6.340)
D Datum Line (Z) Upper Arm Front 55.07 (2.168)
E Datum Line (Z) Toe Link 200.87 (7.908)
F Datum Line (Z) Lower Arm Rear 250.81 (9.874)

Gap and Profile Measurements

The following information is to be used as a guide to assist the technician in installing exterior body panels and trim items so as to achieve a correctly aligned and cosmetically acceptable vehicle.

Front view dimensions



Section Description Gap Profile
A-A Headlamp to Hood 22.0 (0.866) ± 1.4 (0.055) N/A
B-B Headlamp to Bumper 6.0(0.236) ± 1.8 (0.070) N/A
C-C Headlamp to Fender 4.0(0.157) ± 1.2 (0.0472) 0.0 ± 1.2 (0.047)
D-D Headlamp to Grille 4.0(0.157) ± 1.2 (0.0472) 0.0 ± 1.0 (0.039)

Side view dimensions



Section Description Gap Profile
E-E Hood to Fender 22.0 (0.866) ± 1.4(0.055) + 1.0 (0.039)
F-F Rear Door to Bodyside 4.5 (0.177) ± 1.1 (0.043) 0.0 + 1.0 (0.039) - 0.0
G-G Front Door to Rear Door 5.0 (0.196) ± 1.0 (0.039) 0.0 + 1.0 (0.039) - 0.0
H-H Front Fender to Front Door 5.0 (0.196) ± 1.0 (0.039) 0.0 + 1.4 (0.055) - 0.0
X-X Fuel Filler Flap to Bodyside 2.9 (0.114) ± 1.0 (0.039) 1.0 (0.039) ± 1.0 (0.039)

Rear view dimensions



Section Description Gap Profile
L-L Liftgate to Tailgate 6.0 (0.236) ± 1.0 (0.039) 0.0 ± 1.0 (0.039)
M-M Tailgate to Bumper 12.8 (0.503) ± 2.1 (0.0826) N/A
N-N Liftgate to Roof 10 (0.393) ± 1.3 (0.0511) -2.0 (0.078) ± 1.3 (0.0511)
O-O Tailgate to Rear Lamp 5.0 (0.196) ± 1.6 (0.062) 5.0 (0.196) ± 1.3 (0.0511)
P-P Liftgate to Rear Lamp 5.0 (0.196) ± 1.6 (0.062) 3.0 (0.118) ± 1.9 (0.074)