BODY STRUCTURE DETAILS


  1. FUNCTION


    1. Impact Absorbing Structure for Frontal Collisions


      1. The front side members utilize high strength steel sheet in a construction that absorbs and disperses energy in a frontal collision.

      2. The use of under members enables a construction that disperses load from the radiator supports.

      3. Door beltline reinforcements have been strengthened to optimize dispersal of collision energy to the rail, door beltline and rocker panel.

      4. The use of a cross member in the dash panel enables a construction that disperses load from the front side members to the floor member and upper body.

      5. The use of members on the front floor at the sides of the tunnel enables a construction that achieves tunnel strength and dispersal of load from the front side members.

        A01LP9DE01
        Text in Illustration
        *1 Under Member *2 Front Side Member
        *3 Front Door Beltline Reinforcement *4 Cross Member of the Dash Panel (Front Panel Member Sub-assembly)
        *5 Member at the Side of the Tunnel - -
        A01LPNB Path of Collision Energy - -

      6. Impact absorbing pads with sound absorbing performance are installed from the lower surface of the dash panel to the front of the floor as a measure to reduce leg injury in a collision.

        A01LPB7E01
        Text in Illustration
        *1 Foot Rest Area (No. 2 Dash Panel Insulator Pad) *2 Accelerator Pedal Area (No. 1 Dash Panel Insulator Pad)
        *3 Passenger Seat Area (No. 3 Dash Panel Insulator Pad) - -
        *a Front - -

    2. Impact Absorbing Structure for Side Collision


      1. Ultra high strength sheet steel is used for the center pillar outer reinforcement, rocker panel inner, rocker panel outer reinforcement, roof center reinforcement and center pillar hinge reinforcement to ensure high strength.

      2. Bulkheads are placed on both sides of the No. 1 and No. 2 floor cross members and center floor side cross members to efficiently transmit impact load from the impact beam to the floor cross members.

      3. The use of roof reinforcements enables a construction that transmits load to the opposite side of the vehicle in a collision.

      4. Optimal placement of the impact protect beam enables a construction that efficiently transmits load.

      5. The impact support box has been optimally placed on the front floor between the front driver's seat and front passenger's seat to ensure that load is transmitted from the center pillar to the seat pipe, impact support box and seat pipe on the opposite side, thus helping secure sufficient survival space.

        A01LPN6E02
        Text in Illustration
        *1 Impact Support Box *2 Roof Reinforcement
        *3 Impact Beam *4 Floor Cross Member
        *5 Center Pillar *6 Center Console Box
        *7 Front Seat Pipe *8 Front Floor
        *9 Front Seat Pipe (Collision side) *10 Center Pillar Outer Reinforcement
        *11 Hinge Reinforcement - -
        *a A-A Cross Section *b B-B Cross Section
        A01LPNB Path of Collision Energy - -

    3. Impact Absorbing Structure for Rear Collision


      1. Straight rear side members are used to reduce body deformation in a rear collision. Reinforcements in rear side members have been optimally located to ensure high strength.

        A01LPAZE01
        Text in Illustration
        *1 Side Member to Floor Reinforcement Sub-assembly *2 Rear Side Member
        A01LPNB Path of Collision Energy - -

    4. Lessening Pedestrian Injury


      1. An energy absorber is provided at the front of the front bumper reinforcement to dampen the impact to the legs in the event of a collision with a pedestrian.

        A01LPLQE01
        Text in Illustration
        *1 Hood Panel *2 Front Symbol Mark
        *3 Front Bumper Cover *4 Front Bumper Energy Absorber
        *5 Front Bumper Reinforcement *6 Lower Grille
        *7 Front Bumper Spoiler - -
        *a A-A Cross Section - -

      2. A longitudinal ribbed structure is adopted for the inner hood to cushion impact.

      3. The space between the hood panel and the hood lock striker has been formed into a crushable structure so that the hood sub-assembly can collapse easily during a collision.

        A01LP7QE01
        Text in Illustration
        *1 Hood Reinforcement *2 Hood Lock Striker
        *a Longitudinal Ribbed Structure *b A-A Cross Section
        *c Space - -

      4. An impact absorbing bracket is used for the mounting portion of the front fender panel to absorb impact energy to the head of the pedestrian in a collision, thus dampening the impact to the head.

        A01LPN0E02
        Text in Illustration
        *1 Front Fender Panel (Front Fender Sub-assembly RH) *2 Impact Absorbing Bracket (Front Apron to Cowl Side Member Plate RH)
        *3 Impact Absorbing Bracket (Apron Fender Side Extension RH) - -

      5. The back of the hood and the cowl use an open section structure that collapses easily in an impact from the top, thus reducing the impact to and head injuries sustained by a pedestrian in an accident.

        A01LPO0E04
        Text in Illustration
        *1 Windshield Glass *2 Hood Panel
        *a A-A Cross Section *b Open Section Structure (Rear Edge of Hood)
        *c Open Section Structure (Cowl) - -

    5. Aerodynamics


      1. The surface where the front pillar meets the windshield has been leveled off, and the shape around the doors and rockers were smoothed to effectively reduce flow separation. As an additional measure to reduce flow separation, an optimized angle was adopted for the side surfaces of the front bumper.

      2. For controlling flow balance, the optimum rear spoiler shape and air-kick shape at the rear combination lights were studied, considering the flow velocity and direction.

        A01LPBRE01
        Text in Illustration
        *a Leveled off Front Pillar to Reduce Turbulence *b Reduced Flow Separation by Optimizing the Angle of the Side Surface of the Front Bumper
        *c Smooth Flow along Doors and Rocker Surface *d Optimum Height, Length and Angle of Rear Spoiler
        *e Air-kick Shape on Rear Combination Light *f Sharp Edge at the Side of the Rear Bumper
        A01LPNE Airflow - -

      3. Spats are fitted at the front of the front and rear tires to direct the airflow. This reduces air turbulence in the wheel house, leading to ensured straight driving stability at high speeds.

      4. The height, angle and shape of the engine under cover and the floor covers have been optimized, and the location and shape of the covers for chassis, fuel system and exhaust parts have been optimized, resulting in smooth airflow underneath the floor.

        A01LPGEE02
        Text in Illustration
        *1 Front Spoiler *2 Engine Under Cover
        *3 Front Spats *4 Floor Cover
        *5 Body Rocker Panel Moulding *6 Fuel Tank Side Cover
        *7 Rear Spats *8 Rear Floor Cover
        *9 Suspension Member Cover *10 Rear Under Spoiler

      5. A groove has been added at the front of the fender liner, resulting in smooth flow of air. Steps have been added at the rear of the fender liner, and because these steps reduce airflow in the reverse direction, the flow of air into the wheel house has been reduced.

        A01LPG9E01
        Text in Illustration
        *1 Fender Liner - -
        *a A-A Cross Section *b Groove
        *c Steps - -
        A01LPNE Airflow - -

      6. Deflectors are installed onto the radiator support to direct driving airflow into the radiator, thus leading to improved vehicle front section ventilation performance.

        A01LPFFE01
        Text in Illustration
        *1 Radiator Support Opening Cover *2 Radiator Side Deflector RH
        *3 Radiator Side Deflector LH - -

      7. Flat surfaces on the wheel caps and wheels have been optimized, resulting in smooth airflow around the wheel house.

  2. CONSTRUCTION


    1. Light Weight and Highly Rigid Body


      1. A highly rigid yet lightweight vehicle body has been created by considerable use of mainly high strength sheet steel and Ultra high strength sheet steel for body frame components, thus ensuring a high level of impact safety, driving stability and quietness.

      2. Aluminum is used in the hood panel, back door panel, front bumper reinforcement and rear bumper reinforcement, resulting in reduced weight.

        A01LP6O
        Text in Illustration (Upper Body:)
        A01LPH3 Ultra High Strength Steel Sheet A01LPK8 High Strength Steel Sheet
        A01LP8L Aluminum - -
        A01LPJ9
        Text in Illustration (Under Body:)
        A01LPH3 Ultra High Strength Steel Sheet A01LPK8 High Strength Steel Sheet
        A01LP8L Aluminum - -

    2. Body Shell Construction


      1. A brace (front stabilizer bush bracket) is used on the lower side of the front suspension member to improve front suspension member fore-aft rigidity and ensure excellent driving stability.

        A01LP7KE01
        Text in Illustration
        *1 Brace (Front Stabilizer Bush Bracket) *2 Front Suspension Member
        *a Front *b Lower View of Vehicle

      2. Front fender apron rear extensions are used to connect the left and right front spring supports to the cowl top outer front panel, which is straight, improving lateral rigidity and ensuring front suspension input point rigidity and body rigidity.

      3. Cowl top inner to pillar brace brackets are used to connect the front spring supports, cowl top outer front panel and front body inner pillar, resulting in improved fore-aft rigidity.

        A01LPJCE02
        Text in Illustration
        *1 Cowl Top Inner to Pillar Brace Bracket *2 Front Body Inner Pillar
        *3 Front Spring Support Plate *4 Front Spring Support
        *5 Cowl Top Outer Panel *6 Front Fender Apron Rear Extension
        *7 Cowl Top Outer Front Panel - -

      4. The entire circumference of the back door opening from the rear header to the lower back panel uses an open structure, ensuring rigidity for the back door opening.

      5. Reinforcements (body lower back panel center reinforcement and body lower back No. 2 reinforcement RH/LH) are used to connect both rear side members and side panels beneath the lower back panel, ensuring rigidity to counter twisting forces and delivering excellent driving stability.

      6. An inner gusset (quarter wheel house inner gusset) and outer reinforcement (roof side outer panel) are used for the rear wheel house construction, ensuring lateral rigidity at the rear absorber mounting portions, thus ensuring rigidity to counter twisting forces and achieving excellent driving stability.

        A01LPHVE01
        Text in Illustration
        *1 Roof Side Outer Panel *2 Quarter Wheel House Inner Gusset
        *3 Quarter Wheel House Inner Panel *4 Body Lower Back Panel
        *5 Body Lower Back No. 2 Reinforcement LH *6 Body Lower Back Panel Center Reinforcement
        *7 Body Lower Back No. 2 Reinforcement RH - -
        *a Rear View of Vehicle *b A-A Cross Section
        *c Close Section Structure *d B-B Cross Section
        *e C-C Cross Section *f D-D Cross Section

    3. Anti-corrosion Steel Sheet


      1. Anti-corrosion sheet steel is used as in the following illustration.

        A01LPKA
        Text in Illustration (Upper Body:)
        A01LPK8 Anti-corrosion Steel Sheet - -
        A01LPK9
        Text in Illustration (Under Body:)
        A01LPK8 Anti-corrosion Steel Sheet - -

    4. Wax and Sealer


      1. Wax is applied to front end of the hood, lower edge portion of the doors, battery charger lid hinge and fuel filler lid hinge to improve rust-resistant performance. Sealer is applied to hemmed portions of the front end of the hood, door panels, battery charger lid and fuel filler lid.

    5. Under Coat


      1. Acrylic acid resin is applied to the under side of the body, inside the wheel housing and other parts that are susceptible to stone chipping damage, thus improving the rust-resistant performance of these areas.

        A01LPG7E01
        Text in Illustration
        *a Under Floor *b Front Wheel House
        *c Rear Wheel House - -
        A01LPEY Edge Seal A01LPK8 Acrylic Acid Resin Coating Area
        A01LPH3 Acrylic Acid Resin Coating Area (Thick Coating) - -

    6. Anti-chipping Application


      1. To help prevent the paint from chipping, anti-chipping paint is applied to the rockers and the front end of the hood panel.

      2. Quarter panel protectors and rear door panel protectors are applied to the quarter panel on the back of the rear doors to protect the paint surface from icy snow or gravel and to achieve a high level of rust resistance.

        A01LPADE01
        Text in Illustration
        *1 Soft Chipping Primer *2 Plastic Rocker
        *3 Rear Door Panel Protector *4 Quarter Panel Protector
        *5 Urethane Coating - -
        *a A-A Cross Section - -

    7. Low Vibration and Low Noise Body


      1. A dash panel insulator outer is provided. This reduces the amount of engine noise leaking into and out of the cabin.

        A01LP5SE01
        Text in Illustration
        *1 Dash Panel Insulator Outer - -

      2. A hood insulator is provided on the rear of the hood panel. This helps achieve excellent sound insulation performance.

        A01LPIKE01
        Text in Illustration
        *1 Hood Insulator - -

      3. The front (engine side) of the cowl top outer front panel uses a cowl top insulator sheet to reduce the amount of engine noise entering the vehicle cabin from the engine compartment.

        A01LPF6E01
        Text in Illustration
        *1 Cowl Top Outer Front Panel *2 Windshield Glass
        *3 Hood Panel *4 Cowl Top Insulator Sheet
        *a A-A Cross Section - -

      4. Sound absorbing material (Thinsulate) is used in the front fender liner to reduce road noise.

        A01LP4YE01
        Text in Illustration
        *1 Front Fender Liner *2 Thinsulate (Front Fender Seal)

      5. A front fender side panel protector is used to reduce the amount of noise transmitted from the area between the fender and front pillar to the vehicle cabin.

        A01LP6JE01
        Text in Illustration
        *1 Front Fender Side Panel Protector *2 Fender
        *3 Front Door *4 Side Outer Panel
        *a A-A Cross Section - -
        A01LPNB Noise - -

      6. A front fender upper protector is used on the engine compartment side of the fender side cover to reduce the amount of noise transmitted from the area between the fender and apron to the vehicle cabin.

        A01LPAOE01
        Text in Illustration
        *1 Front Fender *2 Fender Side Cover
        *3 Front Fender Upper Protector *4 Apron
        *a A-A Cross Section *b Noise

      7. Foamed urethane sponge, foamed sealing material and sealing material are applied to the roof panel and pillars to reduce wind and road noise.

        A01LPEO
        Text in Illustration
        A01LPHA Polyethylene Sealer A01LPK8 Expanded Form
        A01LPH3 Polyurethane Form - -

      8. The following body structures are used in order to reduce panel vibration and body frame movement.

        Panel vibration reduction structure

        • The dash panel to cowl brace and the cowl top panel are connected.

        • The cross member of the dash panel is provided.

        • The tunnel reinforcement is connected to the floor.

        • The floor pan panel rigidity has been improved.

        • The floor pan bead layouts have been changed.
        Body frame movement prevention structure

        • Rocker inner bulkheads are provided.

        • The rocker inner rear and floor are rigidly connected.

        • A straight shape No. 1 cross member is used.
        A01LP5PE01
        Text in Illustration
        *1 Dash Panel to Cowl Brace *2 Cross Member of The Dash Panel
        *3 Tunnel Reinforcement *4 Bead
        *5 Rocker Inner Bulkhead *6 Rocker Inner Rear
        *7 No. 1 Cross Member - -

      9. Anti vibration material is applied to the floor in order to reduce noise in the cabin. As a replacement for the conventional asphalt-based vibration damping sheet, high rigidity spray type damping material is used, thus optimizing material coating thickness. This ensures high quality sound insulation and weight reduction. By applying it also to vertical part of the dash panel, noise from the engine compartment has been reduced.

        A01LPH8E01
        Text in Illustration
        *A LHD Models *B RHD Models
        *1 Dash Panel *2 Floor
        A01LPK8 Spray Type Damping Material Application Area - -

      10. The following part shapes have been changed and the following structure is used for reducing wind noise.

        Hood rear edge shape change

        • The rear edge of the hood is raised to control the airflow to the wiper.

        • An air flow routing plate has been provided to the fender parting section in order to smooth the airflow.
        Flush surface structure usage

        • The gap between the windshield glass and the roof has been made smaller to smooth the airflow.
        Front pillar shape change

        • The gap between the windshield and the front pillar has been optimized to reduce reverse airflow.

        • The gap between the front door frame and the front window fixed moulding has been made smaller.
        A01LP69E01
        Text in Illustration
        *1 Air Flow Routing Plate *2 Hood Rear Edge
        *3 Windshield Glass *4 Roof Panel
        *5 Front Window Fixed Moulding *6 Front Door Frame
        *a A-A Cross Section *b B-B Cross Section
        *c C-C Cross Section *d D-D Cross Section
        *e Gap - -
        A01LPNE Airflow - -

    8. Parts with Low Repair Cost


      1. A front bumper reinforcement crash box (front side member bracket sub-assembly) absorbs impact energy reducing damage to the body frame. The front bumper reinforcement is connected to the front side member using bolts to improve ease of repair and replacement.

      2. A structure which connects the radiator support to the front side members using bolts is used to improve the ease of repair, by reducing the damage to related parts (only the damaged parts need to be replaced).

        A01LPAYE01
        Text in Illustration
        *1 Radiator Support Sub-assembly *2 Crash Box (Front Side Member Bracket Sub-assembly)
        *3 Front Bumper Reinforcement Sub-assembly - -

      3. In case of a minor collision, the radiator support moves rearward together with the cooling unit, thus protecting the cooling unit and reducing damage.

        A01LP7WE01
        Text in Illustration
        *a Barrier *b Barrier Intrusion
        *c The Radiator Support Moves Rearward Together with the Cooling Unit *d Before Collision
        *e After Collision - -
        A01LPNB Collision Energy Load Application Direction - -

      4. A crash box (rear bumper arm sub-assembly) is connected to the rear side member using bolts to improve the ease of repair and replacement.

        A01LPJFE01
        Text in Illustration
        *1 Crash Box (Rear Bumper Arm Sub-assembly) *2 Body Lower Back Panel Sub-assembly