INTRODUCTION IN
PAINT • COATING
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This body repair manual introduces to you fundamental knowledge necessary for servicing the bodies of Daihatsu vehicles and basic operations thereof. Furthermore, this manual describes the replacement procedures for principal sheet panels of the M401 series including their welding methods as well as those seal applying points. It is urged that every body repair technician be acquatined with accurate operations by making the most of this body repair manual in order that rationalized, efficient repairs and reliable body servicing operations may be carried out.
All information used in this body repair manual was in effect at time when the manual was printed. However, the specifications and procedures may be revised owing to continuing improvements in design without advance notice and without incurring any obligation to us.
Published in October, 2006
MANUAL NAMEMANUAL NO.PUBLISHED Service manual Chassis MATERIANo. 9894October, 2006
All rights reserved. This material may not be reproduced or copied, in whole or in part, without the written permission of Daihatsu Motor Co., LTD.
Scope of the repair work explanation
•This text explains the welding panel replacement instructions from the vehicle’s white body condition.
We have abbreviated the explanations of the removal and reinstallation of the equipment parts up to the while body condition and of the installation, inspection, adjustment and final inspection of equipment parts after replacing the weld panel.
Section categories
•This manual has been divided as shown below.
INTRODUCTION
BODY PANEL REPLACEMENT
Explanation of general body repair View of weld panel replacement instructions.
Instructions for replacing the weld panels from the while body conditions, from which bolted parts have been removed, with individual supply parts.
Cautionary items. Views of weld panel replacement instructions.
Front side member replacement. Quarter panel replacement.
BODY DIMENSIONSBody aligning measurements.Dimension diagrams.
PAINT • COATING Scope and type of anti-rust treatment, etc. Together with weld panel replacement.
Contents omitted in this manual
Under coating Body sealer.
•Make sure to perform the following essential procedures, although they are omitted in this manual. (1)Clean and wash removed parts, if necessary.
(2)Visual inspection.
This manual has references to the DAIHATSU MATERIA Repair Manual’s heater & air conditioning system, body electrical and suspension & axle sections.
(a)VEHICLE PROTECTION
(1)When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fireproof covers.
(b)SAFETY
(1)Never stand in a direct line with the chain when using a puller on the body or frame, and be sure to attach a safety cable.
(2)Before performing repair work, check for fuel leaks.
If a leak is found, be sure to close the opening completely.
(3)If it is necessary to use a flame in the area of the fuel tank, first remove the tank and plug the fuel line.
(c)SAFETY
(1)In addition to the usual mechanic’s wear, cap and safety shoes, the appropriate gloves, head protector, glasses, ear plugs, face protector, dust-prevention mask, etc. should be worn as the situation demands.
CodeName
ADust-Prevention Mask
BFace Protector
CEye Protector
DSafety Shoes
EWelder’s Glasses
FEar Plugs
GHead Protector
HWelder’s Gloves
(a)HEAT
Daihatsu prohibits the use of the heat repair method on body structure panels when repairing a vehicle damaged in a collision.
Panels that have high strength and rigidity, as well as a long life span for the automobile body are in high demand.
At Daihatsu, in order to fulfill these requirements, we use high tensile strength steel sheets and rust preventive steel sheets on the body. High tensile steel sheets are made with alloy additives and a special heat treatment in order to improve their strength.
To prevent the occurrence of rust for a long period of time, the surface of the steel is coated with a zinc alloy. If body structure parts are heat repaired with an acetylene torch or other heating source, the crystalline organization of the steel sheet will change and their strength of the steel sheet will be reduced. The ability of the body to resist rust is significantly lowered as well since the rust resistant zinc coating is destroyed by heat and the steel sheet surface is oxidized.
A sharp deformation angle on a panel that cannot be returned to its original shape by pulling or hammering is called a kink.
Structural parts are designed to perform in their original shape. If parts are deformed in an accident, or if the deformed parts are repaired and reused, the parts may be unable to perform as intended.
It is necessary to replace the part where the kink has occurred.
The impact beam and bracket are necessary and important parts that help reduce the probability of injury to passengers in side collisions. For impact beams, we use special high tensile strength steel.
The high tensile strength steel maintains its special crystalline organization by heat treatment or alloy additives. Structural parts are designed to perform in their original shape. If parts are deformed in an accident, or if the deformed parts are repaired and reused, the parts may be unable to perform as intended.
If the impact beam or bracket is damaged, replace the door assembly that has the damaged beam. Also, the bumper reinforcement is a necessary and important part that helps reduce the probability of injury to passengers in front collisions, and for the same reasons explained above, should be replaced if damaged.
(a)REMOVAL OF ADJACENT COMPONENTS
(1)When removing adjacent components, apply protective tape to the surrounding body and your tools to prevent damage.
(b)APPLICATION OF WELD-THROUGH PRIMER (SPOT SEALER)
(1)Remove the paint from the portion of the new parts and body to be welded, and apply weldthrough primer.
(c)MAKING HOLES FOR PLUG WELDING
(1)For areas where a spot welder cannot be used, use a puncher or drill to make holes for plug welding.
REFERENCE:
Thickness of welded portionSize of plug hole 1.0 mm underø5 over 1.0 mm - 1.6 mmø6.5 over 1.7 mm - 2.3 mmø8 over 2.4 mm overø10 over
(d)WELDING PRECAUTIONS
(1)The number of welding spots should be as follows. •Spot weld: 1.3 X No. of manufacturer’s spots. •Plug weld: More than No. of manufacturer’s plugs.
(2)Spot weld locations. Avoid welding over previously welded areas.
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(a)BODY SEALER APPLICATION
(1)For water-proofing and anti-corrosion measures, always apply the body sealer to the body panel seams and hems of the doors, hood, etc.
(b)UNDERCOAT APPLICATION
(1)To prevent corrosion and protect the body from damage by flying stones, always apply sufficient under coating to the bottom surface of the under body and inside of the wheel housings.
(c)ANTI-RUST AGENT (WAX) APPLICATION
(1)To preserve impossible to paint areas from corrosion, always apply sufficient anti-rust agent (wax) to the inside of the hemming areas of the doors and hood, and around the hinges, or the welded surfaces inside the box-shaped cross sections of the side members, body pillars, etc.
(a)The repair procedure for plastic body parts must conform with the type of plastic material.
(b)Plastic body parts are identified by the codes in the following table.
(c)When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, painting etc.), consideration must be given to the properties of the plastic.
CodeMateril name
AAS
Acrylonitrile Acrylic Styrene
ABS
Heat* resistant temperature limit (°C)
80
Acrylonitrile Butadiene Styrene
ASA
80
Acrylonitrile Styrene Acrylate
E/VAC Ethylene Vutyl Acetate Copolymer Resin
PA Polyamide (Nylon)
PBT Polybutylene Terephthalate
80
70
80
160
Resistance toalcohol gasolineNote
Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
Alcohol and gasoline are harmless.
Alcohol and gasoline are harmless.
PCPolycarbonate120Alcohol is harmless.
PMMA Polymethyl Methacrylate
80
PPPolypropylene80
PVC Polyvinyl chloride (Vinyl)
TPO Thermoplastic Olefine
80
80
Alcohol is harmless if applied only for short time in small amounts.
Alcohol and gasoline are harmless.
Alcohol and gasoline are harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts.
Avoid gasoline and organic or aromatic solvents.
Avoid gasoline and organic or aromatic solvents.
Avoid gasoline and organic or aromatic solvents.
Avoid gasoline and organic or aromatic solvents.
Avoid battery acid.
Most solvents are harmless.
Avoid gasoline, brake fluid, wax, wax removers and organic solvents. Avoid alkali.
Avoid dipping or immersing in alcohol, gasoline, solvents, etc.
Most solvents are harmless.
Avoid dipping or immersing in alcohol, gasoline, solvents, etc.
Most solvents are harmless but avoid dipping in gasoline, solvents, etc.
* Temperatures higher than those listed here may result in material deformation during repair.
Headlight (PC / PP)
Windsheld Outside Moulding (TPO)
Roof Drip Side Finish Moulding Front (TPO)
Outer Rear View Mirror (AAS / PBT / ABS)
Cowl Top Ventilator Louver (PP)
Emblem (ABS)
Rocker Panel Moulding (PP)
•Resin material differs with model. /Made up of 2 or more kinds of materials.
Rear Door Quarter Window Weatherstrip (PVC)
Door Outside
Handle (PC / PBT • PA)
Front Fender Mudguard (E / VAC)
Rear Combination Light (PMMA / ASA)
Rear Body Mudguard (E / VAC)
Back Door Outside Garnish (PMMA / PVC)
Antenna (PC / ASA / PBT)
Emblem (ABS)
Back Door Outside Handle (PA)
Rear Fog Light (PC / PP)
License Plate Light (PC / PBT)
Rear Bumper Cover (PP)
•Resin material differs with model. /Made up of 2 or more kinds of materials.
···590 MPa High strength steel
···440 MPa High strength steel
···340 MPa High strength steel
···Formed material application areas
···Adhesive Application Area
BODY PANEL REPLACEMENT
QUATER PANEL(CUT)
•With the body lower back panel removed.
Symbol meaning :Remove Weld Points:Cut and Join Location :Cut Location for Supply Parts REMOVAL
Filler Opening Lid
REMOVAL POINT
1 Remove the Fuel Filler Opening Lid at the same time.
REPLACEMENT PART AND METHOD A QUARTER PANEL (CUT)
INSTALLATION OF WELD POINTS G Weld method and panel position symbols SYMBOLS H
Replacement method (ASSY)...Assembly replacement (CUT)...Major cutting(less than 1/2 of part used) (CUT-H)...Half cutting(about 1/2 of part used) (CUT-P)...Partial cutting(most of part used) Replacement part
PART LOCATION B
REMOVAL CONDITIONS C
SYMBOL MEANING D
REMOVAL DIAGRAM E
Describes in detail removal of damaged part involving repair by cutting.
REMOVAL GUIDE F
Provides additional information to more efficiently help you perform the removal.
Symbol meaning :MIG Plug Weld :Body Sealer :Spot Weld :Butt
INSTALLATION
INSTALLATION POINT
1.Before temporarily installing the new parts,apply sealer to the wheel arch. HINT
1)Apply body sealer evenly about 5 mm from the flange,avoiding any oozing.
2)Apply sealer evenly,about 3-4 mm in diameter.
2.Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram.(See the body dimension diagram)
3.After welding,apply body sealer and undercoating to the corresponding parts.
SYMBOL MEANING I INSTALLATION DIAGURAM J
Describes in detail installation of the new parts involving repair by welding and / or cutting,but excluding painting.
INSTALLATION GUIDE K
Provides addition to more effciently help you perform the installation
SYMBOLS L
INSTALLATION OF WELD POINTS M
Weld method and panel position symbols
PART NAME N
The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas and the types of weld required.
SYMBOLSMEANINGSYMBOLS MEANINGILLUSTRATION
CUT AND JOIN
LOCATION (Saw Cut)
CUT
BRAZE
BRAZE
WELD POINTS
WELDING
CUT AND JOIN LOCATION (Cut Location for Supply Parts)
CUT LOCATION
CUT WITH DISC SANDER,ETC
BRAZE (Removal)
BRAZE (Installation)
SPOT WELD OR MIG PLUG WELD
CONTINUOUS MIG WELD (BUTT WELD)
CONTINUOUS MIG WELD (TACK WELD)
SEALERBODY SEALER
SYMBOLSMEANINGSYMBOLSSMEANINGILLUSTRATION
BODY SEALER (Flat finishing)
BODY SEALER (Flat finishing)
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EXAMPLE:
REMOVAL
Weld points
Remove weld point and panel position
SYMBOLSMEANINGILLUSTRATION
INSTALLATION
Weld points
Remove weld point and panel position
SYMBOLSMEANINGILLUSTRATION
REMOVAL • INSTALLATION
Symbol meaning
REMOVAL : Remove Weld Points
INSTALLATION : MIG Plug Weld
INSTALLATION POINT
1Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
2Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
3After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points.
mm
mm
INSTALLATION POINT
1Measure the dimensions before installing the headlights.
2These values are reference values.
mm
Symbol meaning
REMOVAL : Remove Weld Points
INSTALLATION : MIG Plug Weld
REMOVAL • INSTALLATION
INSTALLATION POINT
1Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
2Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
3After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points.
REMOVAL • INSTALLATION
With the radiator support and cowl top side panel removed.
Symbol meaning
REMOVAL : Remove Weld Points
INSTALLATION : MIG Plug Weld : Body Sealer
Front Fender Mounting Bracket
Front Fender Mounting Bracket
Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front wheel alignment.
INSTALLATION POINT
1Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
2Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front wheel alignment.
1Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
2Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
3Before installing a new part, apply body sealer. HINT:
1)Apply sealer in an even, continuous bead.
4After welding, apply body sealer and undercoating to the corresponding parts. (See the paint • coating)
5After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points.
REMOVAL
With the radiator support removed.
Symbol meaning : Remove Weld Points : Cut and Join Location
REMOVAL POINT
1Remove the front side member plate front at the same time.
REMOVAL POINT
1Remove the front side member plate front at the same time.
Symbol meaning : Remove Weld Points : Cut and Join Location
REMOVAL POINT
1 *1: Take care not to damage the internal reinforcement.
2These values are reference values.
Symbol meaning : MIG Plug Weld : Tack Weld : Butt Weld
INSTALLATION
INSTALLATION POINT
1Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram)
2After welding, apply body sealer and undercoating to the corresponding parts. (See the paint • coating)
3After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points.
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