DOWNLOAD Mitsubishi 2008 Lancer Evolution X Body Repair Manual PDF

2008 MITSUBISHI LANCER EVOLUTION BODY REPAIR MANUAL FOREWORD

GROUP INDEX BODY CONSTRUCTION . . . . . . . . .

1

BODY DIMENSIONS . . . . . . . . . . . . .

2

WELDED PANEL REPLACEMENT. .

3

CORROSION PROTECTION . . . . . .

4

This manual has been prepared for the use of all service mechanics engaged in the body repair service. SYNTHETIC-RESIN PARTS . . . . . . .

Body dimensions, welded panel replacement procedures, body sealing application instructions, and BODY COLOR . . . . . . . . . . . . . . . . . . all the other information required to provide quick and accurate body repair service are contained herein. BASE OF BODY REPAIR . . . . . . . . .

One especially important point is the welding method.

All of the vehicle’s original strength and durability can be maintained by following the welding procedures contained in this manual.

Now that, in order to maximize the efficiency of the repair work, first, both the extent of the damage and the replacement parts that are needed must be calculated accurately, and then the actual work must be performed accurately and efficiently.

The publications shown on the following page are also available, and should be used in conjunction with this manual.

TECHNICAL INFORMATION MANUAL MSSP-260B-2008 SERVICE MANUAL MSSP-206B-2008 PARTS CATALOG BUM6Y108A_

Mitsubishi Motors Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured.

©2007 Mitsubishi Motors Corporation All Rights, Reserved Printed in USA MSSP-460B-2008

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GROUP 1

BODY CONSTRUCTION CONTENTS BODY COMPONENTS. . . . . . . . . . . .

1-2

BODY MAIN CROSS-SECTIONAL VIEWS . . . . . . . . . . . . . . . . . . . . . . . .

1-4

MAINTENANCE, SERVICEABILITY .

1-6

BODY CONSTRUCTION CHARACTERISTICS . . . . . . . . . . . . .

1-8

FRONT BODY. . . . . . . . . . . . . . . . . . . . . . .

1-8

SIDE BODY. . . . . . . . . . . . . . . . . . . . . . . . .

1-15

REAR BODY . . . . . . . . . . . . . . . . . . . . . . . .

1-17

ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-18

UNDER BODY. . . . . . . . . . . . . . . . . . . . . . .

1-20

DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-24

SILENCER APPLICATION LOCATIONS . . . . . . . . . . . . . . . . . . . .

1-25

FOAMING MATERIAL USAGE LOCATIONS . . . . . . . . . . . . . . . . . . . .

1-26

STIFFENER AND DAMP SHEET APPLICATION LOCATIONS . . . . . . .

1-27

THEFT PROTECTION . . . . . . . . . . . .

1-28

1-2

BODY CONSTRUCTION BODY COMPONENTS

BODY COMPONENTS

M4010001001309

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40

30 38 39

36

27 29

83

35

28

86

82

26 25 24

34

33*

32 31

81*

80*

85 89

84

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98 87

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92 93

97* 78 22

23

96

48

71

45

59

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4* 61*

57*

58* 65

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68

46 51

55

52* 53

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9*

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49

73 72

11 10

70

74**

60

8

1

75** 47

21 76

14 15

43

19

16*

12

42

95* 94

18

91 41

77

20

13

90

62

66 67 64*

69

63**

: Anti-corrosion steel panels : High-tensile steel panels (*: Indicates 590MPa-high-tensile steel panels.) (**: Indicates 980MPa-ultra-high-tensile steel panels.)

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AB700971AB

BODY CONSTRUCTION BODY COMPONENTS 1.

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Front bumper reinforcement Headlight support panel upper Front body frame to side sill brace Front sidemember rear Front inner sidemember Headlight support panel Front sidemember plate Front outer sidemember Front sidemember extension Front fender gusset Headlight support panel upper Front fender shield Fender shield frame upper outer Fender shield frame upper inner Spring house panel Dash panel crossmember upper Dash panel crossmember lower Dash panel Brake pedal support reinforcement Cowl top panel Brake pedal support bracket Front deck crossmember Hood panel inner Hood panel outer Front door side door beam Front door panel inner Front door panel outer Rear door side door beam Rear door panel inner Rear door panel outer Roof rail front lower Roof rail front upper Roof bow center lower <Vehicles without sunroof (aluminum panel)> Roof bow center upper <Vehicles without sunroof (aluminum panel)> Roof rail rear Roof panel Roof panel reinforcement <Vehicles with sunroof (steel panel)> Rear shelf panel Trunk lid panel inner Trunk lid panel outer Fuel filler door panel (Left side) Rear bumper reinforcement Rear bumper reinforcement Rear end panel outer Rear end panel inner Rear bumper side bracket Rear seatback bracket lower Rear floor

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Rear floor rear end crossmember Rear floor crossmember Rear floor side panel Rear floor sidemember extension Rear floor sidemember lower Rear seat under floor Rear seat belt reinforcement (Left side) Rear seat belt reinforcement (Right side) Rear floor extension Rear floor rear seat under crossmember Front floor crossmember rear Front floor backbone reinforcement Front floor crossmember front Front floor Front floor side sill inner Front floor sidemember Front floor crossmember rear center Front floor crossmember front Front fender Headlight support panel lower Radiator bracket lower Side outer panel Front fender bracket Upper frame to front pillar brace Front deck frame upper outer Side sill reinforcement outer front Side sill reinforcement outer rear Side sill inner support front Front pillar lower reinforcement Front pillar inner lower Front pillar inner center Front upper inner pillar Roof side rail inner Rear seatback brace Rear wheel house panel inner Rear wheel house panel front lower outer Quarter panel lower inner (Left side) Quarter panel inner Quarter panel extension inner Quarter panel extension lower outer Quarter panel extension outer Rear combination light housing panel Rear pillar reinforcement Roof side rail reinforcement rear Rear pillar reinforcement lower Center pillar reinforcement Rear door hinge reinforcement Rear door hinge reinforcement support Roof side rail reinforcement Center pillar inner lower Center pillar inner upper

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1-4

BODY CONSTRUCTION BODY MAIN CROSS-SECTIONAL VIEWS

BODY MAIN CROSS-SECTIONAL VIEWS

M4010002001067

B

A

D

C

F

E AB700285AB

A

D

Roof panel

Roof side rail reinforcement rear

Roof side rail inner

Roof rail front lower

B

Roof side rail reinforcement front

Roof rail front upper Side outer panel

AB601100AC

Side outer panel

E Front end crossmember upper

AB700536AB

Front end crossmember bulkhead

Roof side rail inner Roof side rail support

C

Rear door hinge reinforcement support

Center pillar reinforcement AB700969AB

Center pillar inner upper

Front end crossmember lower

F Front door hinge

reinforcement lower

AB601099 AC

Front pillar inner lower

Side outer panel

Rear door hinge reinforcement

Center pillar reinforcement AB601102AC

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Front pillar reinforcement lower

Side outer panel AB700537AB

1-5

BODY CONSTRUCTION BODY MAIN CROSS-SECTIONAL VIEWS H G

I

K

J L AB700286AB

G

Roof side rail reinforcement front

Side outer panel

J Side sill reinforcement outer rear

Front upper inner pillar

Side outer panel

Front floor side sill inner AB700539AB

AB602354AB

H

Rear floor side sill inner

K Roof panel

Rear pillar reinforcement lower

Rear wheel house panel inner

Side outer panel Quarter inner panel

Roof rail rear

Quarter panel extension lower outer AB700540AB

AB601108AC

I Side sill reinforcement outer front

Front pillar inner lower

L Rear bumper reinforcement Rear end panel inner

Side outer panel

Rear end panel outer

Side sill inner support front AB700538AB

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AB601110AC

1-6

BODY CONSTRUCTION MAINTENANCE, SERVICEABILITY

MAINTENANCE, SERVICEABILITY

M4010003000948

FENDER SHIELD A positioning hole, lug, and notch have been added on the front end upper bar side, front upper frame inner, upper frame extension inner, front side member brace upper and dash panel to improve assembling workability during panel replacement.

AB700964AB

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1-7

BODY CONSTRUCTION MAINTENANCE, SERVICEABILITY

SIDE STRUCTURE A panel positioning notch has been added on the door opening to improve assembling workability when replacing the panel.

Panel positioning notch

AB201388AB

AB700289AB

SIDE OUTER PANEL The extra parts are supplied in 4 different cut forms as a result of employing the integrated side-frame side outer panel.

Center outer pillar

Front outer pillar Quarter panel outer

Front floor side sill outer

AB700613AB

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1-8

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

BODY CONSTRUCTION CHARACTERISTICS FRONT BODY

M4010010001200

HEADLIGHT SUPPORT • The crush box structure, which has an octagonal cross-section at the front end of the front sidemember, has been adopted. This structure can effectively absorb energy upon frontal impact and reduces the vehicle repair cost caused by a light collision.

• The bolt-on headlight support panel upper is used to improve maintainability.

• An aluminum front bumper reinforcement has been adopted to improve the body rigidity, handling stability, and riding comfort.

9.0 ± 2.0 N·m 80 ± 17 in-lb

3

2

3 5

A

4

7 5 6

1 8 9 20 ± 5 N·m 15 ± 3 ft-lb

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10 9

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7 AB700911AB

Front bumper reinforcement Headlight support panel upper Front end crossmember gusset Front end crossmember upper Radiator bracket lower A Front end crossmember bulkhead Radiator bracket lower B Shipping hook front Shipping reinforcement front Front end crossmember lower

A Crush box

AB701123AB

The crush box structure has been changed to straight type with an octagon cross-section so that the structure can effectively absorb energy from the impact at the time of collision.

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1-9

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

FENDER SHIELD The padding structure of the front fender bracket has been adopted to efficiently absorb energy upon impact by the crushable structure and improve the pedestrian protection capability.

(Right side)

7 8

5

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12

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16

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20

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1 19 23 28

27 26

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25

AB700410AB

(Left side)

8 7 12

10

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33

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32

1 29

28

34

26 27 AB700409AB

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BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

Upper side bar front Front end upper bar side Front fender bracket Upper frame bulkhead front Fender shield frame upper outer Upper frame bulkhead center Upper frame bulkhead rear Front fender bracket Front upper frame inner Upper frame inner plate Harness bracket Spring house corner gusset Spring house bracket reinforcement Spring house bracket front Spring house panel rear Spring house reinforcement rear Horn bracket

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Spring house harness bracket Suction hose bracket Spring house panel Power steering reservoir tank bracket Engine mounting bracket upper Front fender shield Engine mounting gusset Condense tank reinforcement Fender gusset Front fender bracket Front sidemember Engine control module bracket Clutch tube bracket <M/T> Harness bracket front Harness bracket rear Relay box bracket Transaxle mounting gusset

1-11

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

• The 590-MPa class high tensile strength steel panels have been adopted for the front sidemember extension, front sidemember rear bulkhead and front sidemember rear to improve the body rigidity.

FRONT SIDEMEMBER REINFORCEMENT • The front sidemember structure has been changed to a straight frame structure with an octagon cross section that efficiently absorbs energy from the impact at the time of collision.

• The front sidemember is supported in three directions by the dash crossmember center, dash crossmember lower and front sidemember rear in order to improve the frontal collision characteristics, and increase the vehicle body rigidity.

(Right side)

3 2

4

17 16 21

22

23

24

5*

1* 11

15

6*

18 19 20

7

13

12

14

10

*: Indicates 590MPa-high-tensile steel panels.

13

21

9

16

A

23

B

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12 10

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AB700925AB

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Front sidemember extension Front sidemember outer Front brake hose bracket Front sidemember reinforcement rear lower Front sidemember rear bulkhead Front sidemember rear Height sensor bracket Dash crossmember extension lower I plate bracket Front body frame to side sill brace Tie down reinforcement front Front suspension crossmember bracket front

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Front sidemember inner Front sidemember plate Front sidemember bulkhead front Engine mounting bulkhead Front suspension crossmember bulkhead Headlight bracket lower Headlight support panel Engine mounting reinforcement Engine mounting bracket front Engine mounting bracket rear Front sidemember brace upper Front sidemember reinforcement rear

AB700929AC

1-12

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

A

B

23

20 2 16

17

21 2

13 12 AB602310AD

13 AB602309AD

(Left side)

7

9 14

6*

5*

8

20 15

10*

13

4 3

21

19

16

22 17

18

12 2

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11

*: Indicates 590MPa-high-tensile steel panels.

AB700920AB

14

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7 12 6

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I plate bracket Dash crossmember extension lower Front body frame to side sill brace Tie down reinforcement front Front sidemember rear Front sidemember rear bulkhead Front sidemember reinforcement rear lower Front sidemember outer Front brake hose bracket Front sidemember extension Front sidemember plate

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Front suspension crossmember bracket front Front sidemember inner Front sidemember brace upper Transaxle mounting bracket Connector bracket Headlight support panel Headlight bracket lower Front suspension crossmember bulkhead Transaxle mounting bulkhead rear Transaxle mounting bulkhead front Front sidemember reinforcement

1-13

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

A

14

B

13

15

8 22

8

13

20

19 12

AB700583AC

FRONT DECK • The impact absorbing opening on the cowl top outer reinforcement upper has been added to efficiently absorb energy upon impact and improve the pedestrian protection capability.

AB700584AC

• Rigidity was heightened and driving stability was improved by bonding the fender shield frame upper outer and front pillar by the upper frame to front pillar brace.

6

5

8

9

7 4 3

2 11

10

13 12 1

14 AB602289AC

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Cowl top panel lower Wiper B bracket Cowl top stay bracket rear Cowl top outer reinforcement upper Cowl top panel inner Cowl top panel outer Deck crossmember stay bracket

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Brake pedal support bracket Clutch pedal support bracket <M/T> Upper frame extension inner Brake pedal support reinforcement Front fender bracket Cowl top outer reinforcement lower Upper frame to front pillar brace

1-14

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

DASH PANEL The 590-MPa class high tensile strength steel panels have been adopted for the dash crossmember center, dash crossmember extension, dash panel reinforcement and dash crossmember side to improve the body rigidity.

9

7

12* 6

10

8

13

11

5 4*

3*

14*

2

15

1 16 *: Indicates 590MPa-high-tensile steel panels.

1.

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4.

5.

6.

7.

8.

AB700934AB

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Brake tube bracket Harness bracket Dash crossmember center Dash crossmember extension Canister bracket Dash heat protector bracket Dash panel Backbone reinforcement front

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Dash panel lower Accelerator pedal bracket Steering shaft bracket Dash panel reinforcement Clutch pedal reinforcement lower <M/T> Dash crossmember side Dash crossmember lower bulkhead Dash crossmember lower

1-15

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

SIDE BODY

M4010011001087

• A rear shelf lower brace is used to connect the spring house middle panel and rear shelf upper brace, so that the body rigidity, handling stability, and riding comfort are improved.

• The number of the spot welding points at the door opening has been increased to heighten the body rigidity and to improve handling stability.

SIDE STRUCTURE • The 590-MPa class high tensile strength steel panels or 980-MPa class ultra high tensile strength steel panels have been adopted for the front pillar, center pillar, side sill, and roof side rail to improve the body rigidity.

• Rigidity was heightened and driving stability was improved by bonding the roof bow and roof rail and the roof side rail inner by the roof rail extension.

16

17

20

24 25

5

2

22

23

15*

28

27

29

4

13

12 8*

6*

10

11 1

2

9

7

14

31

65*

40 37 33

39

70

71

68

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66

61

38

30

69

63*

62

36

26

32

1

35

34

64* 3

18

19

21

47

45

42 43 44

72 46

58

73 67*

60 55**

59 56**

57

53

52 48

54

*: Indicates 590MPa-high-tensile steel panels. **: Indicates 980MPa-ultra-high-tensile steel panels.

52

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AB700954AB

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BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

Front pillar inner lower Front pillar inner center Hood opener bracket (Left side) Cowl side trim bracket (Right side) Deck crossmember bracket (Right side) Front upper inner pillar Center pillar inner lower Center pillar inner upper Center pillar seat belt reinforcement lower Center pillar seat belt reinforcement upper Roof rail front extension Roof rail center extension <Vehicles without sunroof (aluminum panel)> Bracket C <Vehicles with sunroof (steel panel)> Roof rail rear extension Roof side rail inner Harness bracket (Right side) Rear shelf upper brace Rear seat belt reinforcement Nut plate <Vehicles with subwoofer> Subwoofer upper bracket <Vehicles with subwoofer> Rear seat hook A Rear seatback brace rear Rear seatback plate reinforcement Rear seatback brace bulkhead Rear seatback brace front Rear spring house reinforcement upper front Rear shelf lower brace Rear spring house reinforcement upper rear Rear spring house bracket Trunk trim bracket Washer tank center bracket (Left side) Spring house middle front panel (Left side) Filler pipe mounting bracket (Left side) Spring house middle panel Harness bracket (Left side) Rear wheel house panel inner

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Rear wheel house panel front lower outer Curtain air bag bracket Quarter panel lower inner (Left side) Quarter inner panel Quarter panel extension inner Quarter panel extension lower outer Rear combination light housing Quarter corner panel Quarter outer upper extension Quarter outer upper side extension Fuel filler neck bracket (Left side) Side outer panel Fender bracket Fender bracket lower Front fender bracket Cowl side trim bracket Front upper outer frame rear Upper frame outer reinforcement Side sill reinforcement outer rear Side sill reinforcement outer front Side sill inner support front Front pillar reinforcement lower Front door hinge reinforcement lower Front pillar reinforcement center bulkhead Front door hinge reinforcement upper Deck support pipe (Left side) Front pillar support Roof side rail support Roof side rail reinforcement front Rear door hinge reinforcement support Rear door hinge reinforcement Center pillar reinforcement Roof side rail reinforcement rear Rear pillar reinforcement Flap gate striker reinforcement Nut plate Rear pillar reinforcement lower

1-17

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

SIDE STRUCTURE REINFORCEMENT

The ring structure of the side structure reinforcement has been adopted to improve the collision characteristics and the rigidity of the whole vehicle.

Roof side rail reinforcement rear

Roof side rail reinforcement front

Rear pillar reinforcement

Rear pillar reinforcement lower

Side sill reinforcement outer rear

Center pillar reinforcement Front pillar reinforcement lower

Side sill reinforcement outer front AB700608AB

REAR BODY REAR DECK

M4010012000764

3

4

2 1 5 18 ± 7 N·m 13 ± 5 ft-lb

6 7

1.

2.

3.

4.

AB700406AB

5.

6.

7.

Washer tank bracket upper Rear seat hook A Rear shelf panel Rear shelf reinforcement

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Seat belt reinforcement center Rear shelf extension Rear seatback reinforcement

1-18

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

REAR END PANEL

5.0 ± 1.0 N·m 44 ± 9 in-lb

3

4

5

2

1 AB700570AB

1.

2.

3.

4.

5.

Rear bumper side bracket Rear end panel inner Trunk lid striker reinforcement

ROOF • An aluminum roof panel has been adopted to improve lightweightness for greater handling stability. <Vehicles without sunroof (aluminum panel)> • The closed section structure has been adopted for the roof rail front and the roof bow center to heighten body rigidity, improve handling stability and riding comfort, and to reduce vibration and noise.

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Rear end panel outer Rear bumper reinforcement

M4010013001306

• The 590-MPa class high tensile strength steel panel has been adopted for the roof bow center lower to improve the body rigidity. <Vehicles without sunroof (aluminum panel)>

1-19

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS <Vehicles without sunroof (aluminum panel)>

5

6 7

8* 4

1

9 3 2

*: Indicates 590MPa-high-tensile steel panels.

1

AB700936AB

<Vehicles with sunroof (steel panel)>

5 6 10

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14 13

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Sunvisor bracket Reading light bracket Roof rail front lower Roof rail front upper Roof panel Roof rail rear Roof bow center upper

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AB700863AE

Roof bow center lower Dome light bracket Roof panel reinforcement Set rear bracket Bracket A Bracket B Set front bracket

1-20

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

UNDER BODY

M4010014001202

FRONT FLOOR The 590-MPa class high tensile strength steel panels have been adopted for the front floor crossmember front and front floor sidemember, and the 980-MPa class ultra high tensile strength steel panels for the front floor side sill inner, to improve the body rigidity.

5

6

7 8 9

4 3* 2

10 1

16

14

*: Indicates 590MPa-high-tensile steel panels.

15 **: Indicates 980MPa-ultra-high-tensile steel panels.

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Front floor Front floor crossmember front reinforcement Front floor crossmember front Parking brake lever reinforcement Backbone reinforcement Parking brake cable reinforcement Seat center bracket rear Front floor crossmember rear

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12** 13*

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11 AB700937AB

Seat side bracket rear Seat belt reinforcement Front floor side sill inner center reinforcement Front floor side sill inner Front floor sidemember Front floor crossmember rear center Front floor crossmember front Front floor reinforcement lower (Right side)

1-21

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

• The rear floor rear end crossmember has been straightened to heighten body rigidity, improve handling stability and riding comfort, and to reduce vibration and noise.

REAR FLOOR • The 590-MPa class high tensile strength steel panels have been adopted for the rear floor extension and rear seat crossmember to improve the body rigidity.

7

8 5

6 4 2 3

9

1* 14

10

13

11 11

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12 17

15*

*: Indicates 590MPa-high-tensile steel panels.

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Rear floor extension Rear seat under floor Rear floor pan rear Rear seatback bracket lower Rear floor crossmember upper Battery bracket rear floor front Battery bracket rear floor Spare tire bracket Rear floor rear end crossmember

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Rear floor crossmember front Fuel tank rear bracket Rear seat belt reinforcement (Left side) Rear seat belt reinforcement (Right side) Rear seat crossmember bulkhead inner Rear seat crossmember Sidemember front floor extension Rear floor sidemember

1-22

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

REAR FLOOR SIDEMEMBER REINFORCEMENT The 590-MPa class high tensile strength steel panels have been adopted for the rear floor sidemember reinforcement, rear floor sidemember extension, rear floor side sill inner and rear floor sidemember bulkhead to improve the body rigidity.

33

2

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29 6*

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10

31

11

4 28

7

12*

9 13

27

26 3

8

1

25 23

24*

22

16

14

15

17 19 21 18*

20

*: Indicates 590MPa-high-tensile steel panels.

15

29 30

6 A

10 12

AB700587

18

24

28 31 25 22

AB700942AB

23

19

20

27

11

B

AB700953AC

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1-23

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

Rear floor side panel Rear bumper beam reinforcement Rear floor crossmember extension rear Rear suspension bracket center Rear suspension center reinforcement Rear floor sidemember reinforcement Rear floor crossmember extension rear upper Rear floor crossmember extension rear Muffler hanger rear Shipping pipe Shipping bracket reinforcement Rear floor sidemember extension Rear bumper support Canister bracket (Left side) Rear spring house panel lower ABS sensor bracket Brake hose bracket

A

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

Rear floor side sill inner Rear suspension bracket front Trailing arm bracket lower Rear floor sidemember lower Rear floor sidemember extension front Rear tie down plate Rear floor sidemember bulkhead Trailing arm bracket Trailing arm bulkhead Rear floor sidemember rear reinforcement Rear suspension center bulkhead Rear floor sidemember bulkhead rear Rear suspension bracket rear Pipe nut Hydraulic unit bracket front (Right side) Hydraulic unit bracket rear (Right side)

B

1

1

6 21 21

25 20

18

AB700589AC

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29

15 AB700588AB

1-24

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

DOOR An uneven thickness steel sheet* has been used for the front and rear door panel inners to make the forward part of the vehicle thicker for reduction in vehicle weight and higher rigidity.

M4010015000893

NOTE: *: A steel sheet of varying thickness that is welded into one steel sheet.

(Front door)

6 7 8 2 5

11

9

10

3

1

12 4

13 14

12 (Rear door)

AB602334AB

19

23

18

24

21 22

16

20

25 15 17

12 27

26 AB700413AB

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Front door panel outer Front door beltline outer reinforcement Front door outer stiffener Front door side door beam Front door window front sash Front door window upper sash Front door window rear sash Front door latch reinforcement Front door beltline inner reinforcement Front door mirror reinforcement Front door inside handle bracket Nut plate Front door checker reinforcement Front door panel inner

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15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

Rear door panel outer Rear door beltline outer reinforcement Rear door side door beam Rear door window front sash Rear door window upper sash Rear door beltline inner reinforcement Rear door beltline bracket Rear door sash reinforcement Rear door stat corner bracket Rear door latch reinforcement Rear door window sash lower bracket Rear door inside handle bracket Rear door panel inner

BODY CONSTRUCTION SILENCER APPLICATION LOCATIONS

SILENCER APPLICATION LOCATIONS A silencer (MD-12, RSS and melting sheet) has been affixed on the upper surface of the floor for vibration damping.

NOTE: .

• MD-12 is a high performance sheet composed of asphalt applied with mica and thermosetting resin for improving anti-vibration performance. <GSR>

<MR>

of Nihon Tokushu Toryo Co., Ltd. The product features the same performance as a steel sheet sandwich type and refers to a heat cured resin sheet that is molded into a sheet with a uniform thickness. It contains degenerating resin and filler with asphalt and rubber as the main contents.

;;; ;;; ;;; ;;; ;;;

: 1.6 mm (0.063 in) thick melting sheet : 1.6 mm (0.063 in) thick MD-12 [Place a 1.6 mm (0.063 in) melting sheet.] : 3.2 mm (0.126 in) thick MD-12 [Place two 1.6 mm (0.063 in) melting sheet one on top of another.] : 1.6 mm (0.063 in) thick melting sheet and 2.0 mm (0.079 in) thick RSS [Place three 1.6 mm (0.063 in) melting sheet one on top of the next.]

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M4010005001271

• RSS (Rubber Special Sheet) is a product name

;;;; ;; ;;;; ;; ;;;; ;; ;;;; ;; ;;;; ;; ;;;; ;; ;;;;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;;; ;;;;;; ;;;;;;;; ;;;;; ;;;;;;;;; ;;;;;;;;;

NOTE: [ ] indicates the number of melting sheets that are used for repair.

1-25

AB700568AB

AB700568

AB700569AB

1-26

BODY CONSTRUCTION FOAMING MATERIAL USAGE LOCATIONS

FOAMING MATERIAL USAGE LOCATIONS The sound dampening foam material have been adopted to the upper and lower sections of the front pillar, center pillar lower section, rear pillar and wheel house arch inside to shield from external noise.

M4010006000163

CAUTION The sound dampening foam material may burn when heated. Always observe the following instructions: • Never use a gas burner to burn the areas where sound dampening foam material is used.

• When cutting the parts which are provided with sound dampening foam material, ensure to use tools (air saw, etc.) that do not generate fire.

• If there are residual sound dampening foam material remaining on the cut section (body side), remove the sound dampening foam material from periphery of the welding area before welding work.

Sound dampening foam material

Sound dampening foam material

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AB700801AB

BODY CONSTRUCTION STIFFENER AND DAMP SHEET APPLICATION LOCATIONS

1-27

STIFFENER AND DAMP SHEET APPLICATION LOCATIONS A damp sheet (roof insulator) <Vehicles without sunroof (aluminum panel)> on the inner side of the roof panel and a stiffener on the inner side of the rear door panel outer have been adopted for higher surface rigidity.

M4010001400263

NOTE: .

• The main contents of a stiffener are epoxy resin.

It comes in a sheet form and contains a mixture of glass fiber and filler, and cures (stiffens) when heated.

• No spare part of the stiffener for repair is available in the field. If the stiffener is damaged, replace it together with the panel.

Damp sheet (roof insulator)

AB700461

AB700893AB

(Rear door)

Stiffener AB700892AB

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1-28

BODY CONSTRUCTION THEFT PROTECTION

THEFT PROTECTION

M4010017000145

CAUTION When replacing a part that has the theft protection plate, label or stamp on it, be sure that the part has either A or B shown in the figure. It is illegal if both A and B are attached, or neither A nor B is attached.

In order to protect against theft, a Vehicle Identification Number (VIN) is attached as a plate or label to the following major parts of the engine, transaxle and main outer panels: Engine cylinder block, Transaxle housing, Front fender, Hood, Trunk lid, Bumpers, Side outer panel, Doors. In addition, a theft-protection label is attached to replacement parts for main outer panels. The same data is stamped into replacement parts for the engine and the transaxle.

Theft protection plate and label

For original parts

CAUTION Cautions regarding panel repairs: • When repainting original parts, do so after first masking the theft-protection label. After painting, be sure to peel off the masking tape.

• The theft-protection label for replacement parts is covered by masking tape, so such parts can be painted as is. The masking tape should be removed after painting is finished.

• The theft-protection label should not be removed from original parts or replacement parts.

For replacement parts

AC704152AB .

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1-29

BODY CONSTRUCTION THEFT PROTECTION

LOCATIONS

D

E

D'

E'

A

C B F

F'

AC710510AC

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1-30

BODY CONSTRUCTION THEFT PROTECTION

Label area (x: for original equipment parts, y: for replacement parts) Engine

x y

AC612304AB

AC609841AB

Twin clutch sportronic shift transmission (TC-SST)

Manual transaxle (M/T) x

y

x

y

AC708134 AB

View A (Front fender)

Section a - a

AC707965 AB

View B (Hood)

x b a

a

Section b - b

b

x

y

y The illustration indicates left outer side.

Right side is symmetrically opposite.

AC608723AB

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AC708344 AC708456AB

1-31

BODY CONSTRUCTION THEFT PROTECTION

Label area (x: for original equipment parts, y: for replacement parts) View C (Trunk lid)

x y

AC612302 AB

View D (Front bumper)

View D' y

x

AC710511AB

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AC710513

1-32

BODY CONSTRUCTION THEFT PROTECTION

Label area (x: for original equipment parts, y: for replacement parts) View E (Rear bumper)

View E'

x

y

AC608729AB

AC608730AB

View F'

View F (Side outer panel)

y x

The illustration indicates left outer side.

Right side is symmetrically opposite.

Front door (both side)

AC608733AB

View G

The illustration indicates left outer side.

Right side is symmetrically opposite.

Rear door (both side)

AC611136 AB

View H

x

x H

G d

c

Section d - d

Section c - c d

c The illustration indicates left outer side.

Right side is symmetrically opposite.

y AC608731AC

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The illustration indicates left outer side.

Right side is symmetrically opposite.

y AC608734 AC

2-1

GROUP 2

BODY DIMENSIONS CONTENTS BODY DIMENSIONS AND MEASUREMENT METHODS. . . . . . .

2-2

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS). . . . . . . . . . . . . . . . . . .

2-10

UNDER BODY. . . . . . . . . . . . . . . . . . . . . . .

2-10

TYPE A (PROJECTED DIMENSIONS) . . . . . .

2-4

SUSPENSION INSTALLATION DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . .

2-12

UNDER BODY . . . . . . . . . . . . . . . . . . . . . .

2-4

FRONT BODY . . . . . . . . . . . . . . . . . . . . . . .

2-14

SIDE BODY . . . . . . . . . . . . . . . . . . . . . . . . .

2-18

REAR BODY . . . . . . . . . . . . . . . . . . . . . . . .

2-20

INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . .

2-22

SUSPENSION INSTALLATION DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . .

2-8

2-2

BODY DIMENSIONS BODY DIMENSIONS AND MEASUREMENT METHODS

BODY DIMENSIONS AND MEASUREMENT METHODS

M4020001000448

• Type A (projected dimensions) is the dimension when a measurement location is projected onto the plane.

NOTE: The height indicates a distance from the assumed standard line established 100 mm (3.9in) below the lowest measurement point.

Projected dimension

Height Probe

AB302138AE

• Type B (actual-measurement dimensions) is the actual distance between the measurement points.Measure using a tracking gauge or a measuring tape, etc.

NOTE: .

• Make the lengths of the tracking gauge probes the same (A=A’).

• Do not bend or twist the measuring tape.

Ac dim tual en -me sio as n ur

ed

A A'

AB302139AE

Center of hole

• Insert the tracking gauge probes securely into the measurement holes.

• When the standard dimensions in the illustration are enclosed by rectangle, this indicates that the symmetrical left and right positions have the same dimensions.

AB302140AF

• When using a notch for dimension measurement, set the measuring point at the center of the notch.

• The body center points are shown for the purpose of checking the position of the left and right symmetry location.

AB302141AD

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BODY DIMENSIONS BODY DIMENSIONS AND MEASUREMENT METHODS

NOTES

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2-3

2-4

BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS)

TYPE A (PROJECTED DIMENSIONS) UNDER BODY

M4020005002156

mm (in)

76 (3.0)

616 (24.3)

540 (21.3)

2 967 (38.1)

667 (26.3)

510 (20.1) 624 (24.6)

910 (35.8)

1,262 (49.7)

894 (35.2)

375 (14.8)

1,050 (41.3)

76 (3.0)

Center line of the vehicle

1,138 (44.8)

1,079 (42.5) 1,394 (54.9)

763 (30.0)

1,254 (49.4)

1,195 (47.0)

641 (25.2)

7

1,124 (44.3) 1,028 (40.5)

4

5

544

6 (21.4) 686 (27.0)

1,342 (52.8)

1,369 (53.9)

1,025 (40.4)

1,218 (48.0)

1,120 (44.1)

3

13

AB700574AB

969 (38.1)

1

344 (13.5)

545 (21.5)

10

616 (24.3)

2

964 (38.0)

990 (39.0)

393 (15.5) 440 12 (17.3) 11

9

8

877 (34.5)

1,022 (40.2)

350 (13.8)

5

4

3

929 (36.6)

718 (28.3)

894 (35.2)

7

197 875 (7.8) (34.4) 564 (22.2) 6

960 (37.8)

1

833 (32.8)

462 (18.2)

960 (37.8)

1,080 (42.5) 1,117 (44.0)

8

9

11

12

13

10 Center line of the vehicle AB700575AB

No. Standard measurement point

Hole shape

Size mm (in)

1

Center of front end crossmember lower water draining hole (left side)

Round

8 (0.31)

2

Center of front end crossmember lower water draining hole (right side) Round

8 (0.31)

3*

Center of front sidemember inner positioning hole

Round

25 (0.98)

4*

Center of front axle crossmember mounting hole (front)

Round

15.5 (0.61)

5*

Center of front sidemember rear water draining hole

Round

16 (0.63)

6

Center of propeller shaft mounting hole (left side)

Round

11 (0.43)

7

Center of propeller shaft mounting hole (right side)

Round

11 (0.43)

8*

Center of front floor sidemember positioning hole (front)

Round

16 (0.63)

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2-5

BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm (in)

9*

Center of front floor sidemember positioning hole (rear)

Round

16 (0.63)

10*

Center of rear floor sidemember lower positioning hole (front)

Oblong

33.9×18 (1.335×0.71)

11*

Center of rear suspension bracket front water draining hole

Round

16 (0.63)

12*

Center of rear floor sidemember lower positioning hole (rear)

Round

25 (0.98)

13*

Center of rear floor sidemember extension water draining hole (left side), Center of rear shipping bracket mounting hole (right side)

Round

14 (0.55)

NOTE: The * mark indicates the mounting position for the frame centering gauge. mm (in)

1 2

230 (9.1)

486 (19.1)

3

4 5

6

100 (3.9)

157 259 (6.2) 105 (4.1) (10.2)

347 (13.7)

280 (11.0)

294 (11.6)

12

11

7 8

9

350 (13.8)

13

10 154 (6.1)

105 (4.1)

286 (11.3)

357 (14.1)

354 (13.9)

716 (28.2)

510 (20.1) 1,049 (41.3)

291 (11.5)

1,125 (44.3)

715 (28.1) 1,101 (43.3)

Standard line

1,644 (64.7) AB700418AB

NOTE: The assumed standard line is established 100 mm (3.9in) below the measurement point No.5.

2

1, 3

1

4

3 AB700470AB

6, 7

5

AB700472AB

AB700471AB

8, 9

6

8

7

AB700473AB

AB600999AB

TSB Revision

9

AB601000AB

2-6

BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS)

11, 12

10

13

11

12 AB700475AB

AB700474AB

TSB Revision

AB700973AB

BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS)

NOTES

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2-7

2-8

BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS)

SUSPENSION INSTALLATION DIMENSIONS

M4020013001783

mm (in) 331 (13.0)

529 (20.8)

510 (20.1)

768 (30.2) 910 (35.8)

875 (34.4)

1,298 (51.1)

894 (35.2)

886 (34.9)

1,132 (44.6)

787 (31.0)

4

9 (18.9)

5

14 293 (11.5)

17

84 (3.3)

Center line of the vehicle

18

19

760 (29.9)

1,116 (43.9) 1,117 (44.0)

1,272 (50.1)

1,230 (48.4) 1,187 (46.7)

907 (35.7)

1,028 (40.5)

20

441 (17.4)

AB700578AB

1,200 (47.2)

945 (37.2)

903 (35.6)

328 (12.9)

16

217 (8.5)

1,004 (39.5)

1,138 (44.8) 480

15

1,000 (39.4)

1,048 (41.3)

1,323 (52.1)

4 15

5

9

17

14

18

19

20

16 Center line of the vehicle

AB700579AB

No. Standard measurement point

Hole shape

Size mm (in)

4

Center of front axle crossmember mounting hole (front)

Round

15.5 (0.61)

5

Center of front sidemember rear water draining hole

Round

16 (0.63)

9

Center of front floor sidemember positioning hole (rear)

Round

16 (0.63)

14

Center of front shock absorber mounting hole

Round

80 (3.15)

15

Center of front axle crossmember mounting hole (rear)

Round

15.5 (0.61)

16

Center of trailing arm mounting hole (outer side)

Round

15.5 (0.61)

17

Center of trailing arm mounting hole (inner side)

Round

15.5 (0.61)

18

Center of rear suspension crossmember mounting hole (front)

Round

15 (0.59)

19

Center of rear shock absorber mounting hole

Round

70.8 (2.79)

20

Center of rear suspension crossmember mounting hole (rear)

Round

15 (0.59)

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2-9

BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS)

A

Vehicle center

B

Vehicle center 6˚54´

15˚34´

mm (in)

540 (21.3)

3˚06´

1,087 (42.8)

14

A

0˚

19

464 (18.3)

4

18 15

767 (30.2) 294 (11.6)

Standard line

17

5 9

162 (6.4)

105 (4.1)

100 (3.9)

217 (8.5) 510 (20.1)

187 (7.4)

1,066 (42.0)

B

20

16

683 (26.9)

284 187 (11.2) (7.4)

354 (13.9)

489 (19.3) 785 (30.9) 1,223 (48.1)

AB700848AB

NOTE: The assumed standard line is established 100 mm (3.9in) below the measurement point No.5.

4

5, 15

9

15

5 AB700479AB

AB700472AB

14

AB601180AB

18, 20

16, 17

18 16 17 20 AB700478AB

AB700480AB

TSB Revision

AB700481AB

2-10

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

19

AB700482 AB

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) UNDER BODY

M4020005002167

mm (in)

102 (4.0)

856 (33.7)

616 (24.3) 542 (21.3)

2

669 (26.3)

546 (21.5)

7

875 (34.4)

910 (35.8) 960 (37.8)

1

894 (35.2)

222 (8.7)

5

4

894 1,262 (35.2) (49.7)

1,022 (40.2)

877 (34.5)

990 (39.0)

378 (14.9)

567 (22.3)

3

350 (13.8)

6 8

399 (15.7) 460 12 (18.1) 11

9

545 (21.5)

13

10

1,079 (42.5)

101 (4.0)

348 (13.7)

616 (24.3)

AB700576AB

1,081 (42.6)

2 971 (38.2)

1,138 (44.8)

1,120 (44.1)

1,124 (44.3)

1,415 (55.7)

966 (38.0)

1

487 (19.2)

644 (25.4)

967 (38.1)

932 (36.7)

740 (29.1)

3

4

765 (30.1)

1,046 (41.2)

7

1,255 (49.4) 643 (25.3)

566

960 (37.8)

8

9

6 (22.3) 5

1,118 (44.0)

704 (27.7)

1,209 (47.6)

1,225 (48.2)

1,357 (53.4)

1,371 (54.0)

1,027 (40.4) 1,080 (42.5)

11

12

13

10

AB700577AB

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2-11

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm (in)

1

Center of front end crossmember lower water draining hole (left side)

Round

8 (0.31)

2

Center of front end crossmember lower water draining hole (right side) Round

8 (0.31)

3

Center of front sidemember inner positioning hole

Round

25 (0.98)

4

Center of front axle crossmember mounting hole (front)

Round

15.5 (0.61)

5

Center of front sidemember rear water draining hole

Round

16 (0.63)

6

Center of propeller shaft mounting hole (left side)

Round

11 (0.43)

7

Center of propeller shaft mounting hole (right side)

Round

11 (0.43)

8

Center of front floor sidemember positioning hole (front)

Round

16 (0.63)

9

Center of front floor sidemember positioning hole (rear)

Round

16 (0.63)

10

Center of rear floor sidemember lower positioning hole (front)

Oblong

33.9×18 (1.335×0.71)

11

Center of rear suspension bracket front water draining hole

Round

16 (0.63)

12

Center of rear floor sidemember lower positioning hole (rear)

Round

25 (0.98)

13

Center of rear floor sidemember extension water draining hole (left side), Center of rear shipping bracket mounting hole (right side)

Round

14 (0.55)

2

1, 3

1

4

3 AB700470AB

6, 7

5

AB700472AB

AB700471AB

8, 9

6

8

7

AB700473AB

11, 12

10

9

AB600999AB

AB601000AB

13

11

12 AB700475AB

AB700474AB

TSB Revision

AB700973AB

2-12

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

SUSPENSION INSTALLATION DIMENSIONS

M4020013001794

mm (in) 345 (13.6)

535 (21.1)

546 (21.5)

786 (30.9) 807 (31.8)

886 (34.9) 1,298 (51.1)

910 (35.8)

1,138 (44.8)

894 (35.2)

1,000 (39.4)

903 (35.6)

875 (34.4)

15

4

322 (12.7)

487

17

5

9 (19.2)

226 (8.9)

84 (3.3)

342 (13.5)

16

446 (17.6)

20

18 778 (30.6) AB700580AB

1,120 (44.1)

1,203 (47.4)

954 (37.6) 909 (35.8)

1,191 (46.9)

1,046 (41.2)

4

1,283 (50.5)

1,120 (44.1) 1,243 (48.9)

15

5

9

17

1,050 (41.3)

1,333 (52.5)

18

20

16 AB700581AB

No. Standard measurement point

Hole shape

Size mm (in)

4

Center of front axle crossmember mounting hole (front)

Round

15.5 (0.61)

5

Center of front sidemember rear water draining hole

Round

16 (0.63)

9

Center of front floor sidemember positioning hole (rear)

Round

16 (0.63)

15

Center of front axle crossmember mounting hole (rear)

Round

15.5 (0.61)

16

Center of trailing arm mounting hole (outer side)

Round

15.5 (0.61)

17

Center of trailing arm mounting hole (inner side)

Round

15.5 (0.61)

18

Center of rear suspension crossmember mounting hole (front)

Round

15 (0.59)

20

Center of rear suspension crossmember mounting hole (rear)

Round

15 (0.59)

TSB Revision

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

4

5, 15

2-13

9

15

5 AB700479AB

AB700472AB

18, 20

16, 17

18 16 17 20 AB700481AB

AB700480AB

TSB Revision

AB601180AB

2-14

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

FRONT BODY

M4020006001101 1

mm (in)

2

1,094* (43.1)

1,106* (43.5)

39 40 41 995 *1 (39.2) 994 *2 (39.1)

1,625 *1 (64.0) 1,630 *2 (64.2)

1,508 (59.4)

509 (20.0)

38

37

1,072 (42.2)

1,438 (56.6)

394 (15.5)

32

1,494 (58.8)

1,486 (58.5)

913 (35.9)

29 27

23

31 30

336 (13.2)

21

35 34

901 (35.5)

391 (15.4)

36 (16.7)

401 (15.8)

877 (34.5)

891 (35.1)

26

425

1,485 (58.5)

901 (35.5)

33

327 (12.9)

Body center point

1,174 (46.2)

25

1,060 (41.7)

28 329 (13.0)

392 (15.4)

24

22

*1 : <Vehicles without sunroof (aluminum panel)> Body center point *2 : <Vehicles with sunroof (steel panel)>

781 (30.7)

AB700431AC

37

855 (33.7) 822 (32.4)

810 (31.9) 896 (35.3)

1,458 (57.4)

33

1,449 (57.0)

29 27 1,032 (40.6)

26

35 34

819 (32.2)

31 30

1,042 (41.0)

713 (28.1)

38 36

1,558 (61.3)

864 (34.0)

32

732 (28.8)

714 (28.1)

23

25

28

24

22 Body center point 21 AB700602AB

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2-15

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

mm (in)

1,556 (61.3)

37

601 (23.7)

555 (21.9)

873 (34.4) 857 (33.7)

953 (37.5)

33 32 29

1,026 (40.4)

937 (36.9) 980 (38.6)

26

782 (30.8)

31

38

36 35 34

860 (33.9)

30

27 549 (21.6)

831 (32.7)

341 (13.4)

774 (30.5)

28

25

23 22

24

544 (21.4)

Body center point 21 AB700603AB

No. Standard measurement point

Hole shape

Size mm (in)

21

Center of front end crossmember positioning notch (Body center point)

−

−

22

Center of front end crossmember dynamic damper mounting hole (left side)

Round

9 (0.35)

23

Center of front end crossmember dynamic damper mounting hole (right side)

Round

9 (0.35)

24

Center of front bumper reinforcement mounting hole (left lower)

Round

9 (0.35)

25

Center of front bumper reinforcement mounting hole (left upper)

Round

9 (0.35)

26

Center of front bumper reinforcement mounting hole (right lower)

Round

9 (0.35)

27

Center of front bumper reinforcement mounting hole (right upper)

Round

9 (0.35)

28

Center of front sidemember inner positioning notch (left side)

−

−

29

Center of front sidemember inner positioning notch (right side)

−

−

30

Center of headlight support panel upper mounting hole (left front)

Round

6.6 (0.26)

31

Center of headlight support panel upper mounting hole (left rear)

Round

6.6 (0.26)

32

Center of headlight support panel upper mounting hole (right front)

Round

6.6 (0.26)

33

Center of headlight support panel upper mounting hole (right rear)

Round

6.6 (0.26)

34

Center of front end upper bar side positioning hole

Round

6 (0.24)

35

Center of front fender mounting hole

Round

6.6 (0.26)

36

Center of front strut mounting hole

Round

11.5 (0.45)

37

Center of cowl top panel mounting hole

Round

6.6 (0.26)

38

Center of hood hinge mounting hole

Round

9 (0.35)

39

Center of roof panel positioning notch (Body center point)

−

−

40

Corner of roof panel <Vehicles without sunroof (aluminum panel)>

−

−

41

Corner of roof panel <Vehicles with sunroof (steel panel)>

−

−

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2-16

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

21, 22

23

24, 25

25

22 24 21 AB700488 AB

26, 27

27

AB700434 AB

AB700489 AB

29

28

26 AB700436 AB

AB700435 AB

30, 31

32, 33

AB700437AB

34, 35

31

33

35 34

30

32 AB601016 AB

37

36

AB601020 AB

AB700438 AB

38

AB601022 AB

AB700439 AB

TSB Revision

AB700440 AB

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

40

39

AB601235 AB

41

AB700849 AB

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2-17

AB601024 AD

2-18

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

SIDE BODY

M4020007001018

mm (in)

48

44 42

762 (30.0) 863 (34.0)

657 (25.9)

1,076 (42.4)

46

50

1,044 (41.1)

1,159 867 (45.6) (34.1) 635 (25.0) 1,290 (50.8)

822 (32.4)

43

970 (38.2) 713 (28.1)

775 (30.5)

47

51

49

45

AB700854AB

48

44 1,049 (41.3)

52 364 (14.3)

1,106 (43.5)

1,096 (43.1) 1,176 (46.3) 1,072 (42.2)

53

640 (25.2)

54 355 (14.0)

781 (30.7)

56

835 (32.9)

55

AB700855AB

No. Standard measurement point

Hole shape

Size mm (in)

42

Front pillar positioning notch (upper)

−

−

43

Front pillar positioning notch (lower)

−

−

44

Roof side rail positioning notch (front)

−

−

45

Side sill positioning notch (front)

−

−

46

Center pillar positioning notch (upper)

−

−

47

Center pillar positioning notch (lower)

−

−

48

Roof side rail positioning notch (rear)

−

−

49

Side sill positioning notch (rear)

−

−

50

Quarter panel positioning notch (upper)

−

−

51

Quarter panel positioning notch (lower)

−

−

52

Center of front door upper hinge mounting hole

Round

11 (0.43)

53

Center of front door lower hinge mounting hole

Round

11 (0.43)

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2-19

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm (in)

54

Center of rear door upper hinge mounting hole

Round

11.5 (0.45)

55

Center of rear door lower hinge mounting hole

Round

11 (0.43)

56

Center of rear door switch mounting hole

Round

5 (0.20)

43, 53

42

44, 46 43 53 44 46 AB700484 AB

AB601025AC

45

47, 55 47

48 55

AB601030AC

AB601028AC

AB601031AC

51, 56

50

49

AB601027AC

56

51

AB700485 AB

AB601033AC

54

52

AB700487AB

AB601029AC

TSB Revision

AB700486 AB

2-20

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

REAR BODY

M4020008001055

mm (in) 2

57 58

1,045*1 1,056* (41.1) (41.6)

743 *1 (29.3)

1,361 *1 (53.6) 1,365 *2 (53.7)

742 *2 (29.2)

Body center point

59

198 (7.8)

1,244 (49.0)

1,252 (49.3)

60

1,190 (46.9)

61 62

63

1,268 (49.9) 655 (25.8)

65

64 1,100 (43.3)

66 *1 : <Vehicles without sunroof (aluminum panel)> *2 : <Vehicles with sunroof (steel panel)>

117 (4.6)

990 (39.0)

67

AB700990AB

295 (11.6)

Body center point

59 649 (25.6) 1,232 (48.5)

60

1,189 (46.8)

61 63

761 (30.0)

62

1,458 (57.4) 505 (19.9)

507 (20.0)

606 (23.9)

778 (30.6)

64 1,346 (53.0)

65 1,050 (41.3)

66 67

AB700991AB

No. Standard measurement point

Hole shape

Size mm (in)

57

Corner of roof panel <Vehicles without sunroof (aluminum panel)>

−

−

58

Corner of roof panel <Vehicles with sunroof (steel panel)>

−

−

59

Body center point of rear shelf panel

−

−

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2-21

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm (in)

60

Center of trunk lid hinge mounting hole (front)

Round

9 (0.35)

61

Center of trunk lid hinge mounting hole (rear)

Round

9 (0.35)

62

Corner of side outer panel

−

−

63

Center of rear combination light mounting hole

Round

8 (0.31)

64

Center of trunk lid latch striker mounting hole (left side)

Round

6.6 (0.26)

65

Center of trunk lid latch striker mounting hole (right side)

Round

6.6 (0.26)

66

Center of rear bumper reinforcement mounting hole (upper)

Round (left side), Oblong (right side)

15 (0.59) (left side), 15×17 (0.59×0.67) (right side)

67

Center of rear bumper reinforcement mounting hole (lower)

Round

15 (0.59)

58

57

59

AB700850AB

AB601054AC

60, 61

62, 63

62

60

AB601056AC

64, 65 65 64

63

61

AB601055AC

66, 67 66

67 AB700992AB

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AB700446AB

AB700447AB

2-22

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

INTERIOR

M4020009001230

mm (in) 1,171 (46.1)

1,190 (46.9)

44

1,375 (54.1)

1,357 (53.4)

1,330 (52.4)

50

46

42 1,430 (56.3) 1,430 (56.3)

48

1,430 (56.3)

1,430 (56.3)

47

51

1,430 (56.3)

43

49 45 AB700461AB

48

44 1,135 (44.7)

42

68 Body center point

1,059 (41.7)

1,179 (46.4)

735 (28.9)

1,073 (42.2)

43

50

1,130

46 (44.5)

Body center point 69

1,190 (46.9)

783 (30.8)

51

47 49

45

834 (32.8)

69 Body center point

720 (28.3)

AB700600AB

59 Body center point

1,067 (42.0)

70

1,004 (39.5) 593 (23.3) 1,076 (42.4)

659 (25.9)

720 (28.3)

71

AB700462AB

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2-23

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm (in)

42

Front pillar positioning notch (upper)

−

−

43

Front pillar positioning notch (lower)

−

−

44

Roof side rail positioning notch (front)

−

−

45

Side sill positioning notch (front)

−

−

46

Center pillar positioning notch (upper)

−

−

47

Center pillar positioning notch (lower)

−

−

48

Roof side rail positioning notch (rear)

−

−

49

Side sill positioning notch (rear)

−

−

50

Quarter panel positioning notch (upper)

−

−

51

Quarter panel positioning notch (lower)

−

−

59

Body center point of rear shelf panel

−

−

68

Center of parking brake lever mounting hole (Body center point)

Round

11 (0.43)

69

Body center point of rear floor extension

−

−

70

Center of rear shock absorber mounting hole

Round

14 (0.55)

71

Center of rear end trim mounting hole

Round

8.5 (0.335)

43

42

44, 46

44 46 AB700598AB

AB601025AC

45

47

AB601028AC

48

AB601030AC

TSB Revision

AB601027AC

AB601031AC

2-24

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

51

50

49

AB700485 AB

69

68

59

AB601056AC

AB601063AC

71

70

AB700858 AB

AB601033AC

AB700464AB

AB700465AB

TSB Revision

AB700463 AB

2-25

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

mm (in) 1,401 (55.2)

72

1,397 (55.0)

74

1,392 (54.8)

140 (5.5)

130 (5.1)

1,392 (54.8)

73

75

AB600984AE

No. Standard measurement point

Hole shape

Size mm (in)

72

Center of deck crossmember mounting hole (left-upper)

Round

13 (0.51)

73

Center of deck crossmember mounting hole (left-lower)

Round

13 (0.51)

74

Center of deck crossmember mounting hole (right-upper)

Round

9 (0.35)

75

Center of deck crossmember mounting hole (right-lower)

Round

9 (0.35)

72, 73

74, 75

72

74

73

75

AB601066AC

AB601067AC

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NOTES

9-1

GROUP 9

BASE OF BODY REPAIR CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . .

9-2

USING A FRAME STRAIGHTENER . . . . . .

9-27

FRAME REPAIR PROCEDURES . . . . . . . .

9-28

WELDING. . . . . . . . . . . . . . . . . . . . . .

9-2

NOTES REGARDING REPAIR WORK . . . .

9-31

WELDING . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2

ELECTRIC RESISTANCE SPOT WELDING . . . . . . . . . . . . . . . . . . . . . . . . . .

HEAT-WITHSTAND TEMPERATURES OF RESIN-PLASTIC PARTS . . . . . . . . . . .

9-34

9-3

GAS SHIELD ARC WELDING . . . . . . . . . .

9-8

HOW TO DISTINGUISH TYPES OF PLASTICS . . . . . . . . . . . . . . . . . . . . . . . . . .

9-36

OTHER TYPES OF WELDING . . . . . . . . . .

9-12

CORROSION PROTECTION . . . . . . .

9-37

BODY REPAIR. . . . . . . . . . . . . . . . . .

9-14

STANDARD BODY REPAIR PROCEDURES. . . . . . . . . . . . . . . . . . . . . .

ANTICORROSION TREATMENT AT THE FACTORY . . . . . . . . . . . . . . . . . . . . . .

9-37

9-14

THEFT PROTECTION . . . . . . . . . . . . . . . .

9-23

ANTICORROSION TREATMENT AT THE TIME OF BODY REPAIR WORK . . . .

9-40

ATTACHMENT OF SILENCERS . . . . . . . .

9-24

POSITIONING DIMENSIONS FOR OPENINGS . . . . . . . . . . . . . . . . . . . . . . . . .

9-25

REPAIR OF SYNTHETIC-RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . .

9-43

STANDARD PROCEDURES FOR SHEET METAL WORK . . . . . . . . . . . . . . . .

9-26

SYNTHETIC-RESIN PARTS REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . .

9-43

9-2

BASE OF BODY REPAIR GENERAL

GENERAL

M4090000100018

Group 9 is applicable for all models.

WELDING WELDING

M4090001000058

Welding is the partial joining of two or more metals by deposition; the welding methods used for body maintenance and repair can be classified into the following methods.

Fusion methods Temperature: 1,130 – 1,550˚C (2,066 – 2,822˚F) Welding methods

Shielded arc welding CO2 gas arc welding Gas welding

Electric resistance spot welding Pressure methods [Temperature approximatery 1,500˚C (2,732˚F) or higher at weld area] Brazing methods

Brazing Temperature: 620 – 950˚C (1,148 – 1,742˚F) Soldering Temperature: 183 – 310˚C (361 – 590˚F) AB301447AB

FUSION WELDING

BRAZING

Fusion welding is a method of welding in which the weld connection is made by forming or supplying the weld metal at the part where the weld is to be made.

Brazing is a method of welding in which the weld connection is made by supplying a filler metal (which is molten at a temperature lower than the melting temperature of the base metal) at the place where the joining is to be made without melting the base metal itself.

PRESSURE WELDING Pressure welding is a method of welding in which the weld connection is made by applying external pressure while the part where the weld is to be made is in a molten or semi-molten condition.

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BASE OF BODY REPAIR WELDING

ELECTRIC RESISTANCE SPOT WELDING Electric resistance spot welding is a method for fusing metal parts together. Two or three metal sheets are positioned between two copper-alloy electrode tips, and pressure and a large current are then applied, thus causing the contacting surfaces to heat up and fuse together because of the electric contact resistance.

ADVANTAGES OF ELECTRIC RESISTANCE SPOT WELDING

9-3 M4090002000040

• Because the time required for welding at each point is brief, the work can be done quickly and at reduced cost.

• Because both metals are fused and pressure applied to make the weld, the strength and reliability are both high.

• Because the time required to make the welds is short, there is little occurrence of distortion of the panel due to heat.

.

PROCEDURE There are three basic stages in electric resistance spot welding.

1. Initial pressure application stage This stage precedes the current application. Applying pressure to the steel panels through the electrode tips ensures a uniform contact resistance and a smoother current flow.

AB200026

2. Current application stage While an ample amount of pressure is being applied, the current is sent through the electrode tips. The contact resistance causes the contact surfaces of the steel panels to heat up and fuse together.

AB200027

3. Holding stage When the current application is finished and a nugget (a solidified piece of molten metal) forms at the weld, the pressure application is continued in order to strengthen the weld. This is the most important stage of electric resistance spot welding in ensuring the strength of the weld.

AB200028

.

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9-4

BASE OF BODY REPAIR WELDING

NUGGET FORMATION

Weak ← Shear strength per point → Strong

Cooling water

More than 1.6 mm (0.063 in)

C D C' D'

B' B

A' A

1.6 mm (0.063 in) or less

C Is The Scatter Point

Electrode

Melting point

Steel panel

Nugget

Electrode

Small ← Welding current → Large

Cooling water

Water temperature

540 1,095 1,650˚C (1,000) (2,000) (3,000)˚F Max. Heating temperature AB301468 AD

Generally speaking, the size of the nugget will increase as the welding current increases, and as the size of the nugget increases, the strength of the weld will also increase.

Nugget formation will not begin until the current level reaches a certain point; however, once this welding current level is passed, the strength will increase rapidly (between points A and B).

As the current level increases further, the weld strength for thick panels [more than 1.6 mm (0.063 inch)] continues to increase proportionately (between points B and C); however, for thin panels [1.6 mm (0.063 inch) or less], the weld strength reaches a peak very quickly and will increase only slightly, even if the current level increases (between points B' and C').

Then, for both thick panels and thin panels, the molten metal will scatter if the current level increases past a certain point. .

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9-5

BASE OF BODY REPAIR WELDING

NOTES REGARDING WELDING

D

t

90 – 120˚ D : Diameter of the electrode tip t : Thickness of the panel

AB301455AE

1. Selection of the electrode tips • Select the electrode tips according to the thickness of the panels to be welded.

D = 2t + 3 mm (D = 2t + 0.1 inch) • The angle of the tip should be between 90 degree angle and 120 degree angle.

• To always keep the end of tip in the correct shape, use a tip cutter, file or similar tool to shape it if it becomes worn.

2. Alignment of the electrode tips • Adjust the arms so that the upper and lower electrode tips are in a straight line.

3. Alignment and length of the arms • Adjust the electrode tips so that the upper and lower arms are parallel.

• Select an appropriate arm length. Note, however, that the arm length should not be more than 350 mm (13.8 inches) in order to ensure nugget strength.

4. The weld points • The overall strength will increase as the pitch decreases; however, if the pitch decreases too much, the current will be short-circuit diverted to the previous weld point and the strength of the individual nuggets will be insufficient.

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• Make the spot welds at the center of the flanges to provide sufficient adhesion. When welding at an edge, make the spot welds at least 5 mm (0.2 inch) from the edge of the flange.

• The number of spot weld points should be the same as, or slightly more than the number of original repair welds.

• When spot welding three or more panels together, if painted surfaces cause a loss of conductivity, make the welds at the same places as the factory welds. If this is done, extra welds will not be necessary, but if extra welds are necessary, switch to plug welding. .

WELDING REQUIREMENTS Standard steel plate (SPCC, etc.)

CAUTION If the total thickness of the plates at the weld places is 3 mm (0.12 inch) or more, use plug welding, because spot welding will not provide sufficient welded strength.

Example • Center pillar (outer): plate thickness 1.4 mm (0.055 inch), material SPCC • Center pillar (inner): plate thickness 1.5 mm (0.059 inch), material SPCC

9-6

BASE OF BODY REPAIR WELDING

The number of weld points are as below when the outer and inner center pillars are repaired by welding.

Factory welds (F)

8 Points

Repair welds (R)

8 Points

11 Points

11 Points

As shown by the Welding Requirements table, the number of repair welds is as follows.

8 (points) × 130 (%) = 10.4 (points) The number of weld points should, therefore, be ten or eleven.

If, however, a pitch of 26 mm (1.02 inch) or more cannot be maintained, the plug welding method (eight weld points) should be used.

AB200031AE

Panel thickness* [mm (in)] 1.0 (0.04) or Safety equipment less area

Other area

Number of repair weld (percentage of factory weld)

100% Same number as factory welds

1.2 (0.047)

150% Maintain pitch of at least 22 mm (0.87 inch); if not possible, plug weld.

1.4 (0.055) or more

100% Same number as factory welds; plug welding

1.2 (0.047) or less

100% Same number as factory welds

1.4 (0.055)

130% Maintain pitch of at least 26 mm (1.02 inch); if not possible, plug weld.

1.6 (0.063) or more

100% Same number as factory welds; plug welding

NOTE: *: For welding steel plates of different thickness, conform to the welding conditions for the thinner plate. .

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BASE OF BODY REPAIR WELDING

9-7

GALVANIZED STEEL PLATE (SECC) CAUTION If the total thickness of the plates at the weld places is 3 mm (0.12 inch) or more, use plug welding, because spot welding will not provide sufficient welded strength.

Panel thickness* [mm (in)] 0.9 (0.035 or Safety equipment less area 1.0 (0.04)

Number of repair weld (percentage of factory weld)

100% Same number as factory welds 200% Maintain pitch of at least 18 mm (0.71 inch); if not possible, plug weld.

1.2 (0.047) or 100% Same number as factory welds; plug welding more Other area 0.9 (0.035) or 100% Same number as factory welds less 1.0 (0.04)

140% Maintain pitch of at least 18 mm (0.71 inch); if not possible, plug weld.

1.2 (0.047) or 100% Same number as factory welds; plug welding more NOTE: *: For welding steel plates of different thicknesses, conform to the welding conditions for the thinner plate. .

USING A TEST PIECE TO CHECK NUGGET FORMATION

WELD POINT

1

2

3 AB200032AB

Weld a test piece of the same type of steel plate as the panels to be welded. Try to twist the piece, and also check the nugget diameter.

Using the weld point as an axis, apply force in the direction indicated by the arrows in the illustration, and determine the strength of the weld.

1. Good (The welded part remains at one side).

2. and 3.

The weld conditions are unsatisfactory; adjust the welding current, the current application time, and/or the applied pressure. .

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9-8

BASE OF BODY REPAIR WELDING

CHECKING NUGGET STRENGTH FOLLOWING SPOT WELDING

3 mm (0.12 in)

AB200033AC AB200033

CAUTION • Stop wedging the tip or the chisel or flat-tipped screwdriver as soon as the size of the nuggets can be determined; do not wedge it in more than 30 mm (1.18 inches).

• After checking the nugget diameter, correct the place where the checking was done.

Wedge the tip of a chisel or flat-tipped (-) screwdriver into the space between two weld points.

• The nuggets should not break apart.

• The nugget diameter should be 3 mm (0.12 inch) or more.

GAS SHIELD ARC WELDING

M4090003000043

Wire Nozzle Contact tip Metal vapor Shield gas

AB301456 AD

Gas shielded arc welding is one method of arc welding. In this method, while the area to be welded is shielded from the air by a layer of inert gas (such as argon) or carbon dioxide gas, the filler metal (wire) is fed from the torch nozzle at a constant rate and an electric arc is generated between the tip of the wire and the area being welded, thus generating heat to

TSB Revision

fuse the area. There are two types of gas shielded arc welding, classified according to the gas they use as the shield gas: carbon dioxide (CO2) gas shielded arc welding, and MIG welding, which uses an inert gas (such as argon).

However, herein we will refer to all gas shielded arc welding as MIG welding.

9-9

BASE OF BODY REPAIR WELDING

MIG SPOT WELDING Wire Gas cup

Gas outlet

AB200036AE

This welding method is used in areas where regular spot welding cannot be done. The two panels are stacked together, the tip of the torch (one designed for use in MIG spot welding) is positioned on one side, an arc is generated for a short time, and a partial melting is done to obtain a spot weld. .

Procedure CAUTION • Make sure that the area to be welded is perfectly clean; remove oxidation film, scales, rust, dirt, etc.

• The two panels to be welded must be in perfect contact with each other.

• The number and pitch of the weld points should be approximately the same as for the factory welds.

1. Position the tip of the nozzle at a right angle to the surface to be welded.

2. Being sure that the two prongs are not leaning to either side, set them in direct contact with the panel to the welded.

3. Welding will begin when the torch trigger is squeezed, and will stop automatically when the weld is complete. .

FEATURES OF MIG SPOT WELDING In comparison to resistance spot welding, MIG spot welding has the following advantages and disadvantages.

Item

Mig spot welding

Electric resistance spot welding

Working characteristics

• Light weight • Welding possible at various positions (no limit upon welding positions)

• Although the torch with separate transformer is lightweight, the torch combined with transformer type is heavy.

• The arm must be exchanged to conform to the weld location.

Weld time/point

Slow (0.5 second or more)

Fast (0.5 second or less)

Treatment after welding

Necessary (grinding by grinder, etc.)

Unnecessary

Power

High voltage, low current (15 − 30 V, 50 − 200 A)

Low voltage, high current (2 − 4 V, 4 − 10 kA)

Flux material

• CO2 (carbonic acid gas) • Weld wire

Unnecessary

Weld points/10 minutes (rate of use)

• 25 points or less • Arc instability and contact tip burn if rate of use is exceeded.

• 50 − 60 points • Welding rod deformation and transformer overheating if rate of use is exceeded.

Distortion caused by welding

Occurs easily

Rare

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BASE OF BODY REPAIR WELDING

Item

Mig spot welding

Electric resistance spot welding

Welding strength

Depends on strength of welding wire itself.

• Same as base material • Little oxidation • Uniform welding quality

Weld traces

Button head (slightly convex)

Slight concave (Almost no indentation if swivel tip used.)

Swivel tip

AB200037AD

Re-repairability (cutting away welded area)

Difficult Easy (Much welding trace High hardness (Can be separated by spot cutter.) of weld points) .

The MIG welding done around the doors, wheelhouse arches, etc., to prevent the flanges from coming undone after hemming work is also called MIG spot welding.

AB200038 AB

PLUG WELDING

Torch

5 – 6 mm (0.2 – 0.24 in) Diameter hole

Perfect contact

CAUTION In order to prevent the formation of blowholes, fill in each hole completely in one pass.Be sure that the two panels are in perfect contact.Be sure that the penetration goes all the way to the bottom panel.

Plug welding is done by making holes 5 − 6 mm (0.2−0.24 inch) in diameter in one of the panels to be welded together, positioning the torch at a right angle to the holes and then filling in the holes one at a time.

AB301460 AD

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9-11

CONTINUOUS WELDING There are several types of continuous welding: fillet (lap joint) welding, butt welding, T joint welding, gap welding, etc.; these are called short-circuit arc welding, and provide a stable arc at a relatively low current.

AB200041 .

Torch angle and welding technique

15 – 30˚

There are two welding techniques: forehand welding and backhand welding.

Forehand welding: Penetration is shallow and the bead is flat.

Backhand welding: Penetration is deep and the bead has a convex shape.

The angle of the torch should be 15 − 30 degree angle for either technique, and the tip should be maintained at a distance of 6 − 10 mm (0.24 − 0.39 inch) from the surface being welded.

15 – 30˚

Backhand technique

Forehand technique

AB301457AD .

Preventing warping Anti-Warp Welding Techniques 1.

5

4

3

2

1

Backhand technique 4

2

1

3

2.

Symmetrical technique 3.

1

4

2

5

3

"Stepping stone" technique AB200043AD

1. Backhand technique Because the direction for each weld pass and that for the fusion progression are opposite, the residual stress is evenly distributed.

2. Symmetrical technique Because the welds are made in symmetrical positions in relation to the center of the joint, the residual stress is also symmetrical.

3. "Stepping stone" technique Because the welds are made at random positions, the residual stress is the most evenly distributed; however, the possibility of flaws at the starting and stopping points is relatively high.

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BASE OF BODY REPAIR WELDING

NOTES REGARDING MIG WELDING Note the following notes regarding MIG welding.

1. The surface to be welded must be perfectly clean; be sure to remove any non-conductive paint.

2. If the end of the wire forms into a ball, it will adversely affect the formation of the arc; cut the end off with a pair of wire snips or a similar tool.

3. Select a welding current to match the thickness of the panels being welded.

4. For continuous welding, maintain a constant weld speed and keep both the height and the width of the bead constant.

In addition, the tack welding pitch and the welding bead should be shorter as the thickness of the panels being welded decreases.

OTHER TYPES OF WELDING

M4090004000046

BRAZING In brazing, a filler metal is melted into the joint of the panels to be welded at a comparatively low temperature to fuse them together without melting the panels themselves. In other words, through the aid of a flux and because of the capillarity phenomenon, the molten filler metal will flow into the joint between the two panels which are in contact with each other and spread along the metal surfaces. When this molten filler metal cools and solidifies, it will from a strong joint of the two panels. Note that, if two panels of different kinds of metal are brazed, the electrolysis generated between the two metals will cause moisture to from, which will result in corrosion.

Panels should not be connected together by brazing at any place except those places indicated. The following materials (filler metals) are usually used for brazing.

1. Brass filler metal (brass solder) Brass filler metal is an alloy consisting of 60% copper and 40% zinc with a melting temperature of approximately 850 − 1,050°C (1,562 − 1,922°F), and it is the most commonly used brazing filler metal used for body repair.

The filler metal itself is coated with flux to facilitate penetration between the panels to be joined.

2. Silver alloy filler metal (silver solder) Silver alloy filler metal consists of silver, copper, zinc or cadmium, nickel, and tin, or other metals.

This filler metal is most applicable for the brazing of steel and non-ferrous alloy other than aluminum, magnesium, and others with low melting points.

Notes with regard to brazing work

Examples of brazed joints AB200044 AF

• Use a wire brush, sandpaper, file etc., to remove any oxide film grease, dirt, etc., from the surfaces of the panels to be brazed.

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• When doing brass brazing, if the panels and the filler metal are heated excessively, a weak iron-copper alloy will form, which could crack easily. Be careful not to apply excessive heat.

• The joint of the panels must overlap as indicated in the illustration.

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GAS WELDING Oxy-acetylene flame

Welding rod

Deposite

Gas welding is a method in which a high temperature flame is used to melt both a welding rod and the base metal (panels) to make a fused joint. Oxy-acetylene is the most common type of gas welding. However, because of the extremely high temperature of the fused joint, the strength of the steel plate deteriorates, and there is a higher possibility of warping. This method, therefore, is not very suitable for body repair.

Base metal AB200049AD .

The flame in gas welding can be classified according to the ratio of acetylene and oxygen.

2. Standard flame

1. Carburizing flame Flame core

Acetylene cone

3. Peroxide flame

Flame core

Outer flame

Outer flame

Flame core

Outer flame

AB200050 AE

1. Carburizing flame (acetylene-rich flame) This flame has an excess of acetylene or a deficiency of oxygen. The incomplete combustion gives off a black smoke, and two flame cores can be seen inside the deformed yellow flame. The flame itself is large, but the temperature is relatively low, making this flame unsuitable for welding.

2. Standard flame (neutral-mixture flame) This flame has approximately equal amounts of acetylene and oxygen. The length is shorter than that of the carburizing flame; the flame core is rounded; and it is clear and bright.

The carbon in the acetylene is burned completely, resulting in the maximum obtainable temperature.

This is the flame most commonly used for welding.

3. Peroxide flame (oxygen-rich flame) This flame has an excess of oxygen or a deficiency of acetylene. The flame core is shorter and sharper, and the entire flame has a blackish-purplish color. The combustion is unstable, and the flame flickers continuously.

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.

Notes with regard to gas welding 1. Handle the oxygen and acetylene tanks carefully.

2. Adjust the flame in accordance with the type of metal being welded.

3. Select a nozzle to match the work to be done.

Avoid overheating and adhesion of foreign matter (dirt, etc.)

4. The following points are particularly important when welding mild steel plate.

• Melt a sufficient amount of welding rod, but be careful not to melt the base metal. Use the same amount of welding rod on both sides.

• Use the correct amount of welding rod in accordance with the melting point of the base metal.

• Avoid welding over places which have been welded before.

• In order to avoid warping, do only the amount of tack welding that is absolutely required.

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BODY REPAIR STANDARD BODY REPAIR PROCEDURES The following is an explanation of the standard repair procedures for the monocoque body and the frame-type body. Furthermore, please refer to the replacement of welded panels for the applicable model for information concerning the procedures for replacement of panels (as classified by position) for the various models.

NOTE: That reference should be made to page P.9-27 concerning repair procedures for the frame of frame-type vehicles.

M4090006000075

STANDARD PROCEDURES FOR REPLACEMENT OF WELDED PANELS

In order to maintain the proper levels of strength, rigidity, and precision when making welded panel replacements, it is essential to first gain a thorough understanding of the body structure, and then to perform all repair operations carefully and correctly. In addition, when performing the operations, be sure to use the proper protective equipment for each operation.

.

AB200051

CAUTION • Select an appropriate location for the cutting operation, and perform the work carefully, so as not to cut into the reinforcements located inside the pillars, panels which are not be replaced, or any other such parts.

• There are harnesses, hoses, and other such parts routed inside the front pillar, the rear pillar, the fender shield, the side sill, etc.; perform the repair work only after any such material has been removed.

• For overlap cutting, allow an overlap of approximately 30 − 50 mm (1.18 − 1.97 inches) when performing the cutting operation.

1. Rough cutting of panels First make a rough cutting of a portion of the panel to be replaced, and then remove that portion, thus making it easier to break the spot welds.

2. Removal of the paint coat from spot-welded points In order to clearly identify the spot-welded points, remove the paint coat from areas where it is difficult to determine the spot welds.

AB200052

AB200053

3. Cutting and separation of spot-welded points In order to perform cutting and separation of spot-welded points, use a spot weld cutter which is larger than the size of the nugget to make a hole only in the panels to be replaced.

When cutting and separating spot-welded points in places where the surrounding panel or other parts interfere with the spot weld cutter, or if the operation is hampered by a lack of space, bend back the flanges in order to make the work easier.

If a spot-weld cutter cannot be used at all, cut and separate the spot welds by using a chisel or similar tool.

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NOTE: If a replacement panel is to be mounted by doing plug welding from the side of the panel remaining on the body, either a hole can be made in the panel on the body, or a hole can be made right through both the panel which is to remain on the body and the panel to be replaced.

CAUTION When performing this operation, warping of the surrounding panels may occur if an excessive amount of heat is applied; therefore, be careful to avoid doing this.

4. Breaking of brazing and arc welds Heat only the brazed or arc welded portion (such as the upper portion of pillars, etc.), and then separate by using a screwdriver while melting occurs.

AB200054

5. Finishing work of spot welding Grind and smooth any weld traces which might be left on the body surface by using an air grinder or similar tool, being careful not to damage any of the panels which is not to be replaced. When performing this operation, be sure to wear safety goggles (dust proof glasses).

AB200055

6. Making of holes in new parts for MIG plug welding Make holes approximately 5 − 6 mm (0.2 − 0.24 inch) in diameter at points where plug welding is to be performed because spot welding is not possible.

AB200056

AB200057

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7. Flange correction for spot weld traces Correct any flanges that become bent or deformed when spot welds are broken or during other work.

AB200058

CAUTION Do not use a flame for paint coat removal because doing so might damage the paint coat of panels which are not to be replaced, thus causing corrosion.

8. Removal of the paint coat from new parts and from the vehicle body In order to provide for the proper flow of electric current during spot welding operations, remove the paint coat from both sides of the new part and the body by using a polisher wheel or similar tool.

AB200059

9. Rough cutting of new parts Cut off the unnecessary portions of new parts. Allow an overlap of approximately 30 − 50 mm (1.18 − 1.97 inches) when performing overlap cutting of the pillars, side sills, or other locations.

AB200060

Edge of the new part Edge of the panel on the body

AB200061AD

CAUTION Carefully select the location for cutting, taking care not to cut a reinforcement at the inner side of a pillar, etc. or a panel that is not to be replaced.

10.Overlap cutting of new parts For locations in which butt welding is to be done, first temporarily attach the new parts to the body, and then cut the two panels simultaneously.

NOTE: If a reinforcement or a panel which is not to be replaced is cut accidentally, first repair the mistake by welding before proceeding with the rest of the work.

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Twolayer construction

Outer panel Approx. 50 mm (1.97in)

Inner panel

9-17

CAUTION Perform the operations carefully so that the cut ends fit together properly.

11.Cutting of new parts by using a measurement marking If overlap cutting is not possible in a place where butt welding is to be done, make a measurement marking on the new part at the exact same measurement which was used for the cutting of the body panel, and then cut the new part by using this measurement marking.

• Two-layer construction When cutting a front pillar or center pillar which has a two-layer construction but no reinforcement, make the cutting of the inner panel and that of the outer panel approximately 50 mm (1.97 inches) apart in order to obtain maximum strength.

AB200062 AD

Three-layer construction

Inner panel

Inner panel cut line Outer panel and reinforcement cut line

Inner panel cut line

• Three-layer construction When cutting a front pillar or center pillar which has a three-layer (including a reinforcement) construction (double-box construction), cut the outer panel and the reinforcement at the same position, and don't forget to butt weld the reinforcement. If the inner panel is an assembly replacement part, cut it at two places in order to provide ample working space for the butt welding of the reinforcement.

AB200063AD

12.Application of spot sealer to spot-welded points Apply an electro-conductive spot sealer to the connecting surfaces of both the new parts and the vehicle body in order to provide corrosion protection.

AB200064

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AB200065

CAUTION During temporary mounting, it is extremely important to obtain accurate measurements for each component. The mounting positions for the front and rear suspensions are especially crucial with regard to safety; therefore, it is necessary that all work concerning these areas be done carefully and correctly.

13.Temporary mounting of new parts (1) In order to bring the new parts into the proper mounting position, measure each part carefully and make any corrections necessary in order to obtain agreement with the measurements.

(2) In addition, make temporary welds, and then check to confirm that the closing and fit of the doors, fenders, etc., are correct.

For parts which should be symmetrical to the body center, measure the distances from the body center point to both the left part and the right part, and confirm that the distances are the same.

AB200066

CAUTION Weld completely so that there are no pinholes.

14.Butt welding For burr welding, make a 10 − 15 mm (0.39 − 0.59 inch) MIG spot weld, and then, in order to prevent warping which might be caused by the welding heat, complete the welding by making welds of the specified width at alternate positions.

AB200067

AB200068

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AB200070

AB200070

9-19

15.Spot welding When doing spot welding, it is not only important to correctly position the electrode tips, but also to hold the two panels securely together with vise-grip pliers or some other type of clamps, being sure that they are in perfect contact with each other.

• Be sure that the force applied by the arm is sufficient.

• Use a test piece to check the secondary current and the current application time of the spot welder, and adjust the values as appropriate.

16.Plug welding If spot welds cannot be made, make holes for plug welding in the new parts, and then MIG weld. Because the quality of the fusion varies according to the size of the holes, they should be about 5 − 6 mm (0.2 − 0.24 inch) in diameter. In addition, be sure the two surfaces are in complete contact with each other by using vise-grip pliers to securely hold them.

NOTE: Depending on the working conditions, it might also be necessary to make holes in the panel remaining on the body 17.Hemming (Adhesion type) (1) Apply an adhesive to the area to be hemmed of the door outer panel.

Section A–A A AB401282

A AB500010 AD

(2) For the area to be hemmed of the door outer panel, apply an adhesive and smooth the panel with a hammer and a dolly. Then, hem the panel with a hemming tool.

Hemming tool AB200072AD

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18.Hemming (Welded type) (1) For the area to be hemmed of the door outer panel, etc., smooth the panel with a hammer and a dolly, and hem it with a hemming tool.

Hemming tool AB200072AD

(2) After completing the hemming work, make MIG spot welds at 50 − 60 mm (1.97 − 2.36 inches) intervals on the inside.

AB200073

CAUTION Be sure not to grind the panel down too much. Before welding the outer panel, be sure to apply an anticorrosion agent.

19.Finishing work for butt welding and plug welding Do the finishing work to smooth the protruding weld traces.

However, the butt joints of reinforcements and other internal parts will be stronger if the weld traces are not finished.

AB200074

20.Application of body sealant Apply a coating of sealant carefully, without breaks, as described in the section (of the manual corresponding to that model).

NOTE: After application has been made to any external surfaces, perform smooth-finishing work.

AB200076

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AB200077

9-21

CAUTION Wipe off any anticorrosion agent which oozes out onto surfaces to be painted later; the presence of such anticorrosion agent would prevent correct adhesion of the paint coat.

21.Application of an anticorrosion agent Apply an ample amount of anticorrosion agent to any welded areas and to all surfaces from which the paint coat was removed.

The paint coat of welded areas will have been damaged by the heat; be sure to apply an anticorrosion agent to surfaces to be repaired.

Use an aerosol-type anticorrosion agent for application to the side sills, the pillars, and other similar parts which have a hollow construction, by utilizing the trim mounting holes, etc.

AB200078

22.Application of undercoating If the underbody is repaired or replaced, carefully apply a coating of undercoating as described in the section (of the manual corresponding to that model).

AB200079

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CAUTIONS REGARDING BODY REPAIR Because each component part of a single-unit construction body makes some contribution, more or less, to the overall strength of that body, it is necessary to sufficiently understand the actual function of any part to be repaired before attempting any repair or welding procedure.

PREVENTION OF CORROSION AND OF WATER OR DUST ENTRY 1. After any work is completed, it is important to completely remove any welding residue, particles or residue from cutting, and any other dirt, etc.

2. Corrosion-prevention material must without fail be applied at the following places: • At any place where paint has flaked off or peeled away.

• At any surfaces that have been cut.

• At the outer and inner side of every welded place.

• Within any semi-enclosed structure or component (aerosol-type rust inhibitors are effective for difficult-to-reach places).

• At the outer and inner side of any place subjected to heat.

3. Apply a coating of undercoating if the underbody is repaired.

4. Use spot sealer if spot welds are made.

5. Repair any scratches to panels made by moldings, sashes, etc.

6. Carefully apply body sealant to panel connection joints and other fitting places.

7. Tape over any unused holes in the panel inner side by using sealing tape.

.

STRENGTH AND RIGIDITY 1. The suspension installation part plays an important role, determining the wheel alignment. Wheel misalignment is of course potentially very dangerous because it can lead to driving instability, one-sided braking, abnormal tire wear, abnormal vibration, etc.

At the time of repair, it is particularly necessary to take measurements at the components noted below, and to make all welds and installations with special care.

• Front sidemember • Rear floor sidemember • Front wheelhouse (inner) • Rear wheelhouse (inner) (Independent rear suspension type) 2. Because the places where the floor panel and sidemember parts are joined have an important effect upon the rigidity of the entire body, welds in these places must be done with particular care.

3. After repairs have been completed, the wheel alignment, wheel base, tread, etc., must be carefully checked to be sure that there is no deviation.

.

VIBRATION AND NOISE 1. Prevent any decrease of tensional rigidity caused by welding distortion.

2. Carefully apply body sealant to panel connection joints and other fitting places.

3. Tape over any unused holes in the panel inner side by using sealing tape.

.

SAFETY 1. Procedures related to the installation of any component related to safety must be done with particular care in order to assure full maintenance of safety.

• Suspension installation parts • Fuel pipe • Brakes • Fuel tank installation parts, etc.

2. Because seat belts are directly related to driver and passenger safety, any welds of seat belt anchor points or reinforcements must be done with particular care in order to maintain strength. .

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CONTACT AND ALIGNMENT 1. In order to maintain the precision of openings, make careful measurements as repairs are being made.

2. Make contact/alignment adjustments of door hinge, lid, and hood hinge installation parts.

BASE OF BODY REPAIR BODY REPAIR

THEFT PROTECTION

9-23 M4090007000067

In order to prevent theft, following Vehicle Identification Number (VIN) has been engraved and attached, in the form of a label to the engine, transaxle, and main of the outer body: Engine cylinder block, Transaxle housing, Fender, Doors, Quarter panel, Hood, Liftgate, Trunk lid, Bumpers Furthermore, supplementary parts for the main portions of the outer body have theft protection labels attached and the supplementary parts for the engine and the transaxle are engraved with the same details.

Theft protection label For original parts

For replacement parts

AC211646 AD

PANEL REPAIR CAUTION 1. Take care when respraying the original part to cover the theft protection label with masking tape prior to respraying. In addition, remember to peel off the masking tape after completion of the respray.

2. Because theft protection labels on the supplementary parts are covered with masking tape already, they can be resprayed just as they are.

3. Take care not to peel off the theft protection labels from either the original or the supplementary parts.

HOW TO PEEL OFF THE SURFACE MASKING FILM FROM THE THEFT-PROTECTION LABEL CAUTION Be careful not to damage the paint surface or the label itself.

1. Using a sharp knife at the corner of the label surface, lift up the masking film only.

2. Grasp the masking film and peel it all off.

NOTE: If the masking film tears, repeat from step 1. Use the knife, however, to lift the opposite corner of the label, rather than trying to continue peeling from the place where it tore.

Knife

Masking film

AB200080AD

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ATTACHMENT OF SILENCERS

M4090009000052

Dash panel interior side

: Thickness: 1.6 mm (0.063 in) : Thickness: 3.2 mm (0.126 in) (two 1.6 mm (0.063 in) silencers overlapped)

Silencers (petroleum-asphalt sheets) are attached to the upper surface of the floor and at the interior side of the dash panel in order to absorb vibrations and shut out exhaust gas heat. If these silencers are peeled off in the course of replacement or repair of a

AB200097AD

welded panel, cut and attach replacement material (in the shape shown in the figure). For detailed information concerning the locations where silencers are to be attached for individual models, refer to the manual for that model.

1. Heat the "silencer layer" (petroleum-asphalt sheet) with a blow drier to soften it.

AB200098

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9-25

2. Align the silencer layer in the position where it is to be installed, and then press it down with a roller or a block of wood so that it adheres well.

NOTE: An infrared light can also be used to heat both the silencer layer and the body panels (be sure to wear gloves).

AB200099

POSITIONING DIMENSIONS FOR OPENINGS

M4090010000045

Porta power

AB200100 AD

When replacing the panel of the opening of the front pillar, center pillar and other openings, make a point to securely bite the poltapower, etc. so the position of the opening is not off-center. Upon assembling, adjust the opening dimensions to the standard specifications and then weld.

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STANDARD PROCEDURES FOR SHEET METAL WORK

M4090012000030

REPAIRS USING A HAMMER AND DOLLY It a damaged external panel, etc., can be reused, the usual way to repair it is by using a hammer and dolly to hammer out the damaged area. The following describes these repair procedures. .

1. Check whether or not there is foreign material (mud, etc.) on the panel surface. If so, clean it away.

CAUTION The surface of the hammer and dolly must be free of scars, etc.

2. Select the appropriate hammer and dolly to be used according to the panel shape.

CAUTION Care should be taken, as far as possible, not to permit the panel plates to become elongated.

3. Use the hammer and dolly to repair the dents and other uneven surfaces of the panel.

(1) First repair the larger areas of damage so that they are as close as possible to the original condition before the damage occurred.

(2) Next repair the areas of moderate damage.

(3) Finally, smooth the surface out.

(1)

(2)

(3)

AB200101

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AB200102

9-27

CAUTION • Be careful not to file too much; this will reduce the strength and rigidity of the panel.

• Do not use the file in one direction only; alternate use in two directions diagonally opposite each other.

4. Next, file the area so that convex and concave parts are no longer clearly visible, and at the same time remove small projections.

5. After once again smoothing the clearly visible dents and projections by using the hammer and dolly, follow step 4 above.

Alternately repeat hammering and filing until there are file traces over the entire repair area.

6. Make a solder build-up at the repair.

7. Finally, finish up the solder build-up using a body file.

USING A FRAME STRAIGHTENER For serious and extensive damage, when for example the damage extends to the frame of members, it is necessary to first use a frame straightener to make a rough, overall repair of the body, and then to proceed to careful repairs of each individual area of damage. When a frame straightener is used for body repairs, it is a fundamental principle that the pulling should be in the direction from which the impact was sustained, and from the opposite direction. If this is, in error, not done, previously undamaged components will be deformed, and repair may become impossible.

It is for that reason that it is important to decide upon the method of repair, especially regarding the initial overall repair, by following the steps below.

OVERALL ROUGH REPAIRS 1. First, analyze the impact. This means analysis and consideration of the point of collision, the speed at the time of collision, and the strength, weight and shape of the object hit.

2. Then get a complete understanding of the condition of the existing damage. In particular, if the damage extends to the suspension installation components, an inspection must be made to determine whether or not there is any deviation of the frame or body alignment.

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M4090013000044

3. Finally, determine what repair methods should be used.

• To what extent will frame straightening and other overall repairs be necessary in order to restore the damaged areas to the way they were?

• At what stage of the repairs should panels adjoining the components to be frame straightened, etc., be removed?

• Decide upon the work steps and restoration methods to be followed after the rough, overall repairs are completed.

Select the frame straightener based upon the results of above, and use it to pull in the appropriate direction. More than one direction may be appropriate, depending upon the damage.

If the damage is of a moderate degree or less, it may be possible to do all that is necessary in one pull.

If, however, the damage is major, that is to say if repairs must be made to components of the passenger compartment such as the dash panel, etc., it may be necessary, after completing the first pull, to set up the frame straightener at a different position and use it again at that position.

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FRAME STRAIGHTENING NOTES Wires for protection

AB200103AD

• For safety, no one must be standing in the direction of the pull.

• Wires or chains should be used for protection in the event of an accident.

• For frame straightening of body with frame, care should be taken regarding the position (body mount) of installation to the frame. The reason for this is that usually mounting rubber pieces are used at the installation part in order to improve vibration prevention, and these mounting rubber pieces might be deformed if there is a deviation of the installation position.

• If the part to be pulled is made of high-tensile steel (which has a higher tensional strength and yield point than ordinary steel), the pulling must be done with care in order to avoid "over pull" and "spring back". It is particularly important for the pulling of sidemembers and other reinforcement components made of high-tensile steel that the pulling not be all done at one time; pull gradually while using a hammer to repair distorted areas as the pulling is done.

FRAME REPAIR PROCEDURES The frame is subjected to the following types of loads.

• Vertical loads: Vertical loads may occur either while stopped or during travel.

• Lateral (horizontal) loads: This type of loads occurs during turning, start-off and braking.

• Torsional loads: Torsional loads occur while traveling on roads with poor surface conditions.

M4090014000047

These various types of loads are compounded under various conditions, and are applied to the frame.

As a result, it is important, before attempting to repair the frame, to carefully observe the shape of the damaged part and to in that way fully understand the cause of the damage.

CHECKING FOR FRAME CRACKING OR FLAKING Test hammer

Check, by using a test hammer, for flaking or cracking of the welded surface of the sidemembers, crossmembers and brackets.

Sidemember

AB200127 AD

REPAIRING CRACKS If the check reveals a crack(s) in the frame, repair as described bellow.

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1. Remove the components near the crack.

2. Make φ 6 − 8 mm (0.24 − 0.31 inch) holes (to prevent further cracking), by using a drill, at points 7 − 8 mm (0.28 − 0.31 inch) from the crack ends.

Crack-stop hole A A Crack Ø6 – 8 mm (0.24 – 0.31 in) A : 7 – 8 mm (0.28 – 0.31 in)

AB301469 AD Ø10 – 12 mm (0.39 – 0.47 in)

3. Use a φ 10 − 12 mm (0.39 − 0.47 inch) drill to bevel the hole openings.

Ø6 – 8 mm (0.24 – 0.31 in)

Ø10 – 12 mm (0.39 – 0.47 in)

AC AB301470 AB

Crack-stop hole

Crack

Approx.

1 mm (0.04 in)

Approx.

90˚

A

Approx.

8 mm (0.31 in)

Approx.

1 mm (0.04 in)

If a chisel is used

If a gouge is used

A

A

AB301471AD

CAUTION • Gas welding should be avoided because it causes thermal distortion of the frame.

• When using a grinder for finishing, be careful not to grind the frame excessively.

5. Using a grinder for finishing after welding.

AB200131AB

CAUTION • The reinforcement plate should completely cover the cracked part.

• The reinforcement plate should be the same thickness and material as the frame.

6. To avoid a concentration of stress, prepare a reinforcement plate that has been cut to 30 − 45 degree angle at both ends.

A

A

A : 30 – 45˚

4. Use a chisel or gouging tool to open up the crack and holes, and then fill the crack and holes by MIG welding.

AB301461AB

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CAUTION Be sure that the edges of the reinforcement plate are not near any place where a concentration of stress of the crossmember or spring hanger installation part, etc. could easily occur.

7. Attach the reinforcement plate to the repaired crack area by MIG welding. In order to avoid a concentration of stress at the time, weld the reinforcement plate at points about 10 mm (0.39 inch) from its edges.

10 mm (0.39 in)

Welded point AB200133 AD

(1)

(2)

AB200134 AB

NOTE: If the crack is at the upper side of the frame, attach the reinforcement plate facing downward, as shown in (1).

If the crack is at the lower side, attach the reinforcement plate to face upward, as shown in (2).

8. Finally, apply a coating of chassis black to the repaired area and to any places where the coating has flaked off.

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NOTES REGARDING REPAIR WORK

9-31 M4090015000039

SAFETY MEASURES .

PROTECTIVE GEAR

1

2

3

4 5

6

8

7

9

10

11

During body repair work, a work suit, a work cap, and safety shoes should be worn at all times. Depending on the work being done, safety glasses, gloves, ear protectors, a dustproof mask, etc., should also be worn as needed.

1. Safety glasses 2. Work cap 3. Ear protectors 4. Head protector 5. Work suit 6. Dustproof mask 7. Work apron 8. Welding gloves 9. Foot and ankle protectors 10. Safety shoes 11. Work gloves

AB200104

.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 1. Items to review when servicing SRS (1) Be sure to read Service Manual GROUP 52B, Supplemental Restraint System (SRS). For safe operation, please follow the directions and heed all warnings.

(2) Wait at least 60 seconds after disconnecting the battery cable before doing any further work. The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected.

Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected.

(3) Warning labels must be heeded when servicing or handling SRS components.

(4) Always use the designated special tools and test equipment.

(5) Store components removed from the SRS in a clean and dry place. The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward. .

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(6) Never attempt to disassemble or repair the SRS components (SRS-ECU, air bag module and clock spring). If there is a defect, replace the defective part.

(7) Whenever you finish servicing the SRS, check the SRS warning light operation to make sure that the system functions properly.

(8) Be sure to deploy the air bag before disposing of the air bag module or disposing of a vehicle equipped with an air bag.

2. Observe the following when carrying out operations on places where SRS components are installed, including operations not directly related to the SRS air bag.

(1) When removing or installing parts, do not allow any impact or shock to occur to the SRS components.

(2) If heat damage may occur during paint work, remove the SRS-ECU, the air bag module, clock spring, the front impact sensor, the side impact sensor, and the seat belt pre-tensioner.

• SRS-ECU, air bag module, clock spring, front impact sensor, the side impact sensor: 93 °C (200 °F) or more • Seat belt pre-tensioner: 90 °C (194 °F) or more

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SECURING THE VEHICLE If the vehicle is raised on a jack, be sure to always support it with jack stands positioned at the specified points. .

CLEARING THE AREA OF FLAMMABLE MATERIALS

Because of the presence of many various kinds of flammable materials, organic solvents, etc., in the work area, there is always the possibility of a fire or explosion. It is, therefore, important to keep the work area as clear as possible of such dangerous materials. .

HANDLING ELECTRONIC PARTS AND SEMICONDUCTORS WARNING

Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING. When the body is used as the ground during welding for body repairs, be absolutely sure to first disconnect the battery's positive (+) cable.

AB200105

CAUTION • Be sure that both the ignition and lighting switches are "LOCK" (OFF) position before either disconnecting or reconnecting a battery cable. (If this is not done, equipment containing semiconductors could be damaged).

• Note that the memory of electronic equipment having a memory function will be cleared when the battery cable is disconnected.

NOTE: Vehicles today include a great many electronic parts and components, and these are in general very susceptible to adverse effects caused by overcurrent, reverse current, electromagnetic waves, high temperature, high humidity, impacts, etc. In particular, such electronic components can be damaged if there is a large current flow during welding from the body side, etc.

This is because, for electronic components that incorporate a back-up circuit (for memory retention) that functions (by a trickle current) even when the ignition switch is at OFF, an electronic circuit is formed even when the switch is at OFF. .

HANDLING COMBUSTIBLE MATERIALS If welding work is to be done in the area of the fuel tank, the fuel tank must be removed to prevent the generation of flammable gases. Also be sure to cap the inlet port and the pipes of the fuel tank after removal to prevent the escape of any fuel or flammable gases.

Wipe up any fuel, oil, etc., spilled in the work area as soon as possible.

Only the amounts of paint to be used for the day's work should be in the work area; do not keep excessive amounts of paint, or paint which is not going to be used, in the work area.

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HEALTH AND SANITATION PROCEDURES The following points should be noted for employee health and sanitation.

• The work area should be well ventilated in order to prevent the inhalation of dust, organic solvent vapors, etc.

• All unused paint cans must be securely covered.

• Care should be taken to avoid exposure to the skin of adhesives, organic solvents, etc.

If an unavoidable exposure occurs, the exposed area should be immediately washed with clean water.

VEHICLE PROTECTION • Vehicle covers (fender covers, seat covers, etc.) and tape (if there is the possibility of damage by tools, equipment, etc.) should be used to protect painted surfaces, interior/exterior parts and components, etc., from staining and damage.

AB200106

• For welding operations, a heat-resistant protective cover should be used to protect glass, seats, instrument panel, carpeting, etc.

AB200107

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HEAT-WITHSTAND TEMPERATURES OF RESIN-PLASTIC PARTS Because resin-plastic parts are deformed by heat, they should be removed if the heat to be applied is high enough to cause deformation, as shown by the table below.

M4090016000054

Material name

Abbreviation

Heat-deformation temperature °C (°F)

Where mainly used

Acrylonitrile styrene acrylate

ASA

80 (176)

Door mirror, Pillar garnish, License garnish, Radiator grille

Acrylonitrile butadiene styrene

ABS

80 (176)

Air spoiler, Console box, Radiator grille, Rear garnish, Headlight bezel

Cellulose acetate

CA

50 − 90 (122 − 194)

-

Cellulose acetate butylate

CAB

60 − 100 (140 − 212)

Door trim molding

Polyamide

PA

140 − 160 (284 − 320)

Harness connector, Wheel cover, Cooling fan, Fuel strainer

Talc filled polyamide

PA-TD

190 − 200 (374 − 392)

Hood garnish, Door outside handle

Polybutylene terephthalate

PBT

120 (248)

Dome light lens, Headlight lens

Polyethylene

PE

100 (212)

Heater duct, Fender liner, Washer tank

High density polyethylene

PE-HD (HDPE)

70 − 90 (158 − 194)

Fuel tank, Splash shield

Phenole formaldehyde

PF

170 − 190 (338 − 374)

Ashtray

Polymethyl methacrylate

PMMA

80 − 100 (176 − 212)

Light lens

Polyacetal

POM

120 (248)

Door regulator handle, Ball joint seat

Polypropylene

PP

80 (176)

Glove compartment, Bumper face, Pillar trim, Steering wheel, Heater unit, Cooling fan

Polyphenylene ether

PPE (PPO)

130 − 140 (266 − 284)

Accelerator pedal pad, Wheel cover, Speaker garnish

Talc filled polypropylene

PP-TD (PPF)

100 (212)

Front deck garnish, Stone guard, Floor console, Instrument panel

Talc filled polypropylene (10%)

PP-TD10 (PPF)

110 − 120 (230 − 248)

Center pillar trim

Talc filled polypropylene (15%)

PP-TD15 (PPF)

110 − 120 (230 − 248)

Front pillar trim, Center pillar trim, Rear pillar trim

Talc filled polypropylene (20%)

PP-TD20 (PPF)

120 − 130 (248 − 266)

Beltline trim, Front deck garnish, Front pillar trim

Talc filled polypropylene (30%)

PP-TD30 (PPF)

130 − 140 (266 − 284)

Quarter trim, Rear side trim

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Material name

Abbreviation

Heat-deformation temperature °C (°F)

Where mainly used

Polyurethane

PUR

80 − 100 (176 − 212)

Bumper, Steering wheel

Polyurethane (formed)

PUR-E

80 − 100 (176 − 212)

Seat cushion, Arm rest, Door trim, Instrument panel

Glass fiber reinforced RIM urethane

PUR-GF [RIM]

100 − 120 (212 − 248)

Air dam panel

Polyvinyl alcohol

PVAL

*1

-

Polyvinyl butyral

PVB

Polyvinyl chloride

PVC

80 (176)

Steering wheel, Side protector molding, Shift lever cover, Window molding

Thermoplastic TPO (TEO) elastomer (olefine)

80 (176)

Mud guard, Side air dam

Urea formaldehyde UF

120 − 145 (248 − 293)

-

Glass fiber reinforced unsaturated polyester

UP-(GT + TD) [SMC], [BMC]

200 (392)

Rear air spoiler

Ethylene vinyl acetate

E/VAC (EVA)

60 (140)

Mud guard

Talc filled polypropylene

PP + E/P-TD [HMPP]

80 − 100 (176 − 212)

Bumper face, Side air dam, Side protector molding

Polyvinyl chloride, Polyurethane

PVC, PUR-E

*2

Instrument panel pad

Thermoplastic TES, PP-TD elastomer (styrene), Talc filled polypropylene

100 − 120 (212 − 248)

Side splash

Polycarbonate + Acrylonitrile butadiene

PC + ABS

120 − 125 (248 − 257)

Door outside handle

Polycarbonate + Polyethylene terephthalate

PC + PET

120 (248)

Door outside handle

Polycarbonate + Polybutylene terephthalate

PC + PBT

130 − 140 (266 − 284)

Door outside handle

Polyphenylene ether + Polyamide 6

PPE (PPO) + PA6 150 − 160 (302 − 320)

Wheel cover

Polyphenylene ether + Polyamide 66

PPE (PPO) + PA66

160 − 170 (320 − 338)

Wheel cover

120 − 130 (248 − 266)

Wheel cover

Polyphenylene PPE (PPO) + PS ether + Polystyrene

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NOTE: .

• A slash (/) in the abbreviation indicates that two different materials make two-layer construction.

A plus sign (+) indicates that the two different materials mix each other.

• If the new material symbols designated by the ISO differ form the old symbols, both are given, with the old symbol being enclosed in brackets. ISO: International Organization for Standardization • *1: Temperature differs depending on the ratio of the materials included.

• *2: Impossible to fix the temperature due to the multi-layer and foam material structure.

• If an infra-red lamp is used for drying, use a heat-resistant cover, etc., to protect parts.

HOW TO DISTINGUISH TYPES OF PLASTICS

M4090017000035

There are various methods that can be employed to determine types of plastics, among them (1) using a chemical solvent, etc., to check it chemically, (2) scratching the material to determine its make-up, (3) cutting of a small piece (where the scar can't be seen) and burning it to judge by the way it burns, etc.

The following is an outline of the burning method, which is a relatively simple method.

Plastic name

Abbreviation Flame color

Combustion Conditions

SelfOdor extinguishing

Polyvinyl chloride PVC

Yellow flame top Blue flame bottom

Burns to black residue Yes

Irritating acid odor

Polyethylene

PE

Yellow flame top Blue flame bottom

Burns cleanly while melting

No

Candle-like odor

Polypropylene

PP

Yellow flame top Blue flame bottom

• Burns briskly and drips • Slight white smoke

No

Petroleum-like odor

Polyurethane

PUR

Orange

No

Rubber odor

TRUR

Orange

Crackles as burns; drips

Polycarbonate

PC

Yellow

Cinders remain

To some extent

Sweet odor

Polyamide (nylon)

PA

Yellow flame top Blue flame bottom

Melts and drips

Yes

Strong formic acid odor

Polyester resin

UP

Yellow

Ashes remain

No

Styrene odor

Glass-fiber-reinfo FRP rced plastic

Yellow

Ashes with glass-fiber No remnants remain

Differs according to plastic type

Phenol resin

PF

Yellow

Ashes remain

Yes

Formalin odor

ABS resin

ABS

Orange

Burns accompanied by No foaming and black smoke

Rubber odor

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CORROSION PROTECTION ANTICORROSION TREATMENT AT THE FACTORY Anticorrosion treatment at the time of production includes the following measures.

M4090019000064

THE USE OF GALVANIZED STEEL PLATE

: locations where galvanized steel plate is used.

AB200136 AB

Because galvanized steel plate has excellent corrosion resistance, it is used in areas which have a high possibility of painting deficiency.

ZINC PHOSPHATE COATING 1 2 3 4 5 6

AB200109

In order to improve the adhesive properties of the paint coat on the steel plate, and also to improve the finish of the paint coat, the entire body is coated with a film of zinc phosphate prior to undergoing the electrodeposition undercoating process.

1. Final coat 2. Intermediate coat 3. Anticorrosion primer 4. Undercoat 5. Zinc phosphate film 6. Steel plate

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CATIONIC ELECTRODEPOSITION UNDERCOATING

Cationic coating

Anionic coating

Counteragent

Counteragent

Anionic electrodeposition

Alkali solution

Cationic electrodeposition

AB200110AD AB200110

In the cationic electrodeposition method, the car body is the negative pole, thus preventing damage to the zinc plating of the galvanized body panels or to the chemically formed phosphate crystals. This method, therefore, maximizes the corrosion resistance and the results obtained are much better than those from conventional anionic electrodeposition.

BODY SEALING Sealant has been applied to all body panel joints and seams in order to provide resistance to water, dust, and corrosion.

A

A

SECTION A – A

AB301462 AB

UNDERBODY COATING An underbody coating has been applied to the underside of the floor pans, the inside of the doors, etc., in order to provide resistance to vibration, corrosion, and wear.

AB200112

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BASE OF BODY REPAIR CORROSION PROTECTION

WAX INJECTION Wax injection is used at the lower part of the frame, side sill and hollow panels, etc., in order to obtain a better anticorrosion effect.

AB200113

ANTICORROSION PRIMER

1

A

1

A AB701034AB

1. Rocker panel primer application

Anticorrosion primer is used at the side sill outer panels in order to prevent corrosion and to suppress vibration.

SEALING TAPE Sealing tape is attached at unused holes, at the inner side of the panel, for waterproofing and anticorrosion protection.

: Locations for attachment of sealing tape

AB301463 AB301463AF

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ANTICORROSION TREATMENT AT THE TIME OF BODY REPAIR WORK

M4090020000046

The following procedures should be followed for anticorrosion protection when making repairs.

AB200116

CORROSION PROTECTION FOR HOLLOW PARTS

AB200117

CAUTION • Wipe away any excess anticorrosion agent on the coated surface, because it can adversely affect the coating.

• When spraying the anticorrosion agent, use holes in different areas to ensure that all weld surfaces of the hollow structure are well coated.

The insides of hollow parts (such as the side sill, pillars, etc.) which have been welded are more susceptible to corrosion.

Spray an aerosol-type anticorrosion agent into these parts by using the trim mounting holes and other openings.

ANTICORROSION TREATMENT OF ROUGH CUTS An anticorrosion agent should be applied to rough cuts made in the course of welding, because the surface film has been damaged by the heat of welding.

SPOT SEALER In order to prevent corrosion from occurring at the contact surfaces of panels which are spot welded, apply an electroconductive spot sealer. .

SPOT SEALER APPLICATION STEPS 1. Remove all paint, etc., from the areas to be spot welded by using sandpaper or a pneumatic belt sander.

AB200118

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2. Use a brush to apply spot sealer to the contact surfaces of the panels (both the new panel and the panel remaining on the body) to be spot welded.

AB200119

3. Do not spot welding.

NOTE: The spot welding can be done as the spot sealer is dry to the touch.

Dry to the touch: 30 minutes or less at 20°C (68°F)

AB200120

BODY SEALING Even if a car body is restored to the exact specified dimensions, the body repair work cannot be considered to be complete if an ample amount of sealant is not applied to each of the panel joints and seams. Insufficient sealant will result in water leakage, corrosion, etc.

NOTE: Use a piece of clean cloth dampened in lead-free gasoline or a similar material to clean parts and areas where sealant is applied.

• When applying sealant to areas at which the external appearance is important (areas which can be seen or where the condition of the paint coat is important), be sure to apply the sealant so that it is perfectly level with the surrounding panels.

Clean away any excess

AB301490AD AB301490

• Apply the sealant at the fuel port so that it is perfectly level with the surrounding panel so that drops of fuel will not collect.

AB200122

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• After applying sealant to the door-stop, etc., clean away any excess so as to be sure that there is no interference with installed parts, etc.

AB200123

UNDERCOATING

: Undercoating application locations

• Be sure to mask any parts installation holes, and the area around the place where undercoating is to be applied, before applying it.

• Be sure not to apply the undercoating to tires or to the drive shaft and other drive components.

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AB301464 AD

If the undercoating application inside the wheel housing, on the under body, etc., is insufficient, it can result in corrosion. Be sure, therefore, to apply a good coating of undercoating to such parts after repairs are completed.

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REPAIR OF SYNTHETIC-RESIN PARTS SYNTHETIC-RESIN PARTS REPAIR PROCEDURES

M4090000300090

Bumper is taken as a repair work example for explanation.

FLOWCHART

Hole (diameter 50 mm (1.97 in) or smaller)

Crack, tear (length 200 mm (7.8 in) or smaller)

Scratch (length 200 mm x width 120 mm (7.8 x 4.7 in) or smaller)

1. Cleaning

2. Reshaping of damaged area

3. Fixing of glass cloth (backing)

4. Adhesive application

5. Base surface preparation (surface grinding)

6. Rough grinding

7. Filling (putty application)

8. Surface grinding

9. Surface preparation for primer-surfacer

10. Cleaning and degreasing

11. Masking

12. Primer-surfacer coating

13. Primer-surfacer grinding

14. Coating

AB401319 AB

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BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS

REPAIR JUDGMENT .

REPAIRABLE AREA • In case of a hole, the damaged area is reshaped to be a circle or ellipse for easier filling of the repair agent. The diameter or major diameter should be 50 mm (1.97 inches) or smaller.

• In case of a crack or tear, if the both ends of the crack or tear are not separated from the body, the length of the area should be 200 mm (7.8 inches) or smaller. If one of the ends reaches the bumper edge, the length of the damaged area should be 200 mm (7.8 inches) or smaller, and also the width should be a half or less of the bumper width.

• In case of a scratch, the area should be 200 x 120 mm (7.8 x 4.7 inches) or smaller. .

UNREPAIRABLE COMPONENTS Black-base area is raw urethane base and repairable, however, its color does not match in color of the repair agent (ash gray).

In this case, the replacement of the bumper is preferable. .

BUMPER REMOVAL AND CLEANING • The damage of holes, cracks, and tears requires a repair work from the rear surface. Remove the bumper to clean the whole surface, degrease the front and rear surfaces of the repair area using SU Silicone Off, and then repair, holding the bumper to avoid twisting.

• In case of a scratch, a softener is applied to the bumper as repair paint. The repair area cannot be polished after painting, and surface/gloss matching is difficult. Therefore, do not apply gradated topcoat painting, and paint the whole surface as a rule.

REPAIR PROCEDURE .

1. CLEANING Using SU Silicone Off, degrease the repair area, and then remove the wax and oil completely. .

AB401311AB

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2. RESHAPING OF DAMAGED AREA CAUTION The grind surface area should be larger than the resin putty application area.

Remove burrs on the rear surface reinforcement point, and grind with a sandpaper #60 to #80, as a surface preparation for painting. When using a sander #80, grind at a low speed 6000 r/min. For PP, apply PP primer after grinding.

PRIMER : PP PRIMER BRAND : 3M™ Automix Polyolefin Adhesion Promoter 5907 or equivalent AB401317AB

.

3. FIXING OF GLASS CLOTH (BACKING) CAUTION • After applying the instant adhesive, fix the repair area.

• For PP, apply PP primer.

Apply the adhesive to the glass cloth fixing area of the repair part in order to adhere the glass cloth.

• TAPE: Glass cloth tape BRAND: 3M™ Glass Cloth Tape 6400 or equivalent • ADHESIVE: Urethane adhesive BRAND: 3M™ Duramix Plastic Repair Semi-rigid 4040 or equivalent AB401293AB AB .

4. ADHESIVE APPLICATION Apply a resin adhesive to cover the fixing glass cloth and its surrounding area. Then smooth it, using a spatula, and dry.

AB401312AB .

5. BASE SURFACE PREPARATION (SURFACE GRINDING) Remove burrs on the surface, and grind with a sandpaper #120 to make the repair area surface lower than the surrounding area. When using a sander #120, grind at a low speed 6000 r/min.

Background

.

Old paint layer AB401316AE AB401316

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6. ROUGH GRINDING Grind the base surface area with a sandpaper #80 as a surface preparation for painting.

AB401315AB .

7. FILLING (PUTTY APPLICATION)

AB401291AB

CAUTION When mixing the two kinds of liquid, be sure that the air is not mixed in.

1. Using SU Silicone Off, degrease the repair area, and then remove the wax and oil completely.

2. For scrape, apply putty to the repair area.

• PUTTY: Epoxy resin putty BRAND: 3M™ Automix EZ Sond Flexble Parts 5887 or equivalent • PUTTY: Epoxy resin putty BRAND: 3M™ Resin Putty No.1, 8120 or equivalent NOTE: .

• The amount to be applied at a time is approximately 1.5 mm (0.059 inches). Therefore, recoat it as needed.

• For tear and scratch, apply putty after sanding the surface.

AB401296AB

.

8. SURFACE GRINDING After drying, grind with a sandpaper #120. .

AB401297AB

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9. SURFACE PREPARATION FOR PRIMER-SURFACER Grind with a sandpaper #180 to #240. Grind the primer-surfacer application area as a surface preparation for painting. In addition, remove the grind mark.

AB401297AB .

10. CLEANING AND DEGREASING Using SU Silicone Off, degrease and wipe off completely. .

11. MASKING To avoid splashing of primer-surfacer during the coating, apply masking.

MASKING: Masking paper tape BRAND: 3M™ Scotch Block Masking Paper or equivalent AB401318AB

.

12. PRIMER-SURFACER COATING CAUTION • If an excessive amount is applied at a time, or force-dried in a short time, the coating film may crack.

• For color separation, use masking tape.

While taking flash off time, apply 1 to 3 times of double coating, using a spray gun.

AB401298AB .

13. PRIMER-SURFACER GRINDING 1. Grind the base surface with a sandpaper #240 to #320.

AB401299AB

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2. Apply the putty to cover pinholes, grind marks, and slight distortion. Do not apply an excessive amount at a time.

Repeat application of small amount, taking a drying time.

AB401300AB

3. Grind with a sandpaper #240 to #320. If the PP base surface is exposed, apply PP primer.

PRIMER : PP PRIMER BRAND : 3M™ Automix Polyolefin Adhesion Promoter 5907 or equivalent

AB401299AB

CAUTION If an excessive amount is applied at a time, or force-dried in a short time, the coating film may crack.

4. While taking flash off time, apply 1 to 3 times of double coating, using a spray gun.

AB401302AB

5. Dry sand with a sandpaper #240 to #300 or finer. Then, as a surface preparation for painting, grind lightly so as not to expose the base surface. Finally, use a sandpaper #600 (#800 for dark color coating) or finer to remove grind marks.

AB401303AB

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3-1

GROUP 3

WELDED PANEL REPLACEMENT CONTENTS ULTRA HIGH STRENGTH STEEL PLATE . . . . . . . . . . . . . . . . . . . . . . . .

3-2

FRONT END CROSSMEMBER . . . . .

3-3

REAR FLOOR. . . . . . . . . . . . . . . . . . .

3-37

QUARTER INNER. . . . . . . . . . . . . . . .

3-39 3-44

FENDER SHIELD. . . . . . . . . . . . . . . .

3-4

QUARTER INNER (PARTIAL REPLACEMENT) . . . . . . .

FRONT SIDEMEMBER (PARTIAL REPLACEMENT) . . . . . . .

3-8

FRONT DOOR OUTER PANEL (WELDED TYPE) . . . . . . . . . . . . . . . .

3-46

FRONT PILLAR . . . . . . . . . . . . . . . . .

3-9

FRONT DOOR OUTER PANEL (ADHESION TYPE). . . . . . . . . . . . . . .

3-47

REAR DOOR OUTER PANEL (WELDED TYPE) . . . . . . . . . . . . . . . .

3-48 3-49

FRONT PILLAR (PARTIAL REPLACEMENT) . . . . . . .

CENTER PILLAR . . . . . . . . . . . . . . . .

3-15 3-19

SIDE SILL. . . . . . . . . . . . . . . . . . . . . .

3-23

REAR DOOR OUTER PANEL (ADHESION TYPE). . . . . . . . . . . . . . .

QUARTER OUTER . . . . . . . . . . . . . .

3-29

ALUMINUM PANEL . . . . . . . . . . . . . .

3-50

ALUMINUM PANEL CHARACTERISTICS .

3-50

REAR END PANEL . . . . . . . . . . . . . .

3-33

ALUMINUM PANEL LOCATIONS . . . . . . . .

3-50

ALUMINUM PANEL REPAIR . . . . . . . . . . .

3-51

ALUMINUM PANEL PAINT . . . . . . . . . . . . .

3-57

ROOF . . . . . . . . . . . . . . . . . . . . . . . . .

3-34

3-2

WELDED PANEL REPLACEMENT ULTRA HIGH STRENGTH STEEL PLATE

ULTRA HIGH STRENGTH STEEL PLATE ADVANTAGES OF ULTRA HIGH STRENGTH STEEL PLATE The ultra high strength steel plate has the following advantages as compared with conventional high strength steel plate.

• It has tensile strength approximately 1.7 times higher than the conventional high strength steel sheet.

• It has a higher yielding point and yielding ratio (yielding point/tensile strength).

These advantages allow thinner and lighter plates and better fuel efficiency than the high strength steel plate.

PRECAUTION UPON MAINTENANCE OF ULTRA HIGH STRENGTH STEEL PLATE • Use a spot cutter for ultra high strength steel plate to ensure that the spot-welded area is cut off.

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M4030002800073

• For the part in which the ultra high strength steel plate is used, do not repair it by cutting and bonding to avoid the reduction in strength by heat.

Instead, replace the whole assembly including the part.

• Be careful with rough extending work, because the ultra high strength steel plate has higher tensile strength and a higher yielding point than high strength steel plate and general steel plate. Careless work will cause symptom such as over-pulling and springback. Do not extend it completely at a time. Do it gradually while removing the distortion by sheet metal processing with a hammer.

• Plug welding of φ 8 mm (0.31 inch) diameter plug for repair ensures the strength equivalent to spot welding for 2 steel sheets. For 3 sheets, weld 2 sheets each time instead of welding from one side to give sufficient welding strength.

3-3

WELDED PANEL REPLACEMENT FRONT END CROSSMEMBER

FRONT END CROSSMEMBER Symbol

M4030003100237

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates indicates three panels to be welded )

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

AB700420AB

REPAIR WELDS

A

B

A

B AB601317AB

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3-4

WELDED PANEL REPLACEMENT FENDER SHIELD

FENDER SHIELD Symbol

M4030004001203

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates indicates three panels to be welded )

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

AB700421AB

REPAIR WELDS

I A

A

AB700993 AB

NOTE: Refer to the Front End Crossmember section on P.3-3 for the welding point with front end crossmember.

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3-5

WELDED PANEL REPLACEMENT FENDER SHIELD

E

B

B D F

G J

C

C

H AB700994 AB

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3-6

WELDED PANEL REPLACEMENT FENDER SHIELD

E

D

(With the upper frame to front pillar brace, Fender shield frame upper outer and front deck frame upper outer removed)

G

Right side only

Right side

F

H

I

J

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AB700933 AB

WELDED PANEL REPLACEMENT FENDER SHIELD

3-7

NOTE: Partial replacement of the front upper frame is possible depending on the range of damage. When performing partial replacement, cut the fender shield frame upper outer 152 mm (6.0 inches) forward of the positioning hole center, and cut the front upper frame inner 25 mm (0.98 inches) forward of the positioning hole center.

Front upper frame inner 25 mm (0.98 in)

152 mm (6.0 in) Fender shield frame upper outer

AB700935 AB

NOTE ON REPAIR WORK .

REMOVAL Front sidemember inner

Turn up the front sidemember outer as shown to cut off the welded point between the front sidemember inner and the front body frame to side sill brace. .

INSTALLATION Front sidemember outer Front body frame to side sill brace AB700299AB

When installing the new front sidemember, align the hole of the front sidemember brace lower with the front sidemember outer to make a hole because the front sidemember outer prevents the front sidemember inner and front sidemember brace lower from being welded. Then, weld the front sidemember outer, front sidemember inner, and front sidemember brace lower.

Front sidemember outer

Front sidemember inner AB601423AB

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3-8

WELDED PANEL REPLACEMENT FRONT SIDEMEMBER (PARTIAL REPLACEMENT)

FRONT SIDEMEMBER (PARTIAL REPLACEMENT)

M4030000100700

Symbol

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates indicates three panels to be welded )

MIG spot welding MIG arc welding (continuous) Braze welding

AB700422 AB

Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

REPAIR WELDS (Left side)

(Right side)

B

A

275 mm (10.8 in)

315 mm (12.4 in) Engine room side cover mounting hole

210 mm (8.3 in)

135 mm (5.3 in)

B

A

AB700444 AB

NOTE: .

• Refer to the Front End Crossmember section on P.3-3 for the welding point with front end crossmember.

• Refer to the Fender Shield section on P.3-4 for the welding points with the front fender Shield front.

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3-9

WELDED PANEL REPLACEMENT FRONT PILLAR

FRONT PILLAR Symbol

M4030005001563

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates indicates three panels to be welded )

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

AB700423AB

REPAIR WELDS

F A Cutting position

40 mm (1.57 in)

B A

Sound dampening foam material

B D

C 230 mm (9.05 in)

G

Sound dampening foam material

Cutting position E

(With the upper frame to front pillar brace and front deck frame upper outer removed)

C

AB700449 AB

NOTE: Refer to the Fender Shield section on P.3-4 for the welding points with the upper frame to front pillar brace and front deck frame upper outer.

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3-10

WELDED PANEL REPLACEMENT FRONT PILLAR

CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn.

Sound dampening foam material

Sound dampening foam material Cutting position Cutting position

E

D

AB601219

AB700381

G

F

(With the side outer panel removed)

(With the side outer panel removed) AB700978 AB

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WELDED PANEL REPLACEMENT FRONT PILLAR

3-11

NOTE ON REPAIR WORK .

REMOVAL After removing the front pillar, cut the side outer panel 140 mm (5.5 inches) behind the positioning notch to remove the side sill reinforcement outer front, side sill inner support front, and front pillar inner lower remaining on the body side.

140 mm (5.51 in)

Front pillar inner lower

Side sill inner support front

Side outer panel Side sill reinforcement outer front

AB601206 AD .

INSTALLATION 1. To reinforce the strength in the front pillar cut area, cut the side outer panel 50 mm (1.97 inches) above the cut area and cut the front upper inner pillar 100 mm (3.9 inches) above the cut area.

2. Assemble the new front pillar inner lower parts.

3. Assemble the new front upper inner pillar part.

Side outer panel 50 mm (1.97 in)

Front upper inner pillar Front pillar support

100 mm (3.93 in)

Roof side rail front reinforcement AB601213AB

Side sill reinforcement front

Aluminum tape

4. Assemble the new side sill reinforcement front parts. After that, cover the hole with aluminum tape to prevent the sound dampening foam material from dropping when the material is filled into the front pillar in the next process.

AB601208AB

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3-12

WELDED PANEL REPLACEMENT FRONT PILLAR

A

50 mm (1.97 in)

20 mm (0.78 in)

5. Align the new roof side rail reinforcement parts to the body side to cut and install. After that, machine the body loose panel cushion (MR535301 or MR435765) as shown and apply it to the body side to prevent the sound dampening foam material from dropping when the material is filled into the front pillar in the next process.

6. Assemble the new front pillar reinforcement lower.

40 mm (1.57 in)

Front pillar reinforcement lower

Front pillar inner upper

A : Body loose panel cushion

AB601297AB AB601297

65 mm (2.55 in)

20 mm (0.78 in) 25 mm (0.98 in)

35 mm (1.37 in)

7. When installing the new front outer pillar parts, machine the body loose panel cushion (MR535301 or MR435765) as shown and apply it to the body side to prevent the sound dampening foam material from dropping when the material is filled into the front pillar upper in the next process (for front pillar upper).

20 mm (0.78 in) 15 mm (0.59 in)

A

Side outer panel

Front pillar reinforcement lower A

: Body loose panel cushion

AB700912 AB

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WELDED PANEL REPLACEMENT FRONT PILLAR

10 mm (0.39 in)

35 mm (1.37 in)

80 mm (3.14 in)

90 mm (3.54 in)

3-13

8. When installing the new front outer pillar parts, machine the body loose panel cushion (MR535301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material is filled into the front pillar (for front pillar lower).

A

30 mm (1.18 in)

110 mm (4.33 in)

Front pillar reinforcement lower

A

Side outer panel

: Body loose panel cushion

AB700451AB

9. When installing the new front outer pillar parts, apply the body sealant to the areas as shown in advance.

: Body sealant

AB601221AB

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3-14

WELDED PANEL REPLACEMENT FRONT PILLAR

10.Assemble the front outer pillar, bolt and tape the hole and flange with aluminum tape, then fill the hole with sound dampening foam material as shown in the figure of the instructions.

Sound dampening foam material: 3M™ AAD ULTRAPRO Panel foam-Yellow

A AB601214

Front pillar reinforcement lower

Front pillar A inner lower : Sound dampening foam material AB700452 AC

11.Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminum tape, then melt the sound dampening foam material with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with sound dampening foam material.

AB100787

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3-15

WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT)

FRONT PILLAR (PARTIAL REPLACEMENT) Symbol

M4030001200089

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates indicates three panels to be welded )

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

AB700945AB

REPAIR WELDS

Cutting position

110 mm (4.33 in)

B Sound dampening foam material

A

230 mm (9.05 in)

D

G Cutting position

E Sound dampening C foam material (With the upper frame to front pillar brace and front deck frame upper outer removed)

B

Cutting position

A

C AB700938 AB

CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn.

NOTE: Refer to the Fender Shield section on P.3-4 for the welding points with the upper frame to front pillar brace and front deck frame upper outer.

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3-16

WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT)

AB601219

Cutting position E D

(With the side outer panel removed) AB700941AB

NOTE ON REPAIR WORK .

REMOVAL Front pillar inner lower

After removing the front pillar, cut the side outer panel 140 mm (5.5 inches) behind the positioning notch to remove the side sill reinforcement outer front, side sill inner support front, and front inner pillar lower remaining on the body side.

140 mm (5.51 in)

Side sill inner support front

Side outer panel Side sill reinforcement outer front

AB601206 AD .

INSTALLATION Side outer panel

1. To reinforce the strength in the front pillar cut area, cut the side outer panel 50 mm (1.97 inches) above the cut area.

2. Assemble the new front lower inner pillar parts.

50 mm (1.97 in)

AB601207AB

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WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT)

Side sill reinforcement front

Aluminum tape

10 mm (0.39 in)

3-17

3. Assemble the new side sill reinforcement front parts. After that, cover the hole with aluminum tape to prevent the sound dampening foam material from dropping when the material is filled into the front pillar in the next process.

4. Assemble the new front pillar reinforcement lower.

AB601208AB

35 mm (1.37 in)

80 mm (3.14 in)

90 mm (3.54 in)

5. When installing the new front outer pillar, machine the body loose panel cushion (MR535301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the front pillar.

A

30 mm (1.18 in)

110 mm (4.33 in)

Front pillar reinforcement lower

A

Side outer panel

: Body loose panel cushion

AB700451AB

6. When installing the new front outer pillar, apply the body sealant to the areas as shown in advance.

: Body sealant

AB700989 AB

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3-18

WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT)

7. Assemble the front outer pillar, bolt and tape the hole and flange with aluminum tape, then fill the hole with sound dampening foam material as shown in the figure of the instructions.

Sound dampening foam materiaL: 3M™ AAD ULTRAPRO Panel foam-Yellow A

Front pillar reinforcement lower

Front inner pillar lower : Sound dampening foam material A

AB700943AB

8. Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminum tape, then melt the sound dampening foam material with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with sound dampening foam material.

AB100787

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3-19

WELDED PANEL REPLACEMENT CENTER PILLAR

CENTER PILLAR Symbol

M4030006001016

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates indicates three panels to be welded )

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

AB700424 AB

REPAIR WELDS 190 mm (7.48 in)

A

Cutting position

Sound dampening foam material B

A

The same position as the new center outer part

B

C

The same position as the new center outer part Sound dampening foam material

C

D

D AB700944 AB

CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn.

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3-20

WELDED PANEL REPLACEMENT CENTER PILLAR

NOTE ON REPAIR WORK .

REMOVAL Side outer panel Center pillar reinforcement

Side sill reinforcement outer rear

1. To cut the welding points between the center pillar reinforcement and side sill reinforcement outer rear, cut the side outer panel as shown.

AB601418AB

2. After removing the center pillar, remove the center pillar inner upper left on the body side. .

INSTALLATION

Center pillar inner upper AB601247AB

Center pillar reinforcement 50 mm (1.97 in)

Side outer panel

1. To reinforce the strength in the center pillar cut area, cut the side outer panel 100 mm (3.94 inches) above the cut area and cut the center pillar reinforcement 50 mm (1.97 inches) above the cut area.

100 mm (3.94 in)

AB601248 AB

2. Remove the center pillar inner lower from the new center inner pillar, and install the center inner pillar to the body.

Center pillar inner lower

AB601249AB

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WELDED PANEL REPLACEMENT CENTER PILLAR

Rear door hinge reinforcement 50 mm (1.97 in)

100 mm (3.94 in)

Center pillar reinforcement

3-21

CAUTION Weld and repair if the rear door hinge reinforcement is damaged.

3. Cut the new center pillar reinforcement parts by aligning them with the cut area of center pillar reinforcement in the body-side. Then, cut only the center pillar reinforcement 100 mm (3.94 inches) below from the cut area to create a cover, and then cut the rear door hinge reinforcement 50 mm (1.97 inches) below from the cut area.

AB601250 AB

4. Weld the rear door hinge reinforcement then weld the cover of the center pillar reinforcement.

Cover

Rear door hinge reinforcement

Center pillar reinforcement AB601251AB

50 mm (1.97 in) 50 mm (1.97in)

75 mm (2.95 in)

40 mm (1.57 in)

35 mm (1.37 in) 20 mm (0.78 in)

450 mm (17.7 in)

50 mm (1.97 in)

5. When installing the new center outer pillar, machine the body loose panel cushion (MR535301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the front pillar.

A

75 mm (2.95 in) Center pillar reinforcement

A

Side outer panel : Body loose panel cushion AB601254AB

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3-22

WELDED PANEL REPLACEMENT CENTER PILLAR

6. Assemble the center outer pillar, bolt and tape the hole and flange with aluminum tape, then fill the hole with sound dampening foam material as shown in the figure of the instructions.

Sound dampening foam material: 3M™ AAD ULTRAPRO Panel foam-Yellow A

Center pillar reinforcement

A

Side sill reinforcement outer rear : Sound dampening foam material

AB601255AB

7. Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminum tape, then melt the sound dampening foam material with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with sound dampening foam material.

AB200418

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3-23

WELDED PANEL REPLACEMENT SIDE SILL

SIDE SILL Symbol

M4030007001280

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates indicates three panels to be welded )

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

AB700425 AB

REPAIR WELDS Sound dampening foam material

C 50 mm (1.97 in)

B

A

40 mm (1.57 in)

65 mm (2.56 in)

Sound dampening foam material Sound dampening foam material

A

B

C AB700454AC

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3-24

WELDED PANEL REPLACEMENT SIDE SILL

CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn.

AB601437

D

Sound dampening foam material

(With the side outer panel removed)

D AB700455 AB

NOTE: Partial replacement is possible depending on the range of damage. Cut the side sill reinforcement outer rear 50 mm (1.97 inches) away from the cut area of the side outer panel.

Side sill reinforcement outer rear

(With the side outer panel removed) : Cuttable range

AB601311AB

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WELDED PANEL REPLACEMENT SIDE SILL

3-25

NOTE ON REPAIR WORK .

REMOVAL 1. When installing the side sill reinforcement outer rear, cut the center pillar reinforcement 80 mm (3.15 inches) downward from the installation hole of the rear door hinge because the center pillar reinforcement interferes with it. For the rear wheel house, remove the rear wheel house panel front lower outer and quarter panel extension inner because the quarter panel extension inner interferes with the rear wheel house panel front lower outer.

80 mm (3.15 in)

Center pillar reinforcement AB601302

Rear wheel house panel front lower outer AB601296

Quarter panel extension inner

AB700456 AB

2. After removing the side sill reinforcement outer rear, remove the center pillar inner lower.

Center pillar inner lower

.

AB601307 AB

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3-26

WELDED PANEL REPLACEMENT SIDE SILL

INSTALLATION 1. Remove the center pillar inner upper from the new center inner pillar, and install the center inner pillar to the body.

Center pillar inner upper AB601249 AC

2. Remove the side sill reinforcement outer front from the new side sill reinforcement, and install the side sill reinforcement to the body.

Side sill reinforcement outer front

AB601309AB

10 mm (0.39 in)

35 mm (1.37 in)

80 mm (3.14 in)

90 mm (3.54 in)

3. When installing the new front floor side sill outer, machine the body loose panel cushion (MR535301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the front pillar.

A

30 mm (1.18 in)

110 mm (4.33 in)

Front pillar reinforcement lower

A

Side outer panel

: Body loose panel cushion

AB700451AD

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WELDED PANEL REPLACEMENT SIDE SILL 50 mm (2.0 in) 50 mm (2.0 in) 75 mm (3.0 in)

35 mm (1.4 in) 20 mm (0.8 in)

50 mm (2.0 in)

3-27

4. When installing the new front floor side sill outer, machine the body loose panel cushion (MR535301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the center pillar.

75 mm (3.0 in) 40 mm (1.6 in)

450 mm (17.7 in)

A

Center pillar reinforcement

A

: Body loose panel cushion

Side outer panel AB601310AB

5. Assemble the front floor side sill outer, bolt and tape the hole and flange with aluminum tape, then fill the hole with sound dampening foam material as shown in the figure of the instructions.

Sound dampening foam material: 3M™ AAD ULTRAPRO Panel foam-Yellow A

Center pillar reinforcement

A

Side sill reinforcement outer rear : Sound dampening foam material

AB601255AB

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3-28

WELDED PANEL REPLACEMENT SIDE SILL

6. Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminum tape, then melt the sound dampening foam material with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with sound dampening foam material.

AB100787

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3-29

WELDED PANEL REPLACEMENT QUARTER OUTER

QUARTER OUTER Symbol

M4030008001090

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates indicates three panels to be welded )

MIG spot welding MIG arc welding (continuous) Braze r welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

AB700427 AB

REPAIR WELDS

Sound dampening foam material 3 points on left side only

320 mm (12.6 in)

C E

B

D Sound dampening foam material

35 mm (1.38 in)

A

A

B

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C

AB700483 AB

3-30

WELDED PANEL REPLACEMENT QUARTER OUTER

CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn.

D

E AB602342AD

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WELDED PANEL REPLACEMENT QUARTER OUTER

3-31

NOTE ON REPAIR WORK .

INSTALLATION 40 mm (1.57 in) 185 mm (7.28 in) 25 mm (0.984 in)

1. When installing the new quarter panel outer, machine the body loose panel cushion (MR535301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the rear pillar.

A

Side outer panel

Roof side rail reinforcement rear A

: Body loose panel cushion

AB601738AB

250 mm (9.84 in) 40 mm (1.57 in)

30 mm (1.18 in)

2. When installing the new quarter panel outer, machine the body loose panel cushion (MR535301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the wheel arch.

A

Rear pillar reinforcement lower Quarter panel extension lower outer

Side outer panel A

: Body loose panel cushion

AB700900AC

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3-32

WELDED PANEL REPLACEMENT QUARTER OUTER

3. When installing the new quarter panel outer, apply the body sealant in advance to the areas as shown.

Left side only

: Body sealant

AB700619 AB

4. Partial replacement is possible depending on the range of damage.

: Cuttable range

AB700356 AB

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3-33

WELDED PANEL REPLACEMENT REAR END PANEL

REAR END PANEL Symbol

M4030009000409

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates indicates three panels to be welded )

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

AB700428 AB

REPAIR WELDS

A

A AB601442 AB

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3-34

WELDED PANEL REPLACEMENT ROOF

ROOF Symbol

M4030011001205

Operation description Spot welding MIG plug welding

indicates two panels to be welded ( :: indicates three panels to be welded )

MIG spot welding MIG arc welding (continuous) Rivet

AB700285AB

Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

REPAIR WELDS <Vehicles without sunroof (aluminum panel)>

<Vehicles with sunroof (steel panel)>

: Adhesive 1 : Adhesive 2

AB700919AB

• Adhesive 1: Urethane body sealer Brand: 3M™ AAD Part No.08360 or equivalent

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• Adhesive 2: Epoxyayresin adhesive Brand: 3M™ AAD Part No.8115 or equivalent

WELDED PANEL REPLACEMENT ROOF

3-35

NOTE ON REPAIR WORK <Vehicles without sunroof (aluminum panel)> .

REMOVAL 1. Grind the self piercing rivet foot with a belt sander [belt width of 10 mm (0.39 inch)] or the like.

Self piercing rivet

Roof panel Foot

Belt sander

Roof panel

AB501298 AC

Self piercing rivet

2. Remove the self piercing rivet by striking it up at the bottom with a punch or the like to disconnect it from the side structure. .

INSTALLATION

Punch AB501299 AC

Recommended tool Rivet diameter 4.8 mm (0.18 in)

1. Temporarily install the new roof panel to the body and drill holes at riveting positions with a drill [5 mm (0.19 inch) in diameter].

2. Remove the roof, remove burrs at the drilled holes, and clean the body.

3. Apply structural adhesive to the body, and install the roof.

Adhesive: Epoxyayresin adhesive Brand: 3M™ AAD Part No.8115 or equivalent 4. Use the recommended tool to tighten the roof lid rivet by the following procedure.

AB501393AB

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3-36

WELDED PANEL REPLACEMENT ROOF Recommended tool

Roof panel AB302218

(1) Insert the rivets into the roof.

(2) Mount the recommended tool on the A-section of the rivet.

(3) Operate the tool's handle while pushing the flange surface of the rivet by the recommended tool.

(4) Part A of the rivet is cut and the rivet is tightened.

Recommended tool A Flange surface

AC205918 Roof lid rivet 1

2

3

4 AB501314 AC

5. After the adhesive is dried, remove the excessive residues and apply body sealant to the whole rivets and the roof edge in order to prevent water leakage.

A

AB302189

Roof panel

Body sealing AB302205

Rivet

A AB501313 AC

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3-37

WELDED PANEL REPLACEMENT REAR FLOOR

REAR FLOOR Symbol

M4030010001053

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates indicates three panels to be welded )

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

AB700429 AB

REPAIR WELDS

C

A

D

E

A (With the rear floor removed)

B

AB700939AB

NOTE: Refer to the Rear End Panel section on P.3-33 for the welding points with the rear end panel.

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3-38

WELDED PANEL REPLACEMENT REAR FLOOR

B

C

E

D

AB700940 AB

NOTE ON REPAIR WORK .

REMOVAL (With the rear floor rear removed)

When removing the rear floor side panel, cut it 290 mm (11.4 inches) behind the installation hole of the child restraint bracket.

290 mm (11.4 in)

AB700599 AB

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3-39

WELDED PANEL REPLACEMENT QUARTER INNER

QUARTER INNER Symbol

M4030012001093

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates indicates three panels to be welded )

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

AB700430 AB

Sound dampening foam material

REPAIR WELDS

Sound dampening foam material Sound dampening foam material

B

B

Left side only

A

A Sound dampening foam material

F G (With the quarter outer removed) AB700999AB

CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn.

NOTE: Refer to the Quarter Outer section on P.3-29 for the welding points with the quarter outer.

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3-40

WELDED PANEL REPLACEMENT QUARTER INNER

Right side only

E Right side only Right side Right side only C

D

Right side Right side Right side only

(With the rear pillar reinforcement and the rear pillar reinforcement lower removed)

Right side only D

E

Right side only C

AB701000AB

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3-41

WELDED PANEL REPLACEMENT QUARTER INNER

F

F

(Right side)

(Left side)

H G

H

(With the rear wheel house panel front lower outer removed) AB700546 AB

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3-42

WELDED PANEL REPLACEMENT QUARTER INNER

NOTE ON REPAIR WORK .

INSTALLATION

A

125 mm (4.92 in)

1. When installing the new quarter panel inner, machine the body loose panel cushion (MR535301 or MR435765) as shown and apply it to the body side to prevent the sound dampening foam material from dropping when the material is filled into the rear pillar in the next process.

70 mm (2.75 in) 20 mm (0.787 in) Roof side rail reinforcement rear

Quarter panel inner A

: Body loose panel cushion

AB601339AB AB601339

2. When installing the new rear pillar reinforcement lower parts, machine the body loose panel cushion (MR535301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the rear pillar reinforcement lower.

85 mm (3.35 in)

40 mm (1.57 in)

20 mm (0.787 in)

A

Quarter panel inner

Rear pillar reinforcement lower

A

: Body loose panel cushion

AB700899AB

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WELDED PANEL REPLACEMENT QUARTER INNER

3-43

3. Assemble the rear quarter panel inner, bolt and tape the hole and flange with aluminum tape, then fill the hole with sound dampening foam material as shown in the figure of the instructions.

Sound dampening foam material: 3M™ AAD ULTRAPRO Panel foam-Yellow

AB601338AB

4. Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminum tape, then melt the sound dampening foam material with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with sound dampening foam material.

AB100787

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3-44

WELDED PANEL REPLACEMENT QUARTER INNER (PARTIAL REPLACEMENT)

QUARTER INNER (PARTIAL REPLACEMENT) Symbol

M4030000200127

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates indicates three panels to be welded )

MIG spot welding MIG arc welding (continuous) Braze welding

AB700946 AB

Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

REPAIR WELDS

A

A B

(With the rear pillar reinforcement and the rear pillar reinforcement lower removed)

Rear wheel house panel front lower outer

C

C (With the rear wheel house panel front lower outer removed)

B

AB700972 AB

NOTE: .

• Refer to the Quarter Outer Section on P.3-29 for the welding points with the quarter outer.

• Refer to the Quarter Inner Section on P.3-39 for the welding points with the rear pillar reinforcement and the rear pillar reinforcement lower.

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WELDED PANEL REPLACEMENT QUARTER INNER (PARTIAL REPLACEMENT)

3-45

NOTE ON REPAIR WORK .

REMOVAL 1. Adhere tape along the wheel arch of the quarter inner panel as shown in the figure of the instructions, use the tape as a guide so about 20 mm (0.79 inch) of the flange remains, then cut and remove.

Tape AB700987AB

.

INSTALLATION 1. For the new quarter panel inner parts, cut the wheel arch end are so that it overlaps with the flange on the body-side.

AB700986 AB

2. Overlap, assemble and weld the quarter panel inner with the body-side flange. Weld at a pitch of 40 mm (1.57 inches).

40 mm (1.57 in) AB700988 AB

3. Weld the quarter panel inner then apply a body sealing in the area shown in the figure of the instructions.

Body sealing AB700987AC

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3-46

WELDED PANEL REPLACEMENT FRONT DOOR OUTER PANEL (WELDED TYPE)

FRONT DOOR OUTER PANEL (WELDED TYPE)

M4030001500671

Symbol

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates indicates three panels to be welded )

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

AB601289 AC

REPAIR WELDS

A

50 mm (1.97 in)

A : Adhesive

AB700976AB

Adhesive: Urethane body sealer

Brand: 3M™ AAD Part No.08360 or equivalent NOTE: After hemming the front door outer panel, MIG spot weld the flange overlap section at a pitch of 50 mm (1.97 inches).

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3-47

WELDED PANEL REPLACEMENT FRONT DOOR OUTER PANEL (ADHESION TYPE)

FRONT DOOR OUTER PANEL (ADHESION TYPE)

M4030001700686

Symbol

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates indicates three panels to be welded )

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

AB601288AD

REPAIR WELDS

A

A : Adhesive 1 : Adhesive 2

AB700977 AB

• Adhesive 1: Urethane body sealer Brand: 3M™ AAD Part No.08360 or equivalent • Adhesive 2: Epoxyayresin adhesive

Brand: 3M™ AAD Part No.8115 or equivalent

NOTE ON REPAIR WORK

.

INSTALLATION 1. When installing the front door outer panel, grind and remove the paint from the bonded surface of the outer panel to ensure the bonding strength. After the removal, degrease it.

2. Install the outer panel and hem it. Wipe off the excessive adhesive and finish it.

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3-48

WELDED PANEL REPLACEMENT REAR DOOR OUTER PANEL (WELDED TYPE)

REAR DOOR OUTER PANEL (WELDED TYPE) Symbol

M4030001600548

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates indicates three panels to be welded )

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

AB700852 AB

REPAIR WELDS

A

50 mm (1.97 in)

A : Adhesive

AB700542 AB

Adhesive: Urethane body sealer Brand: 3M™ AAD Part No.08360 or equivalent NOTE: After hemming the front door outer panel, MIG spot weld the flange overlap section at a pitch of 50 mm (1.97 inches).

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3-49

WELDED PANEL REPLACEMENT REAR DOOR OUTER PANEL (ADHESION TYPE)

REAR DOOR OUTER PANEL (ADHESION TYPE)

M4030001800520

Symbol

Operation description Spot welding MIG plug welding

two panels to be welded ( :: indicates indicates three panels to be welded )

MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

AB700853AB

REPAIR WELDS

A

: Adhesive 1 : Adhesive 2

A AB700543 AB

• Adhesive 1: Urethane body sealer Brand : 3M™ AAD Part No.08360 or equivalent • Adhesive 2: Epoxyayresin adhesive

Brand : 3M™ AAD Part No.8115 or equivalent

NOTE ON REPAIR WORK

.

INSTALLATION 1. When installing the rear door outer panel, grind and remove the paint, etc. from the bonded surface of the outer panel to ensure the bonding strength. After the removal, degrease it.

2. Install the outer panel and hem it. Wipe off the excessive adhesive and finish it.

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3-50

WELDED PANEL REPLACEMENT ALUMINUM PANEL

ALUMINUM PANEL ALUMINUM PANEL CHARACTERISTICS Description of aluminum panel A new aluminum panel with higher strength and better workability has been developed by adding a small amount of metallic elements, including magnesium (Mg), copper (Cu) and silicon (Si), to aluminum. This type of aluminum material has equivalent strength to cold rolled steel sheets.

Advantage of aluminum panel 1. Lighter: The specific gravity of aluminum is 2.7, which is only one third of general steel panel (7.9).

However, it requires 1.4 times in thickness to obtain the same rigidity as the steel panel, resulting in one half in weight.

M4030000500173

2. More durable: Aluminum has the property of creating oxide coating on its surface when it contacts with the air. This coating prevents it from being corroded.

3. More heat-conductive: The heat conductivity of aluminum is twice as high as that of iron. This means that aluminum absorbs and disperses heat more quickly, which results in prompt change of its temperature.

4. More electric-conductive 5. Non-magnetic substance

ALUMINUM PANEL LOCATIONS

M4030000600277

Roof panel

Hood

Fender AB701121AB

Application

Thickness

Application

Thickness

Roof panel

1.1 mm (0.043 inch)

Hood outer panel

0.9 mm (0.035 inch)

Hood inner panel

0.8mm (0.031 inch)

Fender

1.0 mm (0.039 inch)

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3-51

WELDED PANEL REPLACEMENT ALUMINUM PANEL

ALUMINUM PANEL REPAIR

M4030000700230 .

Precautions upon sheet metal processing 1. Major difference in processing between sheet metal and steel sheet (On the basis of general body shop) Work Aluminum alloy panel Steel sheet description Hammering

Mallet or plastic hammer

Sheet metal hammer

Washer welding

Not possible

Possible

Gas welding Not good workability but possible

Possible

Spot welding Not possible

Possible

MIG welding Possible by a welding machine for aluminum and argon gas

Possible by a general welding machine and CO2 gas

2. If strong impact is given under low temperature, its strength becomes low and cracking occurs.

3. The springback (returning force to the original condition) is large due to high elastic modules.

4. The thermal effect is large due to high heat conductivity.

5. When excessively heated, its strength will be deteriorated.

When heated additionally, it will be melted without discolouration. [The heating temperature is approximately 250°C (482°F)].

Material

Melting point

Aluminum

475 to 660 °C (887 to 1220 °F) <varying with the alloy content>

Steel sheet

1500 to 2500 °C (2732 to 4532 °F)

CAUTION Weld and repair it if the side sill reinforcement front is damaged.

6. Because the material is soft, choose an abrasive carefully.

Wear a dustproof mask and safety glasses, because ground particle is light and tends to float in the air.

7. If a disk sander is strongly pressed against the aluminum plate, friction heat is generated, resulting in exfoliation of the aluminum alloy and clogging of the disk sander with the exfoliated particles.

8. Because the clogged disk sander will damage the aluminum alloy panel, replace it with a new one as soon as possible.

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3-52

WELDED PANEL REPLACEMENT ALUMINUM PANEL

9. General tools and sanding tools shall not be shared for both aluminum alloy and steel panels. (Iron powder remaining on the surface may cause electric corrosion with a different type of metal).

10.During MIG welding, protect the vicinity because the spatters are hard to see and spread father than expected.

Correction of uneven surface .

Basically, the same as the steel panel. However, give a consideration to the aluminum alloy characteristics.

1. Repair of sheet metal (1) Heat with a burner.

CAUTION • Heat-up the panel until you feel heat with a keplar work glove on the reverse side of the panel.

• Keep moving the burner evenly to prevent heat from concentrating in one point.

AB202119 AB

(2) Because hammering may stretch the panel, use a mallet or plastic hammer.

CAUTION Minimize the stretch and hardening, and give no hammer dent.

AB202120AB

2. Distortion check: Grind the surface with #80 to #120-grit sandpaper and then check for distortion.

AB202113AB

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WELDED PANEL REPLACEMENT ALUMINUM PANEL

3-53

3. Straightening: Remove distortion by the draw correction procedure with a flattening hammer and a burner.

AB202116 AB

CAUTION • The heating temperature should be approximately 250°C (482°F).

• Pay particular attention to heating, because it is melted without discolouration by heat.

• Cover the vicinity of the area to be heated with a wet rag or the like to prevent temperature rise and influence of heat (distortion).

• Do not use a draw hammer for steel sheets because it may cause the panel crack.

4. Sanding: Grind the surface with a disk sander or a double-action sander.

• Disk sander: #100 to #120 • Double-action sander: #150 to #180 CAUTION Aluminum plates are softer than steel sheets, therefore select an appropriate abrasive to prevent the surface from deeply scratched. The heating temperature should be approximately 250°C (482°F).

AB202109 AC

.

Correction of cuts and cracks If cuts, cracks, or holes occur in a steel sheet panel, MIG welding with CO2 is used for repair. However, for an aluminum panel, use MIG or TIG welding with argon gas (inert gas) as shielding gas for repair. .

DEGREE OF DISTORTION CAUSED BY WELDING

AB302173AB

Gas welding (a large amount of distortion) TIG welding MIG welding (a small amount of welding). This manual explains the operation procedure of MIG welding which causes a small amount of distortion by welding heat.

Operation procedure of MIG welding .

CAUTION • Be careful to avoid excessive stretch of or damage to the panel.

• Minimize the gap of the butt joint.

1. Correct the damaged area by hammering lightly while heating it. If any area is stretched by hammering, grind it off with a pneumatic saw.

AB202121AB

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3-54

WELDED PANEL REPLACEMENT ALUMINUM PANEL

CAUTION To minimize distortion and meltdown, divide a welding area into several short segments, and weld one segment at a time.

2. Welding: Use an aluminum dedicated welding machine or a shared welding machine for aluminum and steel sheet for the operation.

Wire diameter: 0.8 or 1.0 mm (0.031 or 0.039 inch) (1) Degrease the welding area by white gasoline or the like.

(2) Remove the oxide coat from the welding area, including its back, with a stainless steel wire brush just before welding. Welding shall be started as soon as the oxide coat is removed.

AB202118 AB

CAUTION Do not over-grind the base of the panel.

3. Refinish the welding area by a #100-grit disk sander, and then check for any faulty welding by the visible dye penetrate testing.

AB202117AB

4. Check for distortion: Grind the surface with #80 to #120-grit sandpaper and then check for distortion.

AB202113AB

CAUTION • The heating temperature should be approximately 250°C (482°F).

• Pay particular attention to heating, because it is melted without discolouration by heat.

• Cover the vicinity of the area to be heated with a wet rag or the like to prevent temperature rise and influence of heat (distortion).

• Do not use a draw hammer for steel sheets because it may cause the panel crack.

5. Remove distortion by the draw correction procedure with a flattening hammer and a burner.

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WELDED PANEL REPLACEMENT ALUMINUM PANEL

3-55

CAUTION Remove any spark spot or carbon residue on the surface by a stainless steel wire brush, because they will cause improper painting in the following process.

AB302174AB

6. Finishing: Finish it with a #100 to #120-grit disc sander.

AB202109 AC

Other welding .

TIG WELDING 1. This welding is conducted by the same arc welding method as for MIG welding, however, it uses a welding rod instead of electrode wire.

Wire diameter: 1.6 mm (0.063 inch).

CAUTION • Be careful to avoid excessive stretch of or damage to the panel.

• Minimize the gap of the butt joint.

AB202108AB

.

GAS WELDING (OXIDE - ACETYLENE) If gas welding is allowed, the welding can be conducted using a welding rod and flux (oxide coat remover). However, before the welding work, do sufficient practice to avoid distortion by welding heat or poor welding.

Wire diameter: 1.6 mm (0.063 inch).

1. Heat the welding rod and bond the flux to it.

AB302175 AB

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3-56

WELDED PANEL REPLACEMENT ALUMINUM PANEL

CAUTION Keep the welding surface as horizontal as possible, because the melted welding rod flows readily.

2. While melting the flux with the burner to remove the oxide coat, conduct the welding.

3. Remove the flux residue from the panel with a stainless steel wire brush.

AB302176 AB

Finish with putty .

AB202114AB

1. Grind the putty-applied area with a #150 to #180-grit double-action sander.

2. Degrease and clean the putty-applied area.

3. Apply 2-liquid type epoxy primer or a pretreatment agent for aluminum.

4. Grind with a #180-grit double-action sander for cutting action.

5. Degrease and clean the putty-applied area.

6. Apply putty for metal sheets, and dry it naturally.

CAUTION Do not dry it forcibly at 60°C (140°F) or higher.

7. Grind with a #180-grit sander.

AB302177AB

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3-57

WELDED PANEL REPLACEMENT ALUMINUM PANEL

ALUMINUM PANEL PAINT

M4030000800163 .

Painting in production line Same as painting for normal steel sheets. .

Precautions upon sheet metal processing CAUTION • Avoid hasty grinding and minimize grinding heat.

• Do not dry it forcibly at higher than 60°C (140°F).

1. Peel-off of paint film 2. Cleaning and degreasing CAUTION Apply 2-liquid type epoxy primer or a pretreatment agent for aluminum to the aluminum base surface.

3. Application of wash primer 4. Drying <60°C (140°F) or lower> 5. Application of primer surfacer 6. Drying <60°C (140°F) or lower> 7. Grinding 8. Cleaning and degreasing 9. Finish coating 10.Drying <60°C (140°F) or lower> NOTE: .

• Refer to paint manufacturers' paint specifications for details.

• The procedure is almost the same as the repair painting procedure of anti-corrosion steel panel.

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NOTES

4-1

GROUP 4

CORROSION PROTECTION CONTENTS BODY SEALING LOCATIONS . . . . .

4-2

UNDERCOAT APPLICATION LOCATIONS . . . . . . . . . . . . . . . . . . . .

4-10

4-2

CORROSION PROTECTION BODY SEALING LOCATIONS

BODY SEALING LOCATIONS If the sealant application is directly visible on the outer plate and requires appearance quality of the application in areas such as the drip rail, pillar, clinch and so on, then apply the sealant so that it is flat, or wipe off any excess mounding after the application.

Be careful not to obstruct the water draining hole.

M4040001001443

NOTE: The bold dotted line indicates the application area on the underside.

.

FLOOR

4 3

1

2

5

6

7

AB701023AB

UPPER BODY

8

9

12

11 10

AB701024AB

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4-3

CORROSION PROTECTION BODY SEALING LOCATIONS

SIDE BODY

Left side only

13

16

14

19

15

17

18

20 AB701025AB

1

AB701017AB

2

AB701001AB

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4-4

CORROSION PROTECTION BODY SEALING LOCATIONS

3

AB701002 AB

4

AB701005AB

5

AB701018AB

6

AB701004 AB

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CORROSION PROTECTION BODY SEALING LOCATIONS

7

AB700615AC

8

AB701006AB

9

AB701007AB

10

AB701008AB

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4-5

4-6

CORROSION PROTECTION BODY SEALING LOCATIONS

11

AB701003AB

12

AB701009AB

13

Right side only Left side only

AB701010AB

14

AB701011AB

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CORROSION PROTECTION BODY SEALING LOCATIONS

15

AB701012AB

16

AB701013AB

17

AB700340AD

18

AB701019AB

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4-7

4-8

CORROSION PROTECTION BODY SEALING LOCATIONS

19

AB701015AB

20

AB701016AB

Hood

AB701020AB

Front door

AB601134AC

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CORROSION PROTECTION BODY SEALING LOCATIONS

Rear door

AB601135AC

Trunk lid (outer)

AB601136AC

Trunk lid (inner)

AB700344AB

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4-9

4-10

CORROSION PROTECTION UNDERCOAT APPLICATION LOCATIONS

UNDERCOAT APPLICATION LOCATIONS • The under parts of the body is undercoated for anti-corrosive, anti-rust, anti-chipping, and anti-vibration performance.

• After correcting the body, restore as shown in the instructions of the figure, if necessary.

*

*

*

*

*

: Undercoat [film thickness is at least 0.5 mm (0.0197 inch)]

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M4040003001030

• Tape the areas marked with an asterisks to protect those areas from getting any undercoating on those areas.

*

* AB701026AB

5-1

GROUP 5

SYNTHETIC-RESIN PARTS CONTENTS LOCATION OF SYNTHETIC-RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . .

5-2

5-2

SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS

LOCATION OF SYNTHETIC-RESIN PARTS

M4050001001433

The location and material of each of the principal synthetic-resin parts are shown below.

4, 9

48

3

2

13

5 17

40 7

6 10

16

11

15 14

28 18

15 8 30 35

29

31

33 1

32

AB700997AB

21

34

38 39

42

43

23

37

19

24

41 20

36 46 12

26

44 22

25

27

47

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45

AB700998AB

5-3

SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS

No.

Part name

Name of resin

Abbreviation

Heatresistant temp [°C (°F)]

1

Radiator grille

Acrylonitrile butadiene styrene

ABS

80 (176)

2

Door mirror

3

Rear spoiler

4

Antenna base <Vehicles without satellite radio tuner>

Acrylonitrile ethylene styrene

AES

80 (176)

5

Front delta garnish

Acrylonitrile styrene acrylate

ASA (AAS)

80 (176)

6

Hood air outlet garnish

PA6-[TD35+GF5] 80 (176)

7

Hood air inlet garnish

Talc (35%) +Glass fiber (5%) filled Polyamide 6

8

Headlight

Polycarbonate

PC

120 (248)

9

Antenna base <Vehicles with satellite radio tuner>

Polycarbonate

PC+AES

80 (176)

10

Rear door outside handle

PC+PET

120 (248)

11

Front door outside handle

Polycarbonate+Polyethylene terephthalate

12

Front splash shield

Low density Polyethylene

PE-LD (LLDPE)

80 (176)

13

High-mounted stoplight

Polymethyl methacrylate

PMMA

80 (176)

14

Front bumper air guide center duct Polypropylene

PP

80 (176)

15

Front bumper core

16

Rear bumper core lower

17

Rear bumper core upper <Vehicles for Canada>

18

Rear bumper core center <Vehicles for Canada>

19

Front door sash trim

20

Front door trim lower

21

Inside rear view mirror

22

Rear door trim lower

23

Rear shelf trim

24

Rear end trim

25

Rear scuff plate

26

Front scuff plate

27

Cowl side trim

28

Rear bumper protector <Vehicles for Canada>

PP+E/P

80 (176)

29

Rear bumper face

30

Front fender garnish

31

Front bumper face

32

Front bumper garnish

33

Grille center garnish

Rubber denatured polypropylene

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5-4

SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS

No.

Part name

Name of resin

Abbreviation

Heatresistant temp [°C (°F)]

34

Front pillar trim

Talc filled rubber modified polypropylene (15%)

PP+E/P-TD15

80 (176)

35

Side air dam

Talc filled rubber modified polypropylene (20%)

PP+E/P-TD20

110 (230)

36

Rear wheel splash shield rear

Talc filled polypropylene

PP-TD (PPF)

100 (212)

37

Front door trim upper

Talc filled polypropylene (10%)

PP-TD10 (PPF)

38

Center pillar trim lower

110 − 120 (230 − 248)

39

Rear door trim upper

40

Front deck garnish

Talc filled polypropylene (20%)

PP-TD20 (PPF)

41

Instrument panel

120 − 130 (248 − 266)

42

Center pillar trim upper

43

Rear pillar trim

44

Floor console box cup holder

45

Floor console rear

46

Floor console panel

47

Floor console side cover

48

Roof drip molding

Polyvinyl chloride

PVC

80 (176)

NOTE: .

• If the material symbols designated by the ISO differ from the old symbols, both are given, with the old symboling enclosed in brackets.

ISO: International Standardization Organization.

• A plus sign (+) indicates that the two different materials mix each other.

• The material symbols for synthetic-resin parts are embossed on the parts in hidden places.

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6-1

GROUP 6

BODY COLOR CONTENTS BODY COLOR CODE . . . . . . . . . . . .

6-2

BODY COLOR CHARTS . . . . . . . . . .

6-2

BODY COLORING . . . . . . . . . . . . . . .

6-3

RADIATOR GRILLE . . . . . . . . . . . . . . . . . .

6-3

GARNISH . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4

BUMPER NET . . . . . . . . . . . . . . . . . . . . . . .

6-5

WHEEL HOUSE . . . . . . . . . . . . . . . . . . . . .

6-5

6-2

BODY COLOR BODY COLOR CODE

BODY COLOR CODE

M4060001000679

Body color code is stamped on the name plate, which is attached on the underside of the center pillar (Right side).

Body color code AB601277AB

BODY COLOR CHARTS

M4060002002021

Color

Color code

Color number Color name

Coating film Composition of structure film

SILVER

A31

CMA10031

Cool Silver Metallic

2M

MEDIUM A39 PURPLISH GRAY

CMA10039

Medium Purplish Gray Mica 2P

Metallic + Interferenced Pearl

BLUE

D06

CMD10006

Lightning Blue Mica

2P

Interferenced Pearl

DARK GRAY

U02

CMU10002

Phantom Black Pearl

2P

Interferenced Pearl

WHITE

W37

CMW10037

White Solid

2S

Solid

RED

P26

CMP10026

Red Metallic

2M

Metallic

Metallic

NOTE: .

• The coating film structure indicates top coating only (2S: 2 coat solid,2M: 2 coat metallic, 2P: 2 coat pearl ).

• For painting, inner panel colors should be similar to the outer panel colors.

TSB Revision

6-3

BODY COLOR BODY COLORING

BODY COLORING RADIATOR GRILLE

M4060007000967

3 2 6 mm (0.24 in)

2

A

3

B

2 C

3 3 C

1

2

MR GSR Gray (CMH18036) 1 Dark warm gray (AC10895) 2 Dark warm gray (AC10895) Chrome plating 3 Material color

Chrome plating

TSB Revision

B

2

A AB700597AB

6-4

BODY COLOR BODY COLORING

GARNISH

M4060001300034

HOOD AIR SCOOP

1

2

A

1 1

2

A

Cool Silver Metallic (CMA10031) Except Cool Silver Metallic (CMA10031) White (CMW10037) White (CMW10037) Body Color 1 Body Color Body Color 2 Gray (CMH18036)

TSB Revision

AB700800 AB

6-5

BODY COLOR BODY COLORING

BUMPER NET

M4060001400020

1

1 GSR 1 Black (AC10657) 2

Black (AC10657) LH Material color RH

MR Gray (CMH18038)

Black (AC10657)

WHEEL HOUSE

2 AB701086 AB

M4060012000598 AB601150

: Black (AC10657)

AB700926AC

TSB Revision

NOTES