DOWNLOAD PDF Mitsubishi 2010 Lancer Sportback Body Repair Manual

GROUP INDEX 2010 MITSUBISHI BODY CONSTRUCTION . . . . . . . . .

LANCER SPORTBACK BODY DIMENSIONS . . . . . . . . . . . . .

1 2

BODY REPAIR MANUAL

WELDED PANEL REPLACEMENT. .

3

FOREWORD

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-214B-2010 SERVICE MANUAL MSCD-014B-2010 PARTS CATALOG BUM6Z400A_

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.

©2009 Mitsubishi Motors Corporation All Rights, Reserved Printed in USA MSSP-419B-2010

5 6 9

MANUAL DESCRIPTION CONTENTS

The first page of this manual contains a table of contents which lists the name of vehicle models and groups within each model.

TEXT

The vehicles to which the information in the text pertains are generally designated according to their body classification. In some cases, other limiting designations such as model name, type of drive system, etc., are given. If there are no such limiting designations, the information can be assumed to cover all models.

PAGE NUMBERS Al pages are numbered consecutively within each model. The page number can be found on the upper left or right of each page.

SECTION TITLES The group titles and section titles can be found at the upper center of each page.

Page number Group number

Group title Section title BODY CONSTRUCTION

1-8

BODY CONSTRUCTION CHARACTERISTICS

BODY CONSTRUCTION CHARACTERISTICS FRONT BODY

M4010010001415

HEADLIGHT SUPPORT x 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.

x The bolt-on headlight support panel upper is used to improve maintainability. x The 590-MPa class high tensile strength steel panels have been adopted for the front bumper reinforcement to improve the body rigidity.

9.0 ± 2.0 N·m 80 ± 17 in-lb

3

2

3 6

4

8 5 1*

10

20 ± 5 N·m 15 ± 3 ft-lb

11

A

10 9

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

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

6 7

9

Front bumper reinforcement Headlight support panel upper Front end crossmember gusset Front end crossmember upper Nut plate <RALLIART> Radiator bracket lower A Front end crossmember bulkhead Radiator bracket lower B Shipping hook front Shipping reinforcement front Front end crossmember lower

8 AB801206AB

A Crush box

AB801213AB

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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1-1

GROUP 1

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

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

1-2

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

1-21

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

1-22

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

1-26

1-27

1-4

MAINTENANCE, SERVICEABILITY .

1-6

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

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

1-9

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

1-28

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

1-9

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

1-17

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

1-20

STIFFENER APPLICATION LOCATIONS . . . . . . . . . . . . . . . . . . . .

1-30

1-2

BODY CONSTRUCTION BODY COMPONENTS

BODY COMPONENTS

M4010001001967

43 41

32

39

91

29 42 40 31

36 34

30

93

37

35*

28 26

27

92

89 38

110*

88* 33

90

109

102 101

108*

100 99 98

104

24 86

25

85 22

97

95

87*

44 105

84

20

107 106*

45*** 81**

83

48

23

21 82

18 13

64

14 15

76 50

80** 79

78 63

17

51

77 56

49 52*

59 57

4* 65*

11 10 8 9* 7

5

69

3 74

72

53 54*

60 58

62* 6

46 47

19

16*

12

61*

55

66

70

2 1*

68*

67**

75 NOTE: 73 71 : Anti-corrosion steel panels : High-tensile steel panels (*: Indicates 590MPa-high-tensile steel panels.) (**: Indicates 980MPa-ultra-high-tensile steel panels.) (***: Indicates 1180MPa-ultra-high-tensile steel panels.)

1.

2.

3.

96

94

103

Front bumper reinforcement Headlight support panel upper Front body frame to side sill brace

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4.

5.

6.

7.

Front sidemember rear Front inner sidemember Headlight support panel Front sidemember plate

AB900232AB

BODY CONSTRUCTION BODY COMPONENTS 8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

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27.

28.

29.

30.

31.

32.

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34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

63.

64.

65.

66.

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 <Except RALLIART> Hood panel outer <Except RALLIART> Hood panel inner <RALLIART> Hood panel outer <RALLIART> 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> Roof bow center upper <Vehicles without sunroof> Roof rail rear inner Liftgate hinge reinforcement Roof rail rear outer Roof panel Roof panel reinforcement <Vehicles with sunroof> Liftgate panel inner Liftgate panel outer Fuel filler door panel Rear bumper reinforcement Rear bumper center reinforcement Rear end crossmember Rear end inner crossmember Rear bumper bracket Rear floor Rear floor rear end crossmember Rear floor crossmember Rear floor side panel Rear floor sidemember extension Rear floor sidemember lower Rear floor crossmember upper Rear seat under floor Rear seat belt reinforcement Rear seat belt reinforcement upper Rear seat belt reinforcement lower Rear floor extension Rear floor rear seat under crossmember Front floor crossmember rear Front floor backbone reinforcement Front floor crossmember front Front floor

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67. Front floor side sill inner 68. Front floor sidemember 69. Front floor crossmember rear center 70. Front floor crossmember front 71. Front fender 72. Battery tray stay rear (Left side) 73. Battery tray stay front (Left side) 74. Headlight support panel lower 75. Radiator bracket lower 76. Side outer panel 77. Front fender bracket lower 78. Upper frame to front pillar brace 79. Front deck frame upper outer 80. Side sill reinforcement outer front 81. Side sill reinforcement outer rear 82. Side sill inner support front 83. Front pillar extension outer 84. Front pillar lower reinforcement 85. Front pillar inner lower 86. Front pillar inner center 87. Front upper inner pillar 88. Roof side rail inner 89. Rear wheel house panel inner 90. Rear wheel house panel front lower outer 91. Quarter panel upper inner 92. Rear end panel inner 93. Quarter panel extension lower inner 94. Quarter panel inner 95. Quarter panel extension inner 96. Quarter panel extension upper outer 97. Liftgate pillar reinforcement 98. Rear combination light housing panel 99. Quarter panel extension lower outer 100. Rear pillar reinforcement lower 101. Rear end corner panel 102. Gate pillar reinforcement 103. Roof side rail reinforcement rear 104. Rear pillar reinforcement lower 105. Center pillar reinforcement 106. Rear door hinge reinforcement 107. Rear door hinge reinforcement support 108. Roof side rail reinforcement 109. Center pillar inner lower 110. Center pillar inner upper

1-3

1-4

BODY CONSTRUCTION BODY MAIN CROSS-SECTIONAL VIEWS

BODY MAIN CROSS-SECTIONAL VIEWS A

M4010002001205

B D

C

F

E

A

Roof panel

Roof rail front lower

B

AB800149AB

Roof side rail reinforcement front

Roof side rail reinforcement rear

D

Roof rail front upper

Side outer panel

Quarter inner panel upper

AB601100AC

Side outer panel

AB800344 AB

E

Front end crossmember bulkhead

Roof side rail inner Roof side rail support

C

Rear door hinge reinforcement support

Center pillar reinforcement AB601101AC

Center pillar inner upper Side outer panel

Rear door hinge reinforcement

Center pillar reinforcement AB601102AC

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Front end crossmember upper

F

Front end crossmember lower AB701374AB

Front door hinge reinforcement lower Front pillar inner lower

Front pillar reinforcement lower

Side outer panel AB601103AC

1-5

BODY CONSTRUCTION BODY MAIN CROSS-SECTIONAL VIEWS H G

K

I

J L AB800150AB

G

Roof side rail reinforcement front

Side outer panel

J Side sill reinforcement outer rear

Front upper inner pillar

Side outer panel

AB602354AB

K Rear pillar

H

reinforcement lower

Rear floor side sill inner

Front floor side sill inner AB602356AB

Rear wheel house panel inner

Roof panel

Roof rail rear outer Roof rail rear inner AB701373AB

I Side sill reinforcement outer front

Front pillar inner lower

Side outer panel

Quarter inner panel AB602357AB

L Liftgate striker reinforcement

Rear end inner crossmember Side outer panel

Side sill inner support front AB602355AB

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Rear end crossmember

AB701372AB

1-6

BODY CONSTRUCTION MAINTENANCE, SERVICEABILITY

MAINTENANCE, SERVICEABILITY

M4010003001026

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, front sidemember reinforcement rear and dash panel to improve assembling workability during panel replacement.

AB801225AB

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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

AB701203AB

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1-8

BODY CONSTRUCTION MAINTENANCE, SERVICEABILITY

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

AB701286AB

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1-9

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

BODY CONSTRUCTION CHARACTERISTICS FRONT BODY

M4010010001415

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.

• The 590-MPa class high tensile strength steel panels have been adopted for the front bumper reinforcement to improve the body rigidity.

9.0 ± 2.0 N·m 80 ± 17 in-lb

3

2

3 6

4

8 5 1*

9 10

20 ± 5 N·m 15 ± 3 ft-lb

11

A

10 9

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

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

6 7

Front bumper reinforcement Headlight support panel upper Front end crossmember gusset Front end crossmember upper Nut plate <RALLIART> Radiator bracket lower A Front end crossmember bulkhead Radiator bracket lower B Shipping hook front Shipping reinforcement front Front end crossmember lower

8 AB801206AB

A Crush box

AB801213AB

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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1-10

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

FENDER SHIELD • The front frame structure 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)

7

5

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

8 9

10

6

11 13

4 14 3

12 19

18 16

2

15

20 1 17 21 22

26

25 24 23

AB602313AB

(Left side)

8 7

6

5

9

11 13

4

14

3

29 12

18

2

21

27

1

28

26

30

24 25 AB602314AB

1.

2.

3.

4.

5.

6.

7.

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

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8.

9.

10.

11.

12.

13.

14.

Front fender bracket Front upper frame inner Harness bracket Spring house corner gusset Spring house bracket reinforcement Spring house bracket front Spring house panel rear

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS 15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

Horn bracket 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 Clutch tube bracket <M/T> Engine control module bracket Relay box bracket transaxle mounting gusset

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1-11

1-12

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

FRONT SIDEMEMBER REINFORCEMENT 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.

(Right side)

3 2

23

21

15

4

22

16

5*

24 20

1* 14

6*

10

17 18 19

7

12

11

13

9 8

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

20, 21

20, 22

16

23

4 12

14 15

A

B

6

11 5

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

AB801214 AB

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 Front body frame to side sill brace Tie down reinforcement front Front suspension crossmember bracket front Front sidemember inner

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10 13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

AB801216AB

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 <Except RALLIART> Engine mounting bracket front <RALLIART> Engine mounting bracket rear <RALLIART> Front sidemember brace upper Front sidemember reinforcement rear

1-13

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

A

B

23

19 2 15 20, 21 2

16

12 11 AB602310AF

12

AB602309AI

(Left side)

6

8 7 15

5*

9*

14

3

4*

16

20

17

21

2 18

13 12 1

19

10 11

24 ± 4 N·m NOTE: *: Indicates 590MPa-high-tensile steel panels. 18 ± 2 ft-lb

AB801220 AB

16 15

4

20

6 13 3

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

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 Battery tray stay front

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5 12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

B

A

21

14 AB801221AB

Battery tray stay rear Front suspension crossmember bracket front Front sidemember inner Front sidemember brace upper Transaxle mounting bracket Connecter bracket Headlight support panel Headlight bracket lower Front suspension crossmember bulkhead Transaxle mounting bulkhead

1-14

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

B

A

15

21

7 16 14

14

7 AB602311AD

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13

20 AB602312 AD

1-15

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

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.

• 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 AB602289AB

1.

2.

3.

4.

5.

6.

7.

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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8.

9.

10.

11.

12.

13.

14.

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

1-16

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

DASH PANEL • The front frame structure 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.

• 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.

2.

3.

4.

5.

6.

7.

8.

AB700934AB

9.

10.

11.

12.

13.

14.

15.

16.

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

1-17

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

SIDE BODY

M4010011001311

• The roof rail extension has been adopted to connect the roof side rail inner to the roof rail and the roof bow. The quarter inner gusset upper has also been adopted to connect the quarter inner panel upper to the roof rail rear. This improves rigidity of the body, handling stability, and riding comfort.

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.

15

27

24

16

21 19 20

25 26

14* 5

2

4

12 8*

6* 11

21

10

22

29

30

9

7

1

28

17 18 13

23 64 63

58

52*

60

61

53* 2

59

31 32 33

62

3

66

1 54*

51

35

65

57

55 34

56*

67

50 49 48

42**

47 46 45

44

43** 40 41

39 36

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

1.

2.

3.

4.

5.

Front pillar inner lower Front pillar inner center Hood opener bracket (Left side) Cowl side trim bracket (Right side) Deck crossmember bracket (Right side)

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37

38 6.

7.

8.

9.

10.

11.

AB801212AB

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

1-18

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

12. Roof rail center extension <Vehicles without sunroof> 13. Bracket C <Vehicles with sunroof> 14. Roof side rail inner 15. Harness bracket (Right side) 16. Rear seat striker reinforcement 17. Rear wheel house reinforcement 18. Rear wheel house bulkhead lower 19. Rear wheel house plate 20. Harness bracket (Left side) 21. Rear wheel house panel inner 22. Filler pipe mounting bracket (Left side) 23. Rear wheel house panel front lower outer 24. Quarter inner gusset upper 25. Quarter inner panel upper 26. Nut plate 27. Rear end panel inner 28. Quarter panel extension lower inner 29. Quarter panel inner 30. Quarter panel extension inner 31. Quarter panel extension upper outer 32. Rear combination light housing panel 33. Liftgate pillar reinforcement 34. Quarter panel extension lower outer 35. Fuel filler neck bracket (Left side) 36. Side outer panel 37. Front fender bracket lower 38. Front fender bracket 39. Cowl side trim bracket 40. Front upper outer frame rear 41. Upper frame outer reinforcement <RALLIART> 42. Side sill reinforcement outer rear 43. Side sill reinforcement outer front 44. Side sill inner support front 45. Front pillar outer extension lower 46. Front pillar outer extension upper 47. Front pillar reinforcement lower 48. Front door hinge reinforcement lower 49. Front pillar reinforcement center bulkhead 50. Front door hinge reinforcement upper 51. Deck support pipe (Left side) 52. Front pillar support 53. Roof side rail support 54. Roof side rail reinforcement front 55. Rear door hinge reinforcement support 56. Rear door hinge reinforcement 57. Center pillar reinforcement 58. Roof side rail reinforcement rear 59. Gate pillar reinforcement upper 60. Rear combination light support bulkhead 61. Rear pillar reinforcement lower 62. Rear end corner panel 63. Gate pillar brace 64. Rear pillar reinforcement 65. Flap gate striker reinforcement 66. Nut plate 67. Rear pillar reinforcement lower

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1-19

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.

Gate pillar reinforcement upper 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 AB701303AB

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1-20

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

REAR BODY

M4010012000902

REAR END CROSSMEMBER 7

5.0 ± 2.0 N·m 44 ± 17 in-lb

5 4 6

3 2 1 1.

2.

3.

4.

AB701191AB

5.

6.

7.

Rear bumper bracket Bracket Rear end inner crossmember Liftgate striker reinforcement

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Nut plate Rear end outer crossmember Rear bumper center reinforcement

1-21

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

ROOF

M4010013001641

• 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. <Vehicles without sunroof>

• The 590-MPa class high tensile strength steel panels have been adopted for the roof bow center lower to improve the body rigidity.

6

5

5.5 ± 1.5 N·m 49 ± 13 in-lb

10

8

4 12 3

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

<Vehicles with sunroof>

8

9

11* 5.5 ± 1.5 N·m 49 ± 13 in-lb

7

2

5

1 AB900235AB

6 5.5 ± 1.5 N·m 49 ± 13 in-lb

7 8 13

9 8 4 5.5 ± 1.5 N·m 49 ± 13 in-lb

1 1.

2.

3.

4.

5.

6.

7.

8.

9.

17 16

3 2

1 10.

11.

12.

13.

14.

15.

16.

17.

Sunvisor bracket Map light bracket Roof rail front lower Roof rail front upper Roof panel Roof rack bracket Roof rail rear outer Liftgate hinge reinforcement Roof rail rear inner

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14 15

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

AB701190AC

1-22

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

UNDER BODY

M4010014001398

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 16 1

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

1.

2.

3.

4.

5.

6.

7.

8.

9.

14 15

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 Seat side bracket rear

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12** 13*

10.

11.

12.

13.

14.

11 AB801180AB

Seat belt reinforcement Front floor side sill inner center reinforcement Front floor side sill inner Front floor sidemember Front floor crossmember rear center <Except RALLIART> 15. Front floor crossmember front 16. Front floor crossmember rear center <RALLIART> 17. Front floor reinforcement lower (Right side)

1-23

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

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

7

6 5

4

3

2 8 9 11

10*

13

19

15

11

1*

19

18 ± 7 N·m 13 ± 5 ft-lb

17

14

12

18

16*

17

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

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Rear floor extension Rear seat under floor Rear floor pan rear <Except RALLIART> Rear floor crossmember upper Jack bracket Spare tire bracket Rear floor pan rear <RALLIART> Rear floor rear end crossmember Rear seat bracket Rear floor crossmember front

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11.

12.

13.

14.

15.

16.

17.

18.

19.

Fuel tank rear bracket Rear seat belt reinforcement Rear seat reinforcement upper Rear seat reinforcement lower Rear seat crossmember bulkhead inner Rear seat crossmember Sidemember front floor extension Rear floor sidemember Extension rear floor reinforcement side

AB801181AB

1-24

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.

35 36 9 8 7

3*

10 11

33 5

32

12

6

2 1

34

30

29

4 13*

31

28*

20

27

14

18

15 16

21 19

26

17

25 24 NOTE: *: Indicates 590MPa-high-tensile steel panels.

A

28

29

22*

23

AB801188AB

33

3

13

10 11

22 25

B

32

34

31 21 30 26

27 AB801205AB

1.

2.

3.

4.

5.

Rear floor side panel Rear floor crossmember extension Rear floor sidemember reinforcement Rear floor crossmember extension rear <Except RALLIART> Rear floor crossmember extension rear upper <Except RALLIART>

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6.

7.

Muffler hanger rear Rear floor crossmember extension rear <RALLIART> 8. Rear floor crossmember extension rear upper <RALLIART> 9. Shipping pipe <RALLIART> 10. Shipping bracket reinforcement <RALLIART>

1-25

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS 11. Rear floor sidemember extension bulkhead <Except RALLIART> 12. Canister bracket (Left side) 13. Rear floor sidemember extension 14. Rear bumper support 15. Rear shipping hook reinforcement (Left side) <Except RALLIART> 16. Rear shipping hook (Left side) <Except RALLIART> 17. Rear spring house panel 18. Rear spring house reinforcement 19. Rear spring house bracket 20. Rear floor crossmember extension reinforcement 21. Rear suspension bracket front 22. Rear floor side sill inner 23. Rear brake hose bracket 24. Rear parking brake cable rear bracket 25. Rear floor sidemember lower 26. Rear floor sidemember extension front 27. Rear tie down plate 28. Rear floor sidemember bulkhead 29. Rear floor sidemember reinforcement front A 30. Trailing arm bracket 31. Rear floor sidemember reinforcement front B 32. Rear floor sidemember bulkhead rear 33. Rear suspension bracket rear 34. Pipe nut 35. Hydraulic unit bracket front (Right side) <RALLIART> 36. Hydraulic unit bracket rear (Right side) <RALLIART>

A

B

1

1

3 25

30

22 AB602307AG

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32

19 25

AB701207AD

1-26

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

DOOR

M4010015000741

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.

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 Welded area

12

AB602334AB

19

(Rear door)

23

18

24

21 22

16

20

25 15 17

12

Welded area

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.

27

26 AB602335AB

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

1-27

BODY CONSTRUCTION SILENCER APPLICATION LOCATIONS

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

M4010005002177

NOTE: MD-12 is a high performance sheet composed of asphalt applied with mica and thermosetting resin for improving anti-vibration performance.

<RALLIART and optional item (Except RALLIART)>

;;;;;;;;;;;; ;;;;;;;;;;;; ;;;;;; ;;;; ;;;;;;;;; ;;;;; ;;;;;;;;;; ;;;;;;;;;; NOTE: : 3.2 mm (0.13 in) thick MD-12 [Place two melting sheet one on top of another.] [ ] indicates the number of 1.6 mm (0.06 in) thick melting sheets that are used for repair. <Except RALLIART>

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

AB900013AB

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

NOTE: : 1.6 mm (0.06 in) thick melting sheet : 1.6 mm (0.06 in) thick MD-12 [Place a melting sheet.] [ ] indicates the number of 1.6 mm (0.06 in) thick melting sheets that are used for repair.

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

AB900014AB

1-28

BODY CONSTRUCTION FOAMING MATERIAL USAGE LOCATIONS

FOAMING MATERIAL USAGE LOCATIONS 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.

The sound dampening foam material have been adopted to the upper and lower sections of the front pillar, center pillar lower section, gate pillar section, the wheel house arch, the rear combination light housing and rear end panel inner inside to shield from external noise.

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M4010006000174

BODY CONSTRUCTION FOAMING MATERIAL USAGE LOCATIONS

1-29

Sound dampening foam material

Sound dampening foam material <RALLIART> Sound dampening foam material

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AB801001AB

1-30

BODY CONSTRUCTION STIFFENER APPLICATION LOCATIONS

STIFFENER APPLICATION LOCATIONS Stiffeners have been adhered on the inner side of the side outer panel for higher surface rigidity.

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.

M4010008000482

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

Stiffener (Right side only) AB800505AB

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2-1

GROUP 2

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

2-2

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

2-8

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

2-8

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

2-3

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

2-10

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

2-3

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

2-13

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

2-16

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

2-18

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

2-20

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

2-5

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 outer panel 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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2-3

BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS)

TYPE A (PROJECTED DIMENSIONS) UNDER BODY 76 (3.0)

M4020005002253

mm (in) 616 (24.3)

462 (18.2)

540 (21.3)

2 967 (38.1)

624 (24.6)

910 (35.8)

7

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

4

3

76 (3.0)

667 (26.3)

510 (20.1)

960 (37.8)

1

833 (32.8)

1,262 (49.7)

6

9

350 (13.8)

440 (17.3)

10

344 (13.5)

375 (14.8)

763 (30.0)

1,218 (48.0)

7

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

6

1,394 (54.9)

3

11

545 (21.5)

12

13

1,138 (44.8)

1,120 (44.1)

1

393 (15.5)

Center line of the vehicle

2

964 (38.0)

990 (39.0)

AB701316AB

1,079 (42.5)

969 (38.1)

877 (34.5) 1,022 (40.2)

894 (35.2)

8

1,050 (41.3)

616 (24.3)

894 (35.2)

5

929 (36.6)

718 (28.3)

641 960 (25.2) (37.8)

1,195 (47.0)

1,025 (40.4)

1,369 (53.9)

1,342 (52.8)

1,080 (42.5)

544 1,254 (21.4) (49.4) 1,117 (44.0)

4

8

5

9

686 (27.0)

11

12

13

10 AB701318AB

Center line of the vehicle

No. Standard measurement point

Hole shape

Size mm (in)

1

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

Round

8.0 (0.31)

2

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

8.0 (0.31)

3*

Center of front sidemember inner positioning hole

Round

25.0 (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 (0.63)

6

Center of front floor backbone brace mounting hole (left side) <Except Round RALLIART>, Center of propeller shaft mounting hole (left side) <RALLIART>

11.0 (0.43)

7

Center of front floor backbone brace mounting hole (right side) <Except RALLIART>, Center of propeller shaft mounting hole (right side) <RALLIART>

11.0 (0.43)

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Round

2-4

BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm (in)

8*

Center of front floor sidemember positioning hole (front)

Round

16.0 (0.63)

9*

Center of front floor sidemember positioning hole (rear)

Round

16.0 (0.63)

10*

Center of rear floor sidemember lower positioning hole (front)

Oblong

33.9× 18.0 (1.33× 0.71)

11*

Center of rear suspension bracket front water draining hole

Round

16.0 (0.63)

12*

Center of rear floor sidemember lower positioning hole (rear)

Round

25.0 (0.98)

13*

Center of rear floor sidemember extension water draining hole

Round

14.0 (0.55)

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

486 (19.1)

1 2

3

4

294 (11.6)

11

7 5

6

100 (3.9)

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

347 (13.7) 280 (11.0)

230 (9.1)

510 (20.1)

8

9

13

10 105 (4.1)

350 (13.8)

12

286 (11.3)

154 (6.1)

354 (13.9)

357 (14.1)

716 (28.2) 291 (11.5)

1,049 (41.3)

715 (28.1) 1,101 (43.3)

1,125 (44.3)

1,644 (64.7)

Standard line

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

1, 3

2

1

AB701336AB

4

3 AB600994AB

6, 7

5

AB600996AB

AB600995AB

8, 9

6

8

7 9 AB600999AB

AB600998 AB

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AB601000AB

2-5

BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS)

11

10

12

AB601006AB

AB601001AB

AB601002AB

13

AB701338AC

SUSPENSION INSTALLATION DIMENSIONS

M4020013001954

mm (in)

787 (31.0)

510 (20.1)

695 (27.4)

570 (22.4)

1,132 (44.6) 910 (35.8)

289 (11.4)

1,288 (50.7)

886 (34.9) 875 (34.4)

894 (35.2)

5

4

9

15

1,000 (39.4) 1,092 (43.0)

254 (10.0) 544 (21.4)

14

17 16

293 217 (11.5) (8.5) Center line of the vehicle

98 (3.9)

903 (35.6) 1,093 (43.0)

441 (17.4)

18

20 19

714 (28.1) AB701332 AB

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2-6

BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS)

1,128 (44.4)

945 (37.2)

1,215 (47.8)

907 (35.7)

1,171 (46.1)

1,028 (40.5)

4 15

5

1,212 (47.7)

1,230 (48.4)

9

17

14

1,048 (41.3)

1,294 (50.9)

18

16

20 19

1,076 (42.4)

Center line of the vehicle

AB701334AB

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 (0.63)

9

Center of front floor sidemember positioning hole (rear)

Round

16.0 (0.63)

14

Center of front shock absorber mounting hole

Round

80.0 (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

14.0 (0.55)

17

Center of trailing arm mounting hole (inner side)

Round

14.0 (0.55)

18

Center of rear suspension crossmember mounting hole (front)

Round

15.0 (0.59)

19

Center of rear shock absorber mounting hole

Round

64.0 (2.52)

20

Center of rear suspension crossmember mounting hole (rear)

Round

15.0 (0.59)

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2-7

BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS) A

B Vehicle center

Vehicle center

6˚30´

6˚54´

540 (21.3) 3˚06´ A

mm (in) 1,087 (42.8)

14

B

16 17

4 15

767 (30.2) 294 (11.6)

Standard line

5

162 (6.4)

18 20

9 222 284 (8.7) (11.2)

105 (4.1)

100 (3.9)

1,066 (42.0)

217 (8.5) 510 (20.1)

19 0˚

462 354 (18.2) (13.9)

535 (21.1) 785 (30.9) 1,223 (48.1)

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

9

5

4

AB600996AB

14

AB701337AB

AB600998 AB

15

AB601180AB

16, 17

16 17

AB601004AB

AB601181AB

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AB601008AB

2-8

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

20

19

18

AB601007AB

AB601005AB

AB601182AB

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) UNDER BODY

M4020005002264

mm (in) 856 (33.7)

616 (24.3)

102 (4.0)

542 (21.3)

2

669 (26.3)

546 (21.5) 644 (25.4)

967 (38.1) 910 (35.8)

875 (34.4)

960 (37.8)

1

4

894 894 1,262 7 (35.2) (35.2) (49.7) 6

222 (8.7)

378 (14.9)

5

350 (13.8)

8

101 (4.0)

1,022 (40.2)

877 (34.5)

399 (15.7) 460 12 (18.1) 11

9

990 (39.0)

545 (21.5)

13

10

1,079 (42.5)

616 (24.3)

932 (36.7)

487 (19.2)

567 (22.3)

3

740 (29.1)

348 (13.7) AB701317AB

1,081 (42.6)

1,255 (49.4)

1,138 (44.8)

2 971 (38.2)

7

1,120 (44.1)

1,124 (44.3)

1,225 (48.2) 643 (25.3)

765 (30.1)

1,415 1,046 (55.7) (41.2)

566

966 (38.0)

6 (22.3) 1 3

4

8

5 704 (27.7)

1,209 (47.6) 960 (37.8)

1,027 (40.4)

1,371 (54.0) 1,080 (42.5)

1,357 (53.4)

1,118 (44.0)

9

11

12

13

10 AB701319AB

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2-9

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 (0.31)

2

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

8.0 (0.31)

3

Center of front sidemember inner positioning hole

Round

25.0 (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 (0.63)

6

Center of front floor backbone brace mounting hole (left side) <Except Round RALLIART>, Center of propeller shaft mounting hole (left side) <RALLIART>

11.0 (0.43)

7

Center of front floor backbone brace mounting hole (right side) <Except RALLIART>, Center of propeller shaft mounting hole (right side) <RALLIART>

Round

11.0 (0.43)

8

Center of front floor sidemember positioning hole (front)

Round

16.0 (0.63)

9

Center of front floor sidemember positioning hole (rear)

Round

16.0 (0.63)

10

Center of rear floor sidemember lower positioning hole (front)

Oblong

33.9× 18.0 (1.33× 0.71)

11

Center of rear suspension bracket front water draining hole

Round

16.0 (0.63)

12

Center of rear floor sidemember lower positioning hole (rear)

Round

25.0 (0.98)

13

Center of rear floor sidemember extension water draining hole

Round

14.0 (0.55)

1, 3

2

1

4

3 AB600994AB

6, 7

5

AB600996AB

AB600995AB

8, 9

6

8

7 9 AB600999AB

AB600998 AB

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AB601000AB

2-10

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

11

10

12

AB601006AB

AB601001AB

AB601002AB

13

AB701338AC

SUSPENSION INSTALLATION DIMENSIONS

M4020013001965

mm (in)

807 (31.8)

546 (21.5)

707 (27.8)

582 (22.9)

910 (35.8)

4

875 (34.4)

15 322 (12.7)

295 (11.6)

1,288 (50.7)

886 (34.9)

5

226 (8.9)

1,092 1,000 (43.0) (39.4)

894 (35.2)

9

903 (35.6)

446 (17.6)

17

557 (21.9)

98 (3.9)

18 20

16

262 727 (10.3) (28.6) AB701333AB

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2-11

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

1,221 (48.1) 1,134 (44.6)

954 (37.6)

1,243 (48.9)

909 (35.8)

4

1,300 (51.2)

1,173 (46.2)

1,046 (41.2)

15

5

17

9

1,050 (41.3)

1,219 (48.0)

20

18

16

1,077 (42.4) AB701335AB

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 (0.63)

9

Center of front floor sidemember positioning hole (rear)

Round

16.0 (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

14.0 (0.55)

17

Center of trailing arm mounting hole (inner side)

Round

14.0 (0.55)

18

Center of rear suspension crossmember mounting hole (front)

Round

15.0 (0.59)

20

Center of rear suspension crossmember mounting hole (rear)

Round

15.0 (0.59)

9

5

4

AB600996AB

15

AB600998 AB

16, 17

AB601180AB

18

16 17

AB601008AB

AB601181AB

TSB Revision

AB601182AB

2-12

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

20

AB601007AB

TSB Revision

2-13

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

FRONT BODY

M4020006001349

mm (in)

1,106 (43.5)

39 Body center point 40 994 (39.1)

1,174 (46.2)

509 (20.0)

1,630 (64.2)

1,508 (59.4)

37

1,438 (56.6)

394 (15.5)

33

1,494 (58.8)

913 (35.9)

327 (12.9) 29

27

30

1,060 (41.7)

391 (15.4)

401 (15.8)

31

891 (35.1)

26

35 34

877 (34.5)

901 (35.5)

425 (16.7)

36

1,485 (58.5)

901 (35.5)

32

38

1,486 (58.5)

1,072 (42.2)

28 329 (13.0)

25

336 (13.2)

392 (15.4)

23

24

22

Body center point 21

781 (30.7)

37

855 (33.7) 822 (32.4)

810 (31.9) 896 (35.3)

36

1,458 (57.4)

33

1,449 (57.0)

38

732 (28.8)

1,558 (61.3)

864 (34.0)

819 (32.2)

32 29

35 34

31 27

26

1,032 (40.6)

1,042 (41.0)

25

713 (28.1)

23 Body center point 21

TSB Revision

30 28

714 (28.1)

24 22 AB600979AD

2-14

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) mm (in)

37

601 (23.7) 857 (33.7)

555 (21.9)

873 (34.4)

33

937 (36.9) 980 (38.6)

29 27 549 26

831 (32.7)

953 (37.5)

32

(21.6)

341 (13.4)

36

860 (33.9)

31

774 (30.5) 544 (21.4)

35 34

28 25 24

23 Body center point 21

38

30

1,026 (40.4) 782 (30.8)

1,556 (61.3)

22 AB601191AD

No. Standard measurement point

Hole shape

Size mm (in)

21

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

−

−

22

Center of charge air cooler bracket mounting hole (left side)

Round

12.0 (0.47)

23

Center of charge air cooler bracket mounting hole (right side)

Round

12.0 (0.47)

24

Center of front bumper reinforcement mounting hole (left-lower)

Round

9.0 (0.35)

25

Center of front bumper reinforcement mounting hole (left-upper)

Round

9.0 (0.35)

26

Center of front bumper reinforcement mounting hole (right-lower)

Round

9.0 (0.35)

27

Center of front bumper reinforcement mounting hole (right-upper)

Round

9.0 (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 (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 (0.35)

39

Center of roof panel positioning notch (Body center point)

−

−

40

Corner of roof panel

−

−

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2-15

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 AB601018 AB

AB700435 AB

30, 31

32, 33

AB601019 AB

34, 35

31

35

33

34

30

32 AB601016 AB

37

36

AB601020 AB

AB700438 AB

38

AB601022AD

AB601021 AB

TSB Revision

AB801273 AB

2-16

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

40

39

AB601024 AB

AB601235 AB

SIDE BODY

M4020007001159

mm (in)

43

47

41

45 762 970 (30.0) (38.2) 1,044 1,159 863 (45.6) 867 (41.1) (34.0) (34.1) 657 713 635 (25.9) (28.1) (25.0) 1,290 1,076 (50.8) (42.4) 822 775 42 50 (32.4) (30.5)

49

46

44

48 AB701237AB

43 1,049 (41.3)

51 1,106 364 (43.5) (14.3)

1,096 (43.1)

47

640 (25.2)

53 1,176 355 (46.3) (14.0)

1,072 (42.2)

52

781 (30.7) 835 (32.9)

55

54

AB701238AB

No. Standard measurement point

Hole shape

Size mm (in)

41

Front pillar positioning notch (upper)

−

−

42

Front pillar positioning notch (lower)

−

−

43

Roof side rail positioning notch (front)

−

−

44

Side sill positioning notch (front)

−

−

45

Center pillar positioning notch (upper)

−

−

46

Center pillar positioning notch (lower)

−

−

47

Roof side rail positioning notch (rear)

−

−

48

Side sill positioning notch (rear)

−

−

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2-17

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm (in)

49

Quarter panel positioning notch (upper)

−

−

50

Quarter panel positioning notch (lower)

−

−

51

Center of front door upper hinge mounting hole

Round

11.0 (0.43)

52

Center of front door lower hinge mounting hole

Round

11.0 (0.43)

53

Center of rear door upper hinge mounting hole

Round

11.5 (0.45)

54

Center of rear door lower hinge mounting hole

Round

11.0 (0.43)

55

Center of rear door switch mounting hole

Round

5.0 (0.20)

41

43, 45

42, 52 42 52

43

45 AB801255AB

AB601025AB

44

46, 54 46

47 54

AB601030AB

AB601028AB

49

48

AB601027AB

AB601031AB

50, 55 55

50

AB800346 AB

AB601032AB

TSB Revision

AB601034AB

2-18

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

53

51

AB801254AB

AB601029AB

REAR BODY

M4020008001174

mm (in)

56 Body center point 57

726 (28.6) 591 (23.3)

58

1,103 (43.4) 1,094 (43.1)

1,351 (53.2)

935 (36.8)

1,278 (50.3)

796 (31.3)

1,361 1,288 (53.6) (50.7) 1,311 (51.6) 1,106 (43.5)

1,125 (44.3)

59 60

1,103 (43.4)

61 1,176 (46.3)

62 1,339 (52.7)

63 704 (27.7)

1,100 (43.3)

407 (16.0)

64 990 (39.0)

65 66 AB800151AB

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2-19

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

1,366 (53.8)

59 60

1,117 (44.0)

61 62

1,313 (51.7)

1,108 (43.6)

609 63 (24.0)

64

117 (4.6)

1,050 (41.3)

65 66 AB800375AB

No. Standard measurement point

Hole shape

Size mm (in)

56

Body center point of roof panel

−

−

57

Center of liftgate hinge mounting hole

Round

13.0 (0.51)

58

Center of liftgate gas spring mounting hole

Round

9.3 (0.37)

59

Corner of side outer panel

−

−

60

Center of rear combination light mounting hole

Round

9.0 (0.35)

61

Center of rear bumper mounting hole

Round

6.6 (0.26)

62

Center of liftgate dumper mounting hole (upper)

Round

6.6 (0.26)

63

Center of liftgate dumper mounting hole (lower)

Round

6.6 (0.26)

64

Center of liftgate striker mounting hole

Round

14.0 (0.55)

65

Center of rear bumper reinforcement mounting hole (upper)

Round (left side), Oblong (right side)

15.0 (0.59)(left side), 15.0 (0.59)× 17.0 (0.67)(right side)

66

Center of rear bumper reinforcement mounting hole

Round

15.0 (0.59)

56

57, 58

59, 60

57

60 59 58

AB701304 AB

AB701305AB

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AB701306AB

2-20

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

61, 62, 63

64

65, 66

61 62

65

63 66 AB701310AB

AB701308 AB

AB701307AB

INTERIOR

M4020009001423

mm (in) 1,190 (46.9) 1,375 43 (54.1)

1,357 (53.4)

41

1,171 (46.1)

1,330 (52.4)

49

45

1,430 (56.3)

1,430 (56.3)

1,430 (56.3)

47

50

1,430

46 (56.3)

1,430

48

42 (56.3) 44

AB800152AB

47

43 67 Body center point

1,135 (44.7)

1,180 (46.5)

42

49

1,130

41

1,190 (46.9)

1,059 (41.7) 735 (28.9)

1,073 (42.2)

45 (44.5)

720

783 (30.8)

Body center point 68

50

46 (28.3) 48

44 834 (32.8)

TSB Revision

AB800378AB

2-21

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) Body center point 68 1,040 (40.9) 1,093 (43.0)

665 (26.2) 1,091 (43.0)

69

685 (27.0)

70

AB800376AB

No. Standard measurement point

Hole shape

Size mm (in)

41

Front pillar positioning notch (upper)

−

−

42

Front pillar positioning notch (lower)

−

−

43

Roof side rail positioning notch (front)

−

−

44

Side sill positioning notch (front)

−

−

45

Center pillar positioning notch (upper)

−

−

46

Center pillar positioning notch (lower)

−

−

47

Roof side rail positioning notch (rear)

−

−

48

Side sill positioning notch (rear)

−

−

49

Quarter panel positioning notch (upper)

−

−

50

Quarter panel positioning notch (lower)

−

−

67

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

Round

11.0 (0.43)

68

Body Center point of rear floor extension (Body center point)

−

−

69

Center of rear shock absorber mounting hole

Round

14.0 (0.55)

70

Center of trunk room rear end trim mounting hole

Round

8.5 (0.33)

41

43, 45

42

43

45 AB801256 AB

AB601025AB

TSB Revision

AB601027AB

2-22

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

44

46

AB601028AB

47

AB601030AB

49

48

50

AB800346 AB

AB601032AB

68

67

AB601031AB

69

AB601064 AD

AB601063AE

70

AB701311AB

TSB Revision

AB601034AB

AB701309AB

2-23

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

mm (in) 1,397 (55.0)

71

1,401 (55.2)

73

1,392 (54.8)

140 (5.5)

130 (5.1)

1,392 (54.8)

72

74

AB600984AG

No. Standard measurement point

Hole shape

Size mm (in)

71

Center of front deck crossmember mounting hole (left-upper)

Round

13.0 (0.51)

72

Center of front deck crossmember mounting hole (left-lower)

Round

13.0 (0.51)

73

Center of front deck crossmember mounting hole (right-upper)

Round

9.0 (0.35)

74

Center of front deck crossmember mounting hole (right-lower)

Round

9.0 (0.35)

71, 72

73, 74

71

73

72

74

AB601066AD

AB601067AD

TSB Revision

NOTES

3-1

GROUP 3

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

3-2

FRONT END CROSSMEMBER . . . . .

3-3

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

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

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

3-41

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

3-42

QUARTER INNER LOWER . . . . . . . .

3-47

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

3-49 3-50

3-4 3-8

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

3-9

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

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

3-16

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

3-51

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

3-21

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

3-52

ALUMINUM PANEL <RALLIART>. . .

3-53

ALUMINUM PANEL CHARACTERISTICS .

3-53

ALUMINUM PANEL LOCATIONS . . . . . . . .

3-53

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

3-54

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

3-60

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

3-25

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

3-30

REAR END CROSSMEMBER . . . . . .

3-34

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

3-38

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. The following tools are recommended.

TSB Revision

M4030002800307

• Drill bit, spot weld cutter (8) (Tool number: MB992621) • 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 (0.3 inch) diameter plug for repair ensures the strength equivalent to spot welding for 2 steel sheets. For 3 sheets, weld 2 sheets each time from both sides instead of welding from one side to give sufficient welding strength.

3-3

WELDED PANEL REPLACEMENT FRONT END CROSSMEMBER

FRONT END CROSSMEMBER Symbol

M4030003100312

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.)

AB800380AB

REPAIR WELDS

A

B

A

B

TSB Revision

AB800455AB

3-4

WELDED PANEL REPLACEMENT FENDER SHIELD

FENDER SHIELD Symbol

M4030004001463

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.)

AB800381AB

REPAIR WELDS <Except RALLIART>

<RALLIART>

A

A Except RALLIART

A AB800279 AB

NOTE: Refer to the Front End Crossmember section on P.3-3 for the welding point with headlight support panel lower.

TSB Revision

3-5

WELDED PANEL REPLACEMENT FENDER SHIELD

B

B

<RALLIART>

<Except RALLIART> G B

F I

H

C Except RALLIART

D

E

C AB801250 AC

TSB Revision

3-6

WELDED PANEL REPLACEMENT FENDER SHIELD AB601414

D (With the front deck frame upper outer and fender shield frame upper outer removed)

E

Except RALLIART

F

G

H

H

(Right side)

(Left side)

I AB801329AC

TSB Revision

WELDED PANEL REPLACEMENT FENDER SHIELD

3-7

NOTE: Partial replacement of the fender shield frame upper outer 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 (1.0 inches) forward of the positioning hole center.

Front upper frame inner 25 mm (1.0 in)

152 mm (6.0 in) Fender shield frame upper outer

AB601431AC

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.

Front sidemember outer Front body frame to side sill brace AB601422 AE .

INSTALLATION When installing the new front sidemember parts, align the hole of the front body frame to side sill brace with the front sidemember to make a hole because the front sidemember outer prevents the front sidemember inner and front body frame to side sill brace from being welded. Then, weld the front sidemember outer, front sidemember inner, and front body frame to side sill brace.

Front sidemember outer

Front sidemember inner AB601423AD

TSB Revision

3-8

WELDED PANEL REPLACEMENT FRONT SIDEMEMBER (PARTIAL REPLACEMENT)

FRONT SIDEMEMBER (PARTIAL REPLACEMENT)

M4030000100829

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

AB800382AB

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

REPAIR WELDS (Left side)

(Right side)

A B

315 mm (12.4 in)

275 mm (10.8 in) Engine room side cover mounting hole

135 mm (5.3 in)

210 mm (8.3 in) B

A

AB601532AB

NOTE: .

• Refer to the Front End Crossmember section on P.3-3 for the welding point with the headlight support panel lower.

• Refer to the Fender Shield section on P.3-4 for the welding points with the headlight support panel, front fender gusset and front fender shield.

TSB Revision

3-9

WELDED PANEL REPLACEMENT FRONT PILLAR

FRONT PILLAR

M4030005002005

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

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.)

AB800383AB

REPAIR WELDS

H

A

Cutting position A

40 mm (1.6 in)

B

Sound dampening foam material

B

G

230 mm (9.1 in)

I

D

Cutting position Sound dampening foam material

E

C

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

C

AB601387AB

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.

TSB Revision

3-10

WELDED PANEL REPLACEMENT FRONT PILLAR

Cutting position

F

Cutting position

D

F

E

Sound dampening foam material

H

(With the side outer panel removed) Sound dampening foam material

Cutting position

G

I

(With the side outer panel removed) AB900234 AB

TSB Revision

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 (5.5 in)

Front pillar inner lower

Side sill inner support front

Side outer panel Side sill reinforcement outer front

AB601206AG .

INSTALLATION 1. To reinforce the strength in the front pillar cut area, cut the side outer panel 50 mm (2.0 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 lower inner pillar parts.

3. Assemble the new front upper inner pillar part.

Side outer panel 50 mm (2.0 in)

Front upper inner pillar Front pillar support

100 mm (3.9 in)

Roof side rail reinforcement AB601213AF

Side sill reinforcement outer front

Aluminum tape

4. Assemble the new side sill reinforcement outer 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.

AB601208AE

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3-12

WELDED PANEL REPLACEMENT FRONT PILLAR

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.

A

50 mm (2.0 in)

20 mm (0.8 in)

40 mm (1.6 in)

Front pillar lower reinforcement

A NOTE: : Body loose panel cushion

Front pillar inner upper AB601297AB AB601297

Front pillar outer extension upper

Front pillar outer extension lower

6. When installing the new front pillar reinforcement lower inner is installed, remove the front pillar outer extension lower and front pillar outer extension upper in advance, and install the front pillar lower reinforcement because there are some points which cannot be welded on the body side. After that, install the front pillar outer extension lower and front pillar outer extension upper.

7. When installing the new front outer pillar parts, perform the following procedures.

AB601220AB

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WELDED PANEL REPLACEMENT FRONT PILLAR 65 mm (2.6 in)

20 mm (0.8 in)

35 mm (1.4 in)

25 mm (1.0 in)

3-13

(1) 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).

15 mm (0.6 in) A

Side outer panel

Front pillar lower reinforcement A NOTE: : Body loose panel cushion

10 mm (0.4 in)

30 mm (1.2 in)

80 mm (3.1 in)

AB602360AB

35 mm (1.4 in) 90 mm (3.5 in)

(2) 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 (for front pillar lower).

B

110 mm (4.3 in)

Front pillar reinforcement lower

B Side outer panel NOTE: : Body loose panel cushion AB601245AB

TSB Revision

3-14

WELDED PANEL REPLACEMENT FRONT PILLAR

(3) Apply the body sealant to the areas as shown in advance.

8. After installing the front pillar outer, perform the following procedures.

NOTE: : Body sealant

AB601221AB

(1) Seal the hole and flange with bolts and 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 Part No.08463

A AB601214

Front pillar lower reinforcement

Front pillar inner lower A NOTE: : Sound dampening foam material

AB601246AB

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WELDED PANEL REPLACEMENT FRONT PILLAR

3-15

(2) Apply the body sealant to close the hole of the side outer panel shown in the figure.

NOTE: : Body sealant

AB900056 AB

9. 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

TSB Revision

3-16

WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT)

FRONT PILLAR (PARTIAL REPLACEMENT)

M4030001200108

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

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.)

AB801207AB

REPAIR WELDS

110 mm (4.3 in)

Cutting position

B Sound dampening foam material

A 230 mm (9.1 in)

G

D

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

B

Cutting position

A

C AB601401AE

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.

TSB Revision

3-17

WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT)

Cutting position

F

D E

Cutting position F

G

(With the side outer panel removed) AB601448AB

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 pillar inner lower remaining on the body side.

140 mm (5.5 in)

Side sill inner support front

Side outer panel Side sill reinforcement outer front

AB601206AG .

TSB Revision

3-18

WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT)

INSTALLATION Side outer panel

1. To reinforce the strength in the front pillar cut area, cut the side outer panel 50 mm (2.0 inches) above the cut area.

2. Assemble the new front inner lower pillar parts.

50 mm (2.0 in)

AB601207AB

Side sill reinforcement outer front

Aluminum tape

3. Assemble the new side sill reinforcement outer 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.

AB601208AE

Front pillar outer extension upper

Front pillar outer extension lower

4. When installing the new front pillar reinforcement lower inner is installed, remove the front pillar outer extension lower and front pillar outer extension upper in advance, and install the front pillar lower reinforcement because there are some points which cannot be welded on the body side. After that, install the front pillar outer extension lower and front pillar outer extension upper.

5. When installing the new front outer pillar parts, perform the following procedures.

AB601220AB

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WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT)

10 mm (0.4 in)

30 mm (1.2 in)

80 mm (3.1 in)

35 mm (1.4 in) 90 mm (3.5 in)

3-19

(1) 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.

B

110 mm (4.3 in)

Front pillar reinforcement lower

B Side outer panel NOTE: : Body loose panel cushion AB601245AB

(2) Apply the body sealant to the areas as shown in advance.

6. After installing the front outer pillar, perform the following procedures.

NOTE : : Body sealant

AB601450AC

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3-20

WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT)

(1) Seal the hole and flange with bolts and 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 Part No.08463

A

Front pillar reinforcement lower

Front inner A pillar lower NOTE : : Sound dampening foam material

AB601590AC

(2) Apply the body sealant to close the hole of the side outer panel shown in the figure.

NOTE: : Body sealant

AB900056 AB

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.

AB100787

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3-21

WELDED PANEL REPLACEMENT CENTER PILLAR

CENTER PILLAR

M4030006001191

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

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.)

AB800384AB

REPAIR WELDS 190 mm (7.5 in)

A

Cutting position

Sound dampening foam material

A

B

B

The same position as the new center outer pillar part

The same position as the new center outer pillar part

C

Sound dampening foam material

C

D

D

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AB601417 AD

3-22

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.

Center pillar inner upper AB800421AB .

INSTALLATION

Center pillar reinforcement 50 mm (2.0 in)

Side outer panel

1. To reinforce the strength in the center pillar cut area, cut the side outer panel 100 mm (3.9 inches) above the cut area and cut the center pillar reinforcement 50 mm (2.0 inches) above the cut area.

100 mm (3.9 in)

AB601248 AE

Center pillar inner lower

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

AB601249AB

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WELDED PANEL REPLACEMENT CENTER PILLAR

Rear door hinge reinforcement 50 mm (2.0 in)

100 mm (3.9 in)

3-23

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 (3.9 inches) below from the cut area to create a cover, and then cut the rear door hinge reinforcement 50 mm (2.0 inches) below from the cut area.

Center pillar reinforcement AB601250 AD

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 (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)

5. When installing the new center outer pillar part, 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

Side outer NOTE : panel AB601310AD : Body loose panel cushion

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3-24

WELDED PANEL REPLACEMENT CENTER PILLAR

6. After installing the center outer pillar, seal the hole and flange with bolts and 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 Part No.08463 A

Center pillar reinforcement

A

Side sill reinforcement outer rear NOTE: : Sound dampening foam material

AB601255AE

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.

AB100787

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3-25

WELDED PANEL REPLACEMENT SIDE SILL

SIDE SILL

M4030007001581

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

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.)

AB800385AB

Sound dampening foam material

REPAIR WELDS

65 mm (2.6 in) 50 mm (2.0 in)

B

A

40 mm (1.6 in) C

Sound dampening foam material

Sound dampening foam material

B

A

C

AB601516 AD

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3-26

WELDED PANEL REPLACEMENT SIDE SILL

D

Sound dampening foam material

(With the side outer panel removed)

D

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AB601517AB

WELDED PANEL REPLACEMENT SIDE SILL

3-27

NOTE ON REPAIR WORK .

REMOVAL 1. When installing the side sill reinforcement outer rear, cut the center pillar reinforcement 80 mm (3.1inches) 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 front lower outer and quarter panel extension inner because the quarter panel extension inner interferes with the rear wheel house front lower outer.

80 mm (3.1in)

Center pillar reinforcement

Rear wheel house panel front lower outer

Quarter panel extension inner

AB800410AB

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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3-28

WELDED PANEL REPLACEMENT SIDE SILL

INSTALLATION 1. Remove the center pillar inner upper from the new center inner pillar parts, 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.

3. When installing the new front floor side sill outer parts, perform the following procedures.

Side sill reinforcement outer front

AB601309AB

10 mm (0.4 in)

30 mm (1.2 in)

80 mm (3.1 in)

35 mm (1.4 in) 90 mm (3.5 in)

(1) 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.

B

110 mm (4.3 in)

Front pillar reinforcement lower

B Side outer panel NOTE: : Body loose panel cushion AB601245AB

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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)

3-29

(2) 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.

4. After installing the front floor side sill outer, perform the following procedures.

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

450 mm (17.7 in)

A

Center pillar reinforcement

A

Side outer NOTE : panel AB601310AD : Body loose panel cushion

(1) Seal the hole and flange with bolts and 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 Part No.08463

A

Center pillar reinforcement

A

Side sill reinforcement outer rear NOTE: : Sound dampening foam material

AB601255AE

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3-30

WELDED PANEL REPLACEMENT QUARTER OUTER

(2) Apply the body sealant to close the hole of the side outer panel shown in the figure.

NOTE: : Body sealant

AB900056 AB

5. 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

QUARTER OUTER

M4030008001197

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

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

AB800341AB

TSB Revision

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

3-31

WELDED PANEL REPLACEMENT QUARTER OUTER

REPAIR WELDS

B

Sound dampening foam material

3 points on left side only

C

300 mm (11.8 in)

Sound dampening foam material

D

35mm (1.4 in)

A

A

TSB Revision

B

AB800294AB

3-32

WELDED PANEL REPLACEMENT QUARTER OUTER

100 mm (3.9 in)

D (Left side)

C RALLIART D (Right side) AB800296AB .

Left side only

NOTE: : Cuttable range

NOTE: Partial replacement is possible depending on the range of damage.

AB800408AB

NOTE ON REPAIR WORK .

INSTALLATION When installing the new quarter panel outer parts, perform the following procedures.

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WELDED PANEL REPLACEMENT QUARTER OUTER

1. 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 gate pillar.

30 mm (1.2 in) 80 mm (3.1 in)

45 mm (1.8 in)

3-33

70 mm (2.8 in) 100 mm (3.9 in) A

30 mm (1.2 in)

Quarter panel extension upper outer

Side outer panel

Roof side rail reinforcement rear A NOTE: : Body loose panel cushion

AB800406AB

2. 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.

185 mm (7.3 in) 30 mm (1.2 in)

40 mm (1.6 in) A

Rear pillar reinforcement lower

Quarter inner panel

Side outer panel A NOTE: : Body loose panel cushion

AB601328AB

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3-34

WELDED PANEL REPLACEMENT REAR END CROSSMEMBER

3. Apply the body sealant in advance to the areas as shown.

Left side only

NOTE: : Body sealant

AB800407AB

REAR END CROSSMEMBER

M4030015000680

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

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

AB800339AB

TSB Revision

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

WELDED PANEL REPLACEMENT REAR END CROSSMEMBER

3-35

REPAIR WELDS Sound dampening foam material for RALLIART only

Sound dampening foam material

Sound dampening foam material

A

Left side only

A AB801204 AB

NOTE ON REPAIR WORK .

REMOVAL

Quarter panel extension lower outer

When removing the rear end panel, remove the following parts because they interfere with the rear end panel.

• Quarter panel extension lower outer • Rear pillar reinforcement lower • Rear end panel inner 1. Remove the quarter panel extension lower outer.

AB800166AB

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3-36

WELDED PANEL REPLACEMENT REAR END CROSSMEMBER

2. When removing the rear pillar reinforcement lower, cut the side outer panel as shown in the figure because the welding points with the gate pillar reinforcement upper are hidden by the side outer panel. Then, fold and turn up the side outer panel 25 mm (1.0 inches) forward from the rear ventilation duct mounting hole.

Cutting position Folding position

Cutting position

25 mm (1.0 in)

Side outer panel Rear pillar reinforcement lower

AB800275AB

3. Remove the rear end panel inner.

Rear end panel inner

AB800271

4. Pull out the rear end panel to the left.

AB800272AB

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WELDED PANEL REPLACEMENT REAR END CROSSMEMBER

3-37

NOTE ON REPAIR WORK .

INSTALLATION 1. When installing the new rear pillar reinforcement lower, in order to prevent the dripping of sound dampening foam material to be filled into the rear end panel inner in the next process, install the rear end side silencer to the rear pillar reinforcement lower, and then apply the butyl-tape to close the hole and gap of rear end side silencer.<RALLIART>

Rear end side silencer <RALLIART>

AB800891AB

2. After installing the quarter panel extension lower outer, seal the hole and flange with bolts and 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 Part No.08463

A

B C

RALLIART only Rear end panel inner

Rear pillar reinforcement lower

Rear end panel inner A

Rear end corner panel B

Rear end panel inner

Rear pillar reinforcement lower C <RALLIART> NOTE: : Sound dampening foam material

AB800912 AB

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3-38

WELDED PANEL REPLACEMENT REAR FLOOR

3. 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

REAR FLOOR Symbol

M4030010001105

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

AB800340AB

TSB Revision

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

3-39

WELDED PANEL REPLACEMENT REAR FLOOR

REPAIR WELDS C

A

D

B

Left side only

Right side

A

(With the rear floor removed)

AB800243AB

NOTE: Refer to the Rear End Crossmember section on P.3-34 for the welding points with the Rear end crossmember.

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3-40

WELDED PANEL REPLACEMENT REAR FLOOR

RALLIART B

E

C

E

D

AB801228 AB

NOTE ON REPAIR WORK .

REMOVAL 1. When removing the rear floor side panel, cut it 290 mm (11.4 inches) behind the installation hole of the child restraint bracket.

(With the rear floor removed)

290 mm (11.4 in)

AB601242 AE

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3-41

WELDED PANEL REPLACEMENT ROOF

ROOF Symbol

M4030011001313

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

AB800426AB

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

REPAIR WELDS <Vehicles without sunroof>

NOTE : : Adhesive

AB801200AB

Adhesive: Urethane body sealer

TSB Revision

Brand: 3M™ AAD Part No.08360 or equivalent

3-42

WELDED PANEL REPLACEMENT QUARTER INNER

QUARTER INNER

M4030012001189

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

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.)

AB800342AB

Sound dampening foam material for RALLIART only

REPAIR WELDS Sound dampening foam material

B Sound dampening foam material Sound dampening foam material B A

C

Right side only Left side only

Sound dampening foam material

Sound dampening foam material

A

Sound dampening foam material C

(With the quarter outer removed)

NOTE: Refer to the Quarter Outer section on P.3-30 for the welding points with the quarter outer.

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AB801003AB

3-43

WELDED PANEL REPLACEMENT QUARTER INNER

Right side only

Sound dampening foam material

E

D D

F

E

G

H

Right side only

Right side for RALLIART

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

F

F

(Left side)

(Right side)

TSB Revision

AB800402AB

3-44

WELDED PANEL REPLACEMENT QUARTER INNER Right side only

Left side only

I

H

G

I

(With the rear wheel house panel front lower outer removed) AB800351AB

NOTE ON REPAIR WORK .

INSTALLATION 1. When installing the new quarter inner panel upper 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 gate pillar.

100 mm (3.9 in) A

65 mm (2.6 in)

30 mm (1.2 in)

30 mm (1.2 in) 50 mm (2.0 in)

15 mm (0.6 in) Roof side rail reinforcement rear

Quarter inner panel upper A NOTE: : Body loose panel cushion

AB800336AB

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WELDED PANEL REPLACEMENT QUARTER INNER

3-45

2. When installing the new rear pillar reinforcement lower part, 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 (3.3 in)

20 mm (0.8 in)

40 mm (1.6 in)

A

Quarter panel inner

Rear pillar reinforcement lower A NOTE: : Body loose panel cushion

AB601327AB

3. When installing the new gate pillar reinforcement parts, in order to prevent the dripping of sound dampening foam material to be filled into the rear end panel inner in the next process, install the rear end side silencer to the rear pillar reinforcement lower, and then apply the butyl-tape to close the hole and gap of rear end side silencer.<RALLIART>

Rear end side silencer <RALLIART>

AB801247AB

Rear combination light support bulkhead 30 mm (1.2 in)

4. After installing the gate pillar reinforcement, in order to fill the sound dampening foam material into the gate pillar in the next process, machine the body loose panel cushion (MR535301 or MR435765) as shown in the figure, and fill the gap of the rear combination light support bulkhead.

20 mm (0.8 in) 50 mm (2.0 in) NOTE: : Body loose panel cushion

AB800313AB

5. When installing the new rear pillar reinforcement lower, in order to prevent the dripping of sound dampening foam material to be filled into the rear end panel inner in the next process, install the rear end side silencer to the rear pillar reinforcement lower, and then apply the butyl-tape to close the hole and gap of rear end side silencer.<RALLIART> 6. After installing the quarter panel outer, perform the following procedures.

Rear end side silencer <RALLIART>

AB800891AB

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3-46

WELDED PANEL REPLACEMENT QUARTER INNER

A

(1) Seal the hole and flange with bolts and 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 Part No.08463

Quarter inner panel upper

Gate pillar reinforcement A upper NOTE: : Sound dampening foam material

AB800405AB

(2) Seal the hole and flange with bolts and 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 Part No.08463

A

B C

RALLIART only Rear end panel inner

Rear pillar reinforcement lower

Rear end panel inner A

Rear end corner panel B

Rear end panel inner

Rear pillar reinforcement lower C <RALLIART> NOTE: : Sound dampening foam material

AB800912 AB

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3-47

WELDED PANEL REPLACEMENT QUARTER INNER LOWER

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.

AB100787

QUARTER INNER LOWER Symbol

M4030001100264

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

AB800425AB

TSB Revision

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

3-48

WELDED PANEL REPLACEMENT QUARTER INNER LOWER

REPAIR WELDS Right side only

Left side only Left side only

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

B B

A

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

AB800424AB

NOTE: .

• Refer to the Quarter Outer section on P.3-30 for the welding points with the quarter outer.

• Refer to the Quarter Inner section on P.3-42 for the welding points with the gate pillar reinforcement and the rear pillar reinforcement lower.

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3-49

WELDED PANEL REPLACEMENT FRONT DOOR OUTER PANEL (WELDED TYPE)

FRONT DOOR OUTER PANEL (WELDED TYPE)

M4030001500455

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.)

AB700008 AB

REPAIR WELDS

A

50 mm (2.0 in)

A NOTE : : Adhesive

AB601280AB

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 (2.0 inches).

TSB Revision

3-50

WELDED PANEL REPLACEMENT FRONT DOOR OUTER PANEL (ADHESION TYPE)

FRONT DOOR OUTER PANEL (ADHESION TYPE)

M4030001700459

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.)

AB601288AB

REPAIR WELDS

A

A

NOTE : : Adhesive 1 : Adhesive 2

AB602376 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

TSB Revision

NOTE ON REPAIR WORK .

INSTALLATION 1. When installing the new front door panel outer part, grind the bonding surface and remove the paint to improve adhesion. Then, degrease the front door panel outer.

2. Install the front door panel outer and hem it. Then, wipe off the adhesive that squeezed out.

WELDED PANEL REPLACEMENT REAR DOOR OUTER PANEL (WELDED TYPE)

REAR DOOR OUTER PANEL (WELDED TYPE) SYMBOL

3-51 M4030001600377

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.)

AB601290AB

REPAIR WELDS

A

50 mm (2.0 in)

A

NOTE: : Adhesive

AB601282 AB

Adhesive: Urethane body sealer

Brand: 3M™ AAD Part No.08360 or equivalent NOTE: After hemming the rear door outer panel, MIG spot weld the flange overlap section at a pitch of 50 mm (2.0 inches).

TSB Revision

3-52

WELDED PANEL REPLACEMENT REAR DOOR OUTER PANEL (ADHESION TYPE)

REAR DOOR OUTER PANEL (ADHESION TYPE)

M4030001800360

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.)

AB601291AB

REPAIR WELDS

A

NOTE : : Adhesive 1 : Adhesive 2

A AB602378 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 new rear door panel outer part, grind the bonding surface and remove the paint to improve adhesion.

Then, degrease the rear door panel outer.

2. Install the rear door panel outer and hem it. Then, wipe off the adhesive that squeezed out.

TSB Revision

WELDED PANEL REPLACEMENT ALUMINUM PANEL <RALLIART>

3-53

ALUMINUM PANEL <RALLIART> 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.

ALUMINUM PANEL LOCATIONS

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

M4030000600330

Hood

AB801233AB

Application

Thickness

Hood panel outer

0.9 mm (0.04 inch)

Hood panel inner

0.8mm (0.03 inch)

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3-54

WELDED PANEL REPLACEMENT ALUMINUM PANEL <RALLIART>

ALUMINUM PANEL REPAIR

M4030000700285

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 descripti on Hammeri Mallet or plastic ng 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 discoloration. [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)

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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WELDED PANEL REPLACEMENT ALUMINUM PANEL <RALLIART>

3-55

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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3-56

WELDED PANEL REPLACEMENT ALUMINUM PANEL <RALLIART>

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 discoloration 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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WELDED PANEL REPLACEMENT ALUMINUM PANEL <RALLIART>

3-57

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 (0.03 or 0.04 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 discoloration 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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3-58

WELDED PANEL REPLACEMENT ALUMINUM PANEL <RALLIART>

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 disk 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 (0.06 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 (0.06 inch).

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

AB302175 AB

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WELDED PANEL REPLACEMENT ALUMINUM PANEL <RALLIART>

3-59

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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3-60

WELDED PANEL REPLACEMENT ALUMINUM PANEL <RALLIART>

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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4-1

GROUP 4

CORROSION PROTECTION CONTENTS BODY SEALING LOCATIONS . . . . .

4-2

UNDERCOAT APPLICATION LOCATIONS . . . . . . . . . . . . . . . . . . . .

4-6

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.

M4040001001551

NOTE: The bold dotted line indicates the application area on the underside. .

FLOOR

4 2

3

5

1

AB900236AB

UPPER BODY

6

7

10

8

9 AB701269AB

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4-3

CORROSION PROTECTION BODY SEALING LOCATIONS

SIDE BODY

Left side only

13 12

11

14

1

15 AB701270AB

3

AB800175AB

AB701165AB

4

2

AB601119AB

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AB801246 AB

4-4

CORROSION PROTECTION BODY SEALING LOCATIONS

5

9

<RALLIART>

<RALLIART>

AB800177AB

AB800173AD

10

6

AB800174 AB

AB801241AB

7

11

Right side only

Left side only AB801242AB

8

AB801302 AC

12

AB900237 AB

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AB701172AB

CORROSION PROTECTION BODY SEALING LOCATIONS

13

4-5

Hood <Except RALLIART>

AB800207 AB

AB601133AD

Hood <RALLIART>

14

AB701020 AD

AB800208AB

15 (Left side)

Front door

AB601134 AB

AB801197AB

Rear door

15 (Right side)

AB801196AB

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AB601135 AB

4-6

CORROSION PROTECTION UNDERCOAT APPLICATION LOCATIONS

Lift gate (outer)

Lift gate (inner)

AB701215AC

AB701216AC

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.

M4040003001115

• Tape the areas marked with an asterisks to protect those areas from getting any undercoating on those areas.

* *

*

*

NOTE: : Undercoat [film thickness is at least 0.8 mm (0.03 inch)]

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*

AB801211AB

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 The location and material of each of the principal synthetic-resin parts are shown below.

51

3, 8

4

6

M4050001001819

16

5

7 44

34

10 9 11 33

12

35

2 13

1

36

40

32

31 30

37 AB801201AB

20

42

46

43

21

39

41

22

17

23

38 19 45 18

24 14 28 15

27 26

47

29

50

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25

49

48

AB800268 AB

5-3

SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS No.

Part Name

Name Of Resin

Abbreviation Heatresistant Temp [° C (° F)]

1

Front bumper center garnish <RALLIART>

Acrylonitrile butadiene styrene

ABS

80 (176)

2

Radiator grille

3

Door mirror outer cover (color)

4

Liftgate spoiler

5

Liftgate garnish

6

Antenna base

Acrylonitrile ethylene styrene

AES

80 (176)

7

Front delta garnish

Acrylonitrile styrene acrylate

ASA (AAS) 80 (176)

8

Door mirror outer cover (black)

9

Hood air outlet garnish <RALLIART>

Talc (35%) filled Polyamide 6

PA6-TD35

80 (176)

10

Hood air inlet garnish <RALLIART>

11

Headlight

Polycarbonate

PC

120 (248)

12

Rear door outside handle

PC+PET

120 (248)

13

Front door outside handle

Polycarbonate+Polyethylene terephthalate

14

Rear wheelhouse splash shield

High density polyethylene

15

Front splash shield

PE-HD (HDPE)

70 −90 (158 −194)

16

Rear wiper arm

Polyethylene terephthalate-Glass fiber (45%)

PET-GF45 90 (194)

17

Quarter trim

Polyethylene terephthalate+Polypropylene

PET+PP

90 (194)

18

Front door trim lower

Polypropylene

PP

80 (176)

19

Front door sash trim

20

Inside rear view mirror

21

Liftgate trim upper

22

Liftgate trim upper (RH/LH)

23

Liftgate lower trim

24

Trunk room rear end trim

25

Rear scuff plate

26

Rear door trim lower

27

Front scuff plate

28

Cowl side trim

29

Fender protector rear

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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)]

30

Front fog light bezel

Rubber denatured polypropylene

PP+E/P

80 (176)

31

Front bumper face

32

Front bumper grille

33

Front bumper core

34

Rear bumper core

35

Rear bumper face

36

Rear bumper extension <RALLIART>

37

Air dam skirt panel <Except RALLIART>

38

Front pillar trim Rear pillar trim

PP+E/P-T D15

110 (230)

39

Talc filled rubber modified polypropylene (15%)

40

Side air dam

Talc filled rubber modified polypropylene (20%)

PP+E/P-T D20

110 (230)

41

Front door trim upper

Talc filled polypropylene (10%)

42

Lower center pillar trim

PP-TD10 (PPF)

110 −120 (230 −248)

43

Rear door trim upper

44

Front deck garnish

Talc filled polypropylene (20%)

45

Instrument panel

PP-TD20 (PPF)

120 −130 (248 −266)

46

Upper center pillar trim

47

Floor console box cup holder

48

Floor console

49

Floor console panel

50

Floor console side cover

51

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 slash (/) in the material symbol indicates that two different materials make two-layer construction. A plus sign (+) indicates that the two different materials mix each other.

• The indicated heat-resistant temperature for parts which are composed of two or more types of material is the value for the material with the lowest heat-resistant temperature.

• 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

HOOD AIR INLET GARNISH <RALLIART>

6-3

FRONT BAMPER <RALLIART> . . . . . . . . .

6-3

WHEELHOUSE . . . . . . . . . . . . . . . . . . . . . .

6-3

6-2

BODY COLOR BODY COLOR CODE

BODY COLOR CODE

M4060001001263

Body color code is stamped on the vehicle information code plate, which is attached on the underside of the center pillar (Right side).

Body color code AB601277AB

BODY COLOR CHARTS

M4060002002883

Check the vehicle’s body color code, and then use this body color chart to determine the refinishing paint supplier from which the color can be purchased.

Color Color Color Color name code number

Coating film Composition of film structure

SILVER

CMA10031 Cool Silver Metallic

2M

Metallic

MEDIUM A39 PURPLISH GRAY

CMA10039 Medium Purplish Gray Mica

2P

Metallic + Interferenced Pearl

BLUE

D06

CMD10006 Lightning Blue Mica

2P

Interferenced Pearl

ORANGE

M08

CMM10008 Passion orange pearl

2M

Metallic

RED

P26

CMP10026 Red Metallic

2M

Metallic

WHITE

W37

CMW10037 White Solid

2S

Solid

BLACK

X42

AC11342

2P

Interferenced Pearl

A31

Black Mica

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.

• The Hood air outlet garnish is coated in dark warm gray (AC10895) <RALLIART>.

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6-3

BODY COLOR BODY COLORING

BODY COLORING HOOD AIR INLET GARNISH <RALLIART>

M4060001500061

2 1

1 Body color 2 Black (AC10085)

AB800555AC

FRONT BAMPER <RALLIART>

M4060000500314

1

1

2

2 2 A

1

1 Body color 2 Material color

A

WHEELHOUSE

NOTE:

AB800091AB

M4060012000651

: Black (AC10657)

AB701267AB

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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 . . . .

9-30

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

9-2

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

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

9-33

9-2

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

9-8

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

9-35

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

9-12

CORROSION PROTECTION . . . . . . .

9-36

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

9-14

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

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

9-36

9-14

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

9-22

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

9-39

ATTACHMENT OF SILENCERS . . . . . . . .

9-24

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

9-25

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

9-25

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

9-42

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

9-42

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.

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.

.

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ADVANTAGES OF ELECTRIC RESISTANCE SPOT WELDING

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.

BASE OF BODY REPAIR WELDING

9-3

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

9-6

BASE OF BODY REPAIR 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

Safety equipme nt area

Other area

Panel thickness* [mm (in)]

Number of repair weld (percentage of factory weld)

1.0 (0.04) or less

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.

Safety equipme nt area

Other area

Panel thickness* [mm (in)]

Number of repair weld (percentage of factory weld)

0.9 (0.035 or less

100% Same number as factory welds

1.0 (0.04)

200% Maintain pitch of at least 18 mm (0.71 inch); if not possible, plug weld.

1.2 (0.047) or more

100% Same number as factory welds; plug welding

0.9 (0.035) or less

100% Same number as factory welds

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 more

100% Same number as factory welds; plug welding

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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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

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.

MIG SPOT WELDING Wire Gas cup

Gas outlet

AB200036AE

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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.

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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.

.

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.

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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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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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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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.

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

11.Cutting of new parts by using a measurement marking

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Twolayer construction

Outer panel Approx. 50 mm (1.97in)

Inner panel

9-17

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

CAUTIONS REGARDING BODY REPAIR

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.

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. .

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. .

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• 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.

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.

.

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.

.

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).

.

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.

THEFT PROTECTION

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

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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)

AB200097AD

Silencers (petroleum-asphalt sheets) are attached to welded panel, cut and attach replacement material the upper surface of the floor and at the interior side (in the shape shown in the figure). For detailed inforof the dash panel in order to absorb vibrations and mation concerning the locations where silencers are shut out exhaust gas heat. If these silencers are to be attached for individual models, refer to the peeled off in the course of replacement or repair of a manual for that model.

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

AB200098

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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.

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.

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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 CAUTIONto the panel shape.

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

AB200102

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.

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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.

9-27 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.

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.

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9-28

BASE OF BODY REPAIR BODY REPAIR

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.

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

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BASE OF BODY REPAIR BODY REPAIR Crack-stop hole

Crack

Approx.

1 mm (0.04 in)

Approx.

90˚

A

Approx.

8 mm (0.31 in)

9-29

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

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.

AB301461AB

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.

A

A

A : 30 – 45˚

10 mm (0.39 in)

Welded point AB200133 AD

(1)

(2)

AB200134 AB

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BASE OF BODY REPAIR BODY REPAIR

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.

NOTES REGARDING REPAIR WORK

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.

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(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.

(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.

BASE OF BODY REPAIR BODY REPAIR

(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.

9-31

• 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

.

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. .

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BASE OF BODY REPAIR BODY REPAIR

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.

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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BASE OF BODY REPAIR BODY REPAIR

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.

Material name Abbreviation Heat-deformation temperature ° C (° F) Acrylonitrile styrene acrylate

M4090016000054

Where mainly used

ASA

80 (176)

Door mirror, Pillar garnish, License garnish, Radiator grille

Acrylonitrile butadiene ABS styrene

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

Polyurethane

PUR

80 −100 (176 −212)

Bumper, Steering wheel

80 −100 (176 −212)

Seat cushion, Arm rest, Door trim, Instrument panel

Polyurethane (formed) PUR-E Glass fiber reinforced RIM urethane

PUR-GF [RIM] 100 −120 (212 −248)

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Air dam panel

9-34

BASE OF BODY REPAIR BODY REPAIR

Material name

Abbreviation Heat-deformation temperature ° C (° F)

Where mainly used

Polyvinyl alcohol

PVAL

-

Polyvinyl butyral

PVB

Polyvinyl chloride

PVC

80 (176)

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

Thermoplastic elastomer (olefine)

TPO (TEO)

80 (176)

Mud guard, Side air dam

Urea formaldehyde

UF

120 −145 (248 −293)

-

*1

-

Glass fiber reinforced UP-(GT + TD) 200 (392) unsaturated polyester [SMC], [BMC]

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 elastomer (styrene), Talc filled polypropylene

TES, PP-TD

100 −120 (212 −248)

Side splash

Polycarbonate + PC + ABS Acrylonitrile butadiene

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 + PPE (PPO) + Polyamide 6 PA6

150 −160 (302 −320)

Wheel cover

Polyphenylene ether + PPE (PPO) + Polyamide 66 PA66

160 −170 (320 −338)

Wheel cover

Polyphenylene ether + PPE (PPO) + Polystyrene PS

120 −130 (248 −266)

Wheel cover

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.

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BASE OF BODY REPAIR BODY REPAIR

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 Abbrevi Flame color Combustion ation Conditions

Self-exting Odor uishing

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

Crackles as burns; drips No

Rubber odor

TRUR

Orange

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 remnants remain

No

Differs according to plastic type

Phenol resin

PF

Yellow

Ashes remain

Yes

Formalin odor

ABS resin

ABS

Orange

Burns accompanied by foaming and black smoke

No

Rubber odor

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9-36

BASE OF BODY REPAIR CORROSION PROTECTION

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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9-37

BASE OF BODY REPAIR CORROSION PROTECTION

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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BASE OF BODY REPAIR CORROSION PROTECTION

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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9-40

BASE OF BODY REPAIR CORROSION PROTECTION

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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9-41

• 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.

9-42

BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS

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

9-43

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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BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS

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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9-45

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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BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS

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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BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS

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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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NOTES