DOWNLOAD PDF Mitsubishi 2014 Mirage Body Repair Manual

2014 MITSUBISHI MIRAGE

BODY REPAIR MANUAL FOREWORD

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

1

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

2

WELDED PANEL REPLACEMENT. .

3

CORROSION PROTECTION . . . . . .

4

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

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

One especially important point is the welding method.

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

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

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

SERVICE MANUAL

MSCD-016B-2015

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.

2014 Mitsubishi Motors Corporation All Rights, Reserved Printed in USA MSSP-416B-2015

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

DASH PANEL 12 42 ± 16 N·m (31 ± 11 ft-lb)

13 7 11 14 12 8

9 15

10

6

11 5 4

42 ± 16 N·m (31 ± 11 ft-lb)

3 2

1 ABB00012AB

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Harness 2-way bracket Flare nut holder Harness bracket Battery holder bracket Air intake bracket Dash panel HVAC bracket Dash panel reinforcement

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Ground bracket EPS -ECU bracket Dash crossmember lower bracket Dash crossmember upper bracket Accelerator pedal bracket J/B lower bracket Pipe

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

DASH PANEL 12 42 ± 16 N·m (31 ± 11 ft-lb)

13 7 11 14 12 8

9 15

10

6

11 5 4

42 ± 16 N·m (31 ± 11 ft-lb)

3 2

1 ABB00012AB

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Harness 2-way bracket Flare nut holder Harness bracket Battery holder bracket Air intake bracket Dash panel HVAC bracket Dash panel reinforcement

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Ground bracket EPS -ECU bracket Dash crossmember lower bracket Dash crossmember upper bracket Accelerator pedal bracket J/B lower bracket Pipe

1-1

GROUP 1

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

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

MAINTENANCE, SERVICEABILITY . . . . . . . . . . . . . . .

1-2

1-4

1-6

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

1-8

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

1-8

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

1-13

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

1-15

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

1-15

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

1-16

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

1-19

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

1-21

URETHANE FOAM USAGE LOCATIONS . . . . . . . . . . . . . . . . . . . .

1-23

BODY CONSTRUCTION

1-2

BODY COMPONENTS

BODY COMPONENTS M4010001002238

28

24

22

20

26

59* 21

19

27

25*

23

29

17 18

61

58*

60* 88*

66*

57* 16

30

68 62 76*

56*

69

31

67 65* 15

80 33

81

14 13

77* 10

54

35

53*

79*

75* 74*

11

51

9

52* 64** 45 49

36

63 87 78* 72* 44

37 39

38

83 86*

41

43

8*

40*

6

7*

4

47

3 4

42 70*

5

71*

85*

84

73** 3

2

34

82

55 12

32

50 48*

46*

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

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ABC00328AB

BODY CONSTRUCTION BODY COMPONENTS 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

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18.

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23.

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27.

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29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

Front panel crossmember lower Front bumper reinforcement Headlight support panel Headlight support bracket Headlight support panel upper Front sidemember plate Front inner sidemember Front outer sidemember Engine mounting gusset Fender shield frame upper inner Front inner wheel house Dash panel crossmember Dash panel Cowl top panel Front deck crossmember Hood inner panel Hood outer panel Front door panel inner Front door side door beam Front door panel outer Rear door panel inner Rear door panel outer Roof rail front Roof panel Roof bow Roof rail rear Liftgate inner panel Liftgate outer panel Gate pillar reinforcement Rear inner pillar Quarter panel extension upper outer Quarter panel extension lower outer Fuel filler lid Side outer panel Rear end panel outer Rear end panel inner Spare tire bracket Rear towing hook bracket Rear floor stay Rear floor sidemember reinforcement Rear floor sidemember extension Rear floor sidemember Rear floor Rear floor crossmember

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45.

46.

47.

48.

49.

50.

51.

52.

53.

54.

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58.

59.

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61.

62.

63.

64.

65.

66.

67.

68.

69.

70.

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72.

73.

74.

75.

76.

77.

78.

79.

80.

81.

82.

83.

84.

85.

86.

87.

88.

Rear floor rear seat under crossmember Front floor side sill inner Front floor sidemember Front sidemember reinforcement rear Front floor Front fender Front floor sidemember Front floor sidemember rear Front pillar reinforcement lower inner Front deck frame upper outer Front fender bracket Front pillar reinforcement upper Front lower inner pillar Front upper inner pillar Roof side rail inner Center inner pillar Rear pillar reinforcement Rear pillar brace Front fender bracket Side sill reinforcement Center pillar reinforcement Roof side rail reinforcement center Side sill rear end plate Rear wheel house inner panel Quarter panel lower inner Side inner sill rear Rear seat crossmember reinforcement Rear floor crossmember reinforcement Front floor front crossmember Front sidemember reinforcement rear lower Dash side brace Rear door hinge reinforcement Side sill bulkhead Side sill reinforcement outer support Side sill reinforcement support front Center pillar reinforcement lower Side sill reinforcement support rear Side sill support rear Canister bracket Side sill reinforcement inner Side sill inner reinforcement Rear floor sidemember reinforcement upper Rear seat pan reinforcement Rail roof side support

1-3

BODY CONSTRUCTION

1-4

BODY MAIN CROSS-SECTIONAL VIEWS

BODY MAIN CROSS-SECTIONAL VIEWS M4010002001380

B

D

E A

C F ABB00524AB

D

A

Cowl top outer panel Cowl top stay Cowl top inner panel Dash panel ABB00614AB

B

Roof panel Roof side rail reinforcement center Rail roof side support Roof side rail Side outer panel inner

ABC00323AB

Center pillar seat belt reinforcement Center pillar Center inner reinforcement pillar upper

E

Roof panel

Side outer panel Front roof reinforcement rail Roof front rail inner ABC00322AB

C

ABB00618AB

F Side sill Side outer panel

Front pillar reinforcement lower

reinforcement support front

Front inner pillar lower

Side sill reinforcement

Side outer panel

Front floor side sill inner

ABB00616AB

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Side sill reinforcement outer support

ABC00324AB

BODY CONSTRUCTION

1-5

BODY MAIN CROSS-SECTIONAL VIEWS K G

I

H

J L ABB00525 AB

G Front pillar reinforcement upper

J

Front inner pillar upper Rear wheel house inner panel Quarter panel lower inner Side outer panel

Side outer panel

ABB00620AB

H

Center pillar reinforcement

Rear door hinge reinforcement

ABB00623AB

K

Center inner pillar upper Roof panel

Side outer panel Roof rear rail inner ABB00624AB

ABC00129 AB

Gate pillar inner upper extension Rear pillar Gate pillar Quarter outer reinforcement reinforcement upper A extension Gate pillar Side outer inner panel panel

I

L Rear end outer panel Rear end inner panel

ABB00622AB

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ABB00625AB

BODY CONSTRUCTION

1-6

MAINTENANCE, SERVICEABILITY

MAINTENANCE, SERVICEABILITY M4010003001145

FENDER SHIELD A positioning hole and cut-out have been added on the front sidemember inner and the dash crossmember to improve assembling workability when replacing the panel.

ABB00389AB

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

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BODY CONSTRUCTION

1-7

MAINTENANCE, SERVICEABILITY

ABB00467AB

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

ABB00600AB

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BODY CONSTRUCTION

1-8

BODY CONSTRUCTION CHARACTERISTICS

BODY CONSTRUCTION CHARACTERISTICS FRONT BODY

M4010010001750

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

HEADLIGHT SUPPORT • The crush box structure has been adopted to the front end of the front sidemember to improve the maintainability at a minor collision and the characteristics at a minor frontal collision.

ABB00350

7.0 ± 3.0 N·m 62 ± 26 in-lb

5

10 ± 4 N·m 89 ± 35 in-lb

7.0 ± 3.0 N·m 62 ± 26 in-lb

3 4

26 ± 6 N·m 19 ± 4ft-lb

3 4 2 26 ± 6 N·m 19 ± 4ft-lb

A

7.0 ± 3.0 N·m 62 ± 26 in-lb

1 ABC00325AB

1.

2.

3.

4.

5.

Front panel crossmember lower Front bumper reinforcement Headlight support bracket Headlight support panel Headlight support panel upper

A

Crush box ABD00021AB

A crash box has been established in order to efficiently absorb energy upon impact.

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BODY CONSTRUCTION

1-9

BODY CONSTRUCTION CHARACTERISTICS

FENDER SHIELD (Right side)

4 3 2 5 1 23 ± 9 N·m 17 ± 6 ft-lb

6

ABB00351AB

(Left side)

3 4

2 23 ± 9 N·m 17 ± 6 ft-lb

7 5 23 ± 9 N·m 17 ± 6 ft-lb

6 ABB00352 AB

1.

2.

3.

4.

5.

6.

7.

FRONT SIDEMEMBER REINFORCEMENT

Engine mounting gusset Fender shield frame upper inner Front spring house gusset Spring house bracket Front spring house panel Front sidemember Transmission mounting gusset

The 590-MPa class high tensile strength steel panels have been adopted for the front sidemember outer, front sidemember reinforcement rear lower, front floor sidemember rear and front sidemember inner to improve the crash safety.

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BODY CONSTRUCTION

1-10

BODY CONSTRUCTION CHARACTERISTICS

7

(Right side)

9*

4

8*

5 6

3*

10 2

12

11

13

1 14* NOTE: *: Indicates 590MPa-high-tensile steel panels.

ABB00353 AB

A

2

5

B

14

8

6 10 13 12

ABB00418AB

1.

2.

3.

4.

5.

6.

7.

Front sidemember plate Engine mounting bulkhead Front sidemember outer Brake hose bracket Front sidemember bulkhead front Front sidemember reinforcement front Front sidemember brace lower

A

8.

9.

10.

11.

12.

13.

14.

Front sidemember reinforcement rear lower Front floor sidemember rear Front sidemember rear A Dash crossmember lower Front suspension crossmember plate rear Front suspension crossmember bracket rear Front sidemember inner

B

14

8 10

2 13 3 ABB00419 AB

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12

ABB00420AB

BODY CONSTRUCTION

1-11

BODY CONSTRUCTION CHARACTERISTICS (Left side)

4 3* 7*

6 2*

8

5 1

14

9

12 13

10

11*

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

ABB00354 AB

A

9

6

11

5 B

1

3

13 12 ABB00421AB

1.

2.

3.

4.

5.

6.

7.

Front sidemember rear A Front floor sidemember rear Front sidemember reinforcement rear lower Front sidemember brace lower Front sidemember reinforcement front Front sidemember bulkhead front Front sidemember outer

A

11

8.

9.

10.

11.

12.

13.

14.

Brake hose bracket Transmission mounting bulkhead Front sidemember plate Front sidemember inner Front suspension crossmember plate rear Front suspension crossmember bracket rear Dash crossmember lower

B

3 1

9 13

7 ABB00422 AB

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12

ABB00423AB

BODY CONSTRUCTION

1-12

BODY CONSTRUCTION CHARACTERISTICS

FRONT DECK The padding structure of the cowl top is designed to have a crushable structure in order to efficiently absorb energy upon impact, thus improving the pedestrian protection capability.

ABB00355

3 2 4 1

5 6

7

8 1.

2.

3.

4.

ABC00181AB

5.

6.

7.

8.

Cowl top inner panel Heater B bracket Cowl top outer panel Cowl top stay

Wiper center bracket Wiper A bracket Heater A bracket Harness bracket

DASH PANEL The 590-MPa class high tensile strength steel panels has been adopted for the dash side brace to improve the crash safety.

ABB00356

8*

9

4

5

6 7 2

9 8* 3

1 10 NOTE: *: Indicates 590MPa-high-tensile steel panels.

1.

2.

3.

4.

5.

Dash panel crossmember Canister bracket Dash panel Accelerator pedal bracket Deck crossmember stay bracket

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ABC00182AB

6.

7.

8.

9.

10.

Brake reinforcement Clutch pedal reinforcement <M/T> Dash side brace Heater bracket lower Flare nut holder

BODY CONSTRUCTION

1-13

BODY CONSTRUCTION CHARACTERISTICS

SIDE BODY

M4010011001708

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.

9* 13 6 12 5

16 14

11 4* 8*

10 ± 4 N·m 89 ± 35 in-lb

17 10

3

15

23 19 22

18

24

25

7* 21

50*

44*

2

27

1*

26

43*

45* 29

20 46*

51* 52*

42 41 40

28

38*

30

53 47*

32

37**

49* 39 36

33 48*

31

35 NOTE: 34 *: Indicates 590MPa-high-tensile steel panels. **: Indicates 980MPa-ultra-high-tensile steel panels.

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23 ± 9 N·m 17 ± 6 ft-lb ABC00326AB

1-14 1.

2.

3.

4.

5.

6.

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8.

9.

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11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS 28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

53.

Front inner pillar lower Instrument panel side bracket Wiper side bracket Front inner pillar upper Sunvisor bracket Front roof rail brace Center inner pillar lower Center inner pillar upper Roof side rail inner Seat belt retractor bracket Center pillar seat belt lower reinforcement Center pillar seat belt reinforcement Rear pillar reinforcement Gate pillar inner upper extension Gate pillar inner panel Gate pillar reinforcement Seat belt reinforcement Rear seat striker reinforcement Gate pillar brace Side sill rear end plate Rear wheel house inner panel Rear wheel house inner extension Absorber reinforcement Quarter panel lower inner Filler neck bracket (Left side) Quarter outer upper B extension Quarter outer upper A extension

Rear light housing Quarter outer lower A extension Quarter outer lower B extension Side outer panel Rear door striker reinforcement Front fender bracket Upper outer frame Front fender bracket Hood hinge reinforcement Side sill reinforcement Front pillar reinforcement lower Front pillar bulkhead hinge lower Checker bracket front pillar Front pillar bulkhead hinge upper Deck crossmember bracket Front pillar reinforcement upper Roof side rail reinforcement center Center pillar reinforcement Rear door hinge reinforcement Side sill bulkhead Side sill reinforcement outer support Side sill reinforcement support front Rail roof side support Center pillar reinforcement lower Side sill reinforcement support rear Side sill support rear

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

Roof side rail reinforcement center

Gate pillar reinforcement

Gate pillar brace

Front pillar reinforcement upper

Center pillar reinforcement

Front pillar reinforcement lower

Side sill reinforcement

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ABC00334AB

BODY CONSTRUCTION

1-15

BODY CONSTRUCTION CHARACTERISTICS

REAR BODY

M4010012000991

REAR END PANEL 5

6

7 8

3 2

4 2 1

ABB00357 AB

1.

2.

3.

4.

5.

6.

7.

8.

Rear end inner panel Bumper bracket lower Liftgate lock reinforcement Nut plate

Rear end outer panel Rear bumper reinforcement Rear license light bracket Garage Jack reinforcement

ROOF

M4010013001834

The 590-MPa class high tensile strength steel panels has been adopted for the roof bow to improve the body strength.

3

7

4 5

8

6*

4

2 1 NOTE: *: Indicates 590MPa-high-tensile steel panels.

1.

2.

3.

4.

2 5.

6.

7.

8.

Roof front rail inner Holder bracket Roof panel Liftgate hinge reinforcement

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ABC00327AB

Roof rear rail inner Roof bow Roof bow center reinforcement Front roof reinforcement rail

BODY CONSTRUCTION

1-16

BODY CONSTRUCTION CHARACTERISTICS

UNDER BODY

M4010014001718

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

2

5

6

4

5 4

7

3

10 11

14**

8 1

9

18

15* 8

16 17 13* 12 NOTE: *: Indicates 590MPa-high-tensile steel panels. **: Indicates 980MPa-ultra-high-tensile steel panels.

1.

2.

3.

4.

5.

6.

7.

8.

9.

ABC00313AB

10.

11.

12.

13.

14.

15.

16.

17.

18.

Backbone panel Parking lever reinforcement ECU bracket Nut plate Front seat center bracket rear Parking cable bracket Backbone reinforcement Front floor side pan Fuel reinforcement tank support

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Front seat side bracket rear Jack bracket Front floor sidemember Front floor side sill inner Front floor front crossmember Front sidemember reinforcement rear Backbone crossmember Backbone crossmember front Front floor crossmember front reinforcement

BODY CONSTRUCTION

1-17

BODY CONSTRUCTION CHARACTERISTICS

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

ABB00360

11 18

10 9 19

8 12

13

7 6* 3

14 7

15

5

2 4*

17

1

16

3 1 NOTE: *: Indicates 590MPa-high-tensile steel panels.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Fuel tank protector Rear seat crossmember Tie down reinforcement Rear seat crossmember reinforcement Rear floor crossmember Rear floor crossmember reinforcement Rear seat bracket Rear floor pan Rear floor stay Rear towing hook bracket

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ABC00314 AB

11.

12.

13.

14.

15.

16.

17.

18.

19.

Spare tire bracket Rear seat reinforcement center Rear seat plate center Rear seat back reinforcement side Rear floor sidemember Side sill reinforcement inner Side sill reinforcement inner support Rear seat pan reinforcement Canister bracket

BODY CONSTRUCTION

1-18

BODY CONSTRUCTION CHARACTERISTICS

REAR FLOOR SIDEMEMBER REINFORCEMENT The 590-MPa class high tensile strength steel panels has been adopted for the side inner sill rear to improve the body strength.

3 2 3

9*

1 8*

4

2 1 5

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

6*

7*

ABC00315AB

B

1

A

3

6 9 8 7 ABC00331AB

1.

2.

3.

4.

5.

Rear floor sidemember Muffler hanger A bracket (Right side) Rear floor sidemember extension Spring seat Torsion arm support bracket

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6.

7.

8.

9.

Side sill inner rear reinforcement Side inner sill rear Rear floor sidemember reinforcement Rear floor sidemember reinforcement upper

BODY CONSTRUCTION

1-19

BODY CONSTRUCTION CHARACTERISTICS

A

B

8

1 1

7 9 6

8

ABC00332 AB

ABC00333AB

DOOR

M4010015001119

(Front door)

5

12

2

1

6

4

11

3 10

9

7 8

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ABB00362 AB

BODY CONSTRUCTION

1-20

BODY CONSTRUCTION CHARACTERISTICS

(Rear door)

17 14 16

13

24

15

18

23 22 21 20

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Front door panel outer Front door window front sash Front door hinge reinforcement Front door beltline outer reinforcement Front door glass guide Glass stopper Front door panel inner Nut plate Front door side door beam Front door outer front stiffener Front door outer rear stiffener Front door latch reinforcement

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13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

19

Rear door panel outer Rear door window front sash Rear door hinge reinforcement Rear door beltline outer reinforcement Rear door glass rear guide Glass stopper Rear door panel inner Nut plate Rear door outer lower stiffener Rear door outer upper front stiffener Rear door outer upper rear stiffener Rear door latch reinforcement

ABB00363 AB

BODY CONSTRUCTION

SILENCER APPLICATION LOCATIONS

SILENCER APPLICATION LOCATIONS • In order to suppress noise, a silencer (melting sheet) has been adhered on the cowl top outer panel.

• In order to suppress noise, a front pillar silencer (damping sheet) has been adhered on the front inner pillar lower.

1-21 M4010005002627

• A silencer (melting sheet) has been affixed on the upper surface of the floor for vibration dampening.

Silencer

(Left side)

(Right side)

Front pillar silencer

Front pillar silencer

NOTE: : 1.5 mm (0.06 in) thick melting sheet (Place a melting sheet.) : 2.0 mm (0.08 in) thick damp sheet (Place two melting sheet one on top of another.) ( ) indicates the number of 1.6 mm (0.06 in) melting sheets that are used for repair.

ABC00126AB

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BODY CONSTRUCTION

SILENCER APPLICATION LOCATIONS

NOTE: : 1.6 mm (0.06 in) thick melting sheet (Place a melting sheet.) : 3.2 mm (0.13 in) thick damp sheet (Place two melting sheet one on top of another.) ( ) indicates the number of 1.6 mm (0.06 in) melting sheets that are used for repair.

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1-22

ABD00276AB

1-23

BODY CONSTRUCTION URETHANE FOAM USAGE LOCATIONS

URETHANE FOAM USAGE LOCATIONS • A front door inner panel pad (urethane foam) is inserted in the front door sash to reduce the transfer of noises to the interior.

M4010007000661

• In order to suppress noise, a center pillar pad (urethane foam) has been filled in the bottom of the center pillar.

Front door inner panel pad

ABB00801AB

Center pillar pad

ABC00223AB

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2-1

GROUP 2

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

2-2

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

2-7

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

2-7

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

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

2-9

2-4

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

2-11

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

2-4

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

2-13

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

2-15

HEADLIGHT SUPPORT PANEL . . . . . . . . .

2-19

BODY DIMENSIONS

2-2

BODY DIMENSIONS AND MEASUREMENT METHODS

BODY DIMENSIONS AND MEASUREMENT METHODS M4020001000619

• 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 (3.9 in) below the lowest measurement point.

Projected dimension

Height Probe

AB302138AE

A

• 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 ure

d

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.

AB302141AD

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BODY DIMENSIONS BODY DIMENSIONS AND MEASUREMENT METHODS

• When measuring the suspension mounting arm, or link mounting position, use the suspension mounting bolt, etc.

(Type B only) • The body center points are shown for the purpose of checking the position of the left and right symmetry location.

Bolt

Measurement point

2-3

AB302142 AB

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BODY DIMENSIONS

2-4

TYPE A (PROJECTED DIMENSIONS)

TYPE A (PROJECTED DIMENSIONS) UNDER BODY

M4020005002576

616 (24.3)

1,109 (43.7)

660 (26.0)

840 (33.1)

885 (34.8)

814 (32.0)

814 (32.0) 350 (13.8)

1

814 (32.0)

3

4

1,086 (42.8) 450 (17.7)

5

378 (14.9)

6

266 173 11 (10.5) (6.8)

Center line of the vehicle

1,078 (42.4)

814 (32.0)

814 (32.0) 487 (19.2)

937 (36.9)

934 (36.8)

974 (38.3)

9

8

663 (26.1)

1,108 (43.6)

328 (12.9)

362 (14.3)

296 (11.7)

7

439 (17.3)

mm (in)

657 (25.9)

814 (32.0)

10

12

690 (27.2) ABB00189AB

936 (36.9)

mm (in)

930 (36.6)

1,009 (39.7) 1,049 (41.3)

832 (32.8)

931 (36.7)

2 1

1,147 (45.2)

1,048 (41.3)

3

4

1,241 (48.9)

5

1,244 (49.0)

1,013 (39.9)

1,122 (44.2)

1,218 (48.0) 1,087 (42.8)

6 7

Center line of the vehicle 869 (34.2)

1,221 (48.1)

9

8

949 (37.4)

10

ABB00190AB

No. Standard measurement point

Hole shape

Size mm (in)

1*

Center of front sidemember inner positioning hole

Round

25.0 (0.98)

2*

Center of front suspension crossmember mounting hole

Round

16.0 (0.63)

3*

Center of front suspension crossmember mounting hole

Round

16.0 (0.63)

4*

Center of front sidemember rear A positioning hole

Round

15.0 (0.59)

5*

Center of front floor sidemember rear positioning hole

Round

25.0 (0.98)

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BODY DIMENSIONS

2-5

TYPE A (PROJECTED DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm (in)

6*

Center of front floor sidemember positioning hole

Round

20.0 (0.79)

7*

Center of tie down mounting hole

Oblong

22.0×40.0 (0.87×1.57)

8

Center of torsion axle arm assembly mounting position

−

−

9*

Center of spring seat positioning hole

Round

10.0 (0.39)

10*

Center of trailer hitch mounting hole

Round

13.0 (0.51)

11

Center of front shock absorber mounting hole

Round

76.0 (2.99)

12

Center of rear shock absorber mounting hole

Round

21.0 (0.83)

NOTE: The * mark indicates the mounting position for the frame centering gauge.

A

B

Vehicle center

Vehicle center

4˚20´ 2˚29´

ABB00113

ABB00573

919 (36.2)

mm (in)

1,198 (47.2)

4˚34´

A

B

11

8˚41´

12 1

2

710 (28.0)

3 340 (13.4)

306 (12.0)

10

9

136 (5.4)

4

5 102 (4.0)

100 (3.9)

487 (19.2) 660 (26.0)

Standard line 926 (36.5) 1,275 (50.2)

101 (4.0)

450 (17.7)

8

7

6

146 (5.7)

616 (24.3)

171 (6.7)

315 (12.4)

353 (13.9) 649 (25.6) 1,008 (39.7) 1,335 (52.6)

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

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295 (11.6)

ABB00465AB

BODY DIMENSIONS

2-6

TYPE A (PROJECTED DIMENSIONS)

3, 4

2, 11

1

11

3

2

4

5

7

6

ABB00484 AB

8

ABB00483 AB

ABB00489AB

ABB00522 AB

ABB00523 AB

9, 10, 12

12 9 10 ABB00487 AB

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ABB00490 AB

ABB00486 AB

BODY DIMENSIONS

2-7

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) UNDER BODY

M4020005002587

649 (25.6)

885 (34.8)

840 814 814 (33.1) (32.0) (32.0)

352 (13.9)

1

661 (26.0)

2

3

316 (12.4)

4

814 (32.0)

487 (19.2)

5

1,086 (42.8)

814 (32.0)

450 (17.7)

381 (15.0)

6

177 (7.0)

1,078 (42.4)

937 (36.9)

974 (38.3)

383 (15.1)

297 (11.7)

9

8

7

486 (19.1)

mm (in)

674 (26.5)

816 (32.1)

666 (26.2)

934 (36.8)

328 (12.9)

10

704 (27.7) ABB00191AB

959 (37.8)

mm (in)

930 (36.6)

1,009 (39.7) 1,069 (42.1)

833 (32.8)

931 (36.7)

2 1

1,150 (45.3)

1,049 (41.3)

3

4

1,241 (48.9)

5

1,245 (49.0)

1,014 (39.9)

1,122 (44.2)

1,226 (48.3) 1,094 (43.1)

6 7

885 (34.8)

1,230 (48.4)

9

8

949 (37.4)

10

ABB00192AB

No. Standard measurement point

Hole shape

Size mm (in)

1

Center of front sidemember inner positioning hole

Round

25.0 (0.98)

2

Center of front suspension crossmember mounting hole

Round

16.0 (0.63)

3

Center of front suspension crossmember mounting hole

Round

16.0 (0.63)

4

Center of front sidemember rear A positioning hole

Round

15.0 (0.59)

5

Center of front floor sidemember rear positioning hole

Round

25.0 (0.98)

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BODY DIMENSIONS

2-8

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm (in)

6

Center of front floor sidemember positioning hole

Round

20.0 (0.79)

7

Center of tie down mounting hole

Oblong

22.0×40.0 (0.87×1.57)

8

Center of torsion axle arm assembly mounting position

−

−

9

Center of spring seat positioning hole

Round

10.0 (0.39)

10

Center of trailer hitch mounting hole

Round

13.0 (0.51)

3, 4

2

1

3 4

5

7

6

ABB00484 AB

8

ABB00483 AB

ABB00482 AB

ABB00522 AB

ABB00523 AB

9, 10

9 10 ABB00487 AB

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ABB00488AB

ABB00486 AB

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

FRONT BODY

2-9 M4020006001640

mm (in)

1,087 (42.8)

880 (34.6)

21

1,507 (59.3)

19 Body center point 1,376 (54.2)

286 (11.3) 1,370 (53.9)

533 (21.0)

306 (12.0)

17

18

1,197 (47.1)

500 (19.7)

781 (30.7)

1,223 (48.1)

16

20

1,407 (55.4)

958 (37.7)

15

958 (37.7)

14 13

19 Body center point

514 (20.2) 1,002 (39.4)

846 (33.3) 700 (27.6)

690 (27.2)

20 17

18 1,426 (56.1)

656 (25.8)

243 (9.6)

16 127 (5.0)

723 (28.5)

877 (34.5) 966 (38.0)

15 14 13

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ABB00170 AB

BODY DIMENSIONS

2-10

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm (in)

13

Center of headlight support panel mounting hole

Round

9.0 (0.35)

14

Center of headlight support panel mounting hole

Round

9.0 (0.35)

15

Center of battery tray stay mounting hole

Round

10.0 (0.39)

16

Center of harness mounting hole

Oblong

12.0×7.0 (0.47×0.28)

17

Center of front fender mounting hole

Round

6.6 (0.26)

18

Center of front strut mounting hole

Round

11.0 (0.43)

19

Center of front deck garnish mounting hole (Body center point)

Round

6.0 (0.24)

20

Center of hood hinge mounting hole

Round

11.0 (0.43)

21

Corner of roof panel

−

−

13, 14, 15

16

17, 18

15 18

14

17

13

ABB00491AB

20

19

ABB00493AB

ABB00492 AB

21

ABB00495AB

ABB00494 AB

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ABB00496 AB

BODY DIMENSIONS

2-11

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

SIDE BODY

M4020007001386

mm (in)

24

28

22 785 443 (30.9) (17.4) 995 (39.2) 857 (33.7)

23

26

699 (27.5)

812 (32.0)

869 465 (34.2) (18.3)

536 (21.1)

1,012 (39.8)

1,127 (44.4)

746 (29.4)

27

25

30

978 (38.5)

31

29

ABB00193AB

mm (in)

24

28

1,119 (44.1)

754 (29.7)

34 32 347 (13.7)

1,086 (42.8)

1,097 (43.2)

1,032 (40.6)

33

1,166 (45.9)

395 (15.6)

746 (29.4)

36

782 (30.8)

35

ABB00194 AB

No. Standard measurement point

Hole shape

Size mm (in)

22

Front pillar positioning notch

−

−

23

Front pillar positioning notch

−

−

24

Roof side rail positioning notch

−

−

25

Side sill positioning notch

−

−

26

Center pillar positioning notch

−

−

27

Center pillar positioning notch

−

−

28

Roof side rail positioning notch

−

−

29

Side sill positioning notch

−

−

30

Quarter panel positioning notch

−

−

31

Quarter panel positioning notch

−

−

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BODY DIMENSIONS

2-12

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm (in)

32

Center of front door upper hinge mounting hole

Round

12.0 (0.47)

33

Center of front door lower hinge mounting hole

Round

12.0 (0.47)

34

Center of rear door upper hinge mounting hole

Round

12.0 (0.47)

35

Center of rear door lower hinge mounting hole

Round

12.0 (0.47)

36

Center of rear door switch mounting hole

Round

5.0 (0.20)

23, 32

22

24

23

32

ABB00497 AB

25

ABB00499AB

ABB00507AB

26

27, 34 34

27

ABB00501 AB

ABB00500 AB

28

30

29

ABB00504 AB

ABB00503 AB

31, 36

ABB00509AB

ABB00505 AB

35

33

36

31

ABB00508 AB

ABB00511AB

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ABB00510AB

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

REAR BODY

2-13 M4020008001356

mm (in)

37

817 (32.2) 894 (35.2)

38

555 (21.9)

1,229 (48.4)

882 (34.7)

1,071 (42.2)

990 (39.0)

39 844 (33.2)

40

41 42 1,056 (41.6)

43

37

600 (23.6)

268 (10.6)

994 (39.1)

38

1,309 (51.5)

795 (31.3)

1,040 (40.9)

1,465 (57.7) 1,312 (51.7)

40 417 (16.4)

43 ABB00184AB

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BODY DIMENSIONS

2-14

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm (in)

37

Center of liftgate hinge mounting hole

Round

10.0 (0.39)

38

Center of liftgate gas spring mounting hole

Round

8.0 (0.31)

39

Center of rear combination light mounting hole

Square

8.5×8.5 (0.33×0.33)

40

Center of rear bumper mounting hole

Square

9.0×9.0 (0.35×0.35)

41

Center of rear bumper mounting hole

Round

6.6 (0.26)

42

Center of liftgate striker mounting hole

Round

14.0 (0.55)

43

Center of rear bumper reinforcement plate mounting hole

Round

12.0 (0.47)

37, 38

41

39, 40

37

39

38

40

ABB00512AB

ABB00513 AB

43

42

ABB00515 AB

ABB00516AB

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ABB00514 AB

BODY DIMENSIONS

2-15

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

INTERIOR

M4020009001713

mm (in) 1,106 (43.5)

1,146 (45.1) 1,265 (49.8)

1,277 (50.3)

22 1,339 (52.7)

23

28

24

1,309 (51.5)

30

26

1,340 (52.8)

1,340 (52.8)

27

31

1,340 (52.8) 1,340 (52.8)

29 25

ABB00478 AB

mm (in)

28

24 22

26 30

1,165 (45.9) 1,119 (44.1)

23

1,082 (42.6)

1,087 1,033 (42.8) (40.7)

27 753

(29.6)

787 (31.0)

1,027 (40.4)

31

675 (26.6)

723 (28.5)

29 25

44 Body center point

45 Body center point

ABB00479 AB

mm (in)

45 Body center point 656 (25.8) 1,036 (40.8) 1,070 (42.1)

46

798 (31.4)

491 (19.3)

47

ABB00480AB

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BODY DIMENSIONS

2-16

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm (in)

22

Front pillar positioning notch

−

−

23

Front pillar positioning notch

−

−

24

Roof side rail positioning notch

−

−

25

Side sill positioning notch

−

−

26

Center pillar positioning notch

−

−

27

Center pillar positioning notch

−

−

28

Roof side rail positioning notch

−

−

29

Side sill positioning notch

−

−

30

Quarter panel positioning notch

−

−

31

Quarter panel positioning notch

−

−

44

Center of backbone reinforcement positioning hole (Body center point)

Round

16.0 (0.63)

45

Center of floor carpet mounting hole (Body center point)

Round

8.5 (0.33)

46

Center of rear seat belt anchor mounting hole

Round

14.0 (0.55)

47

Center of trunk room rear end trim mounting hole

Round

8.5 (0.33)

23

22

ABB00497 AB

25

24

ABB00499AB

ABB00498 AB

27

26

ABB00501 AB

ABB00500 AB

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ABB00502 AB

BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

28

30

29

ABB00504 AB

ABB00503 AB

31

44

ABB00506 AB

46

47

ABB00520 AB

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ABB00505 AB

45

ABB00517AB

ABB00519 AB

2-17

ABB00518 AB

BODY DIMENSIONS

2-18

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

48

1,294 (50.9)

130 (5.1)

1,301 (51.2) 1,294 (50.9)

49

ABB00212 AB

No. Standard measurement point

Hole shape

Size mm (in)

48

Center of front deck crossmember mounting hole

Round

12.5 (0.49)

49

Center of front deck crossmember mounting hole

Round

12.5 (0.49)

48, 49 48

49

ABB00521AB

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BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

HEADLIGHT SUPPORT PANEL

2-19 M4020017000027

mm (in)

816 (32.1)

50 939 (37.0)

404 (15.9)

880 (34.6)

51

ABC00342 AB

No. Standard measurement point

Hole shape

Size mm (in)

50

Center of front end upper bar bracket positioning hole

Round

8.0 (0.31)

51

Center of headlight support panel positioning hole

Round

20.0 (0.79)

51

50

ABB00312 AB

ABB00313 AB

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NOTES

3-1

GROUP 3

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

3-2

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

3-3

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

3-22

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

3-25

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

3-26

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

3-6

QUARTER INNER LOWER . . . . . . . .

3-28

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

3-7

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

3-29

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

3-30

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

3-31

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

3-32

FRONT END CROSSMEMBER . . . . .

3-33

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

3-10

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

3-13

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

3-16

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

3-19

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

3-21

3-2

WELDED PANEL REPLACEMENT ULTRA HIGH STRENGTH STEEL PLATE

ULTRA HIGH STRENGTH STEEL PLATE M4030002800073

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

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

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

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

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

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

Instead, replace the whole assembly including the part.

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

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

WELDED PANEL REPLACEMENT

3-3

FENDER SHIELD

FENDER SHIELD M4030004001720

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.)

ABB00450AB

REPAIR WELDS

A

23 ± 9 N·m 17 ± 6 ft-lb

A ABB00553AB

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WELDED PANEL REPLACEMENT

3-4

FENDER SHIELD

23 ± 9 N·m 17 ± 6 ft-lb

B

B F

D C

23 ± 9 N·m 17 ± 6 ft-lb

23 ± 9 N·m 17 ± 6 ft-lb E

C ABB00554AB

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WELDED PANEL REPLACEMENT

3-5

FENDER SHIELD ; ; ;; ; ; ; ;; ; ; ;; ;;;;; ;; ;;;;; ;;; ;;;; ;;;; ; ;;; ;; ; ;; ;; ; ; ;; ;;; ;; ;;;;; ;;; ;;; ;;;; ;;; ;;;; ;;;; ;;; ;;; ;; ; ;; ;; ; ;;;; ;;; ;;; ;; ; ;;;;; ;;;;; ;;;;;; ;; ; ; ; ; ; ; ;;;; ;; ;; ;; ;;; ; ;;;;;;;;;;;;;;;;;;;; ; ;; ; ;; ;; ; ;;;; ;; ; ; ;;;;;;;; ; ;; ; ; ; ;; ;; ;;;;;;; ;; ;;; ;;;;;;;;; ;;;;;;;;;; ;; ; ; ; ;; ; ;; ;; ; ; ;; ; ;; ;;; ;; ;; ;; ; ;; ; ;;;;;; ; ; ; ; ;; ;;;; ;;;;;;;; ;; ;;;; ;;; ;; ;;;; ; ;; ;;; ;;; ; ; ;; ; ;; ;; ; ; ;; ; ;;;;; ;; ;;; ;; ; ; ; ;;;;;; ;;;;;;; ;; ;;; ;;;;; ;;;;;;;;;; ;;; ;;;;;;;;;; ;; ; ; ;; ;;;; ; ;;;;;; ;;; ;;;;;;;;; ;; ;;;;;;;; ; ;;; ;;;;;;;; ;;; ;; ;;; ; ;; ; ;;;;;;;;;; ; ;; ;;; ;;;; ; ;; ; ;;; ;; ;;;;;;; ;;; ;;;; ;;; ;;; ; ;; ; ; ;;;; ;; ;;; ;;;;;;;;;;;;; ; ;;;;;;;;; ;; ; ;; ;; ;; ;;; ;;;;;; ; ;;;;;; ;;; ;;;;;;;;;;;; ;;; ;;;; ;;; ;;;; ;;;;; ; ;; ; ; ; ; ;; ; ;; ;;; ; ;;; ;;;; ;; ;;; ;;; ; ;; ;;; ; ; ;;;; ;;;;;;; ;;;; ;;; ;; ;;;;;;; ;;;;;;;; ;;;;; ;;; ;;; ; ;; ; ; ;; ;;; ;; ; ;;; ; ;;; ;; ;; ;; ;;;; ; ;;;; ; ;;; ;; ; ; ; ; ;; ;;;; ;; ; ;; ;;; ;; ; ;;;; ;; ; ;; ;; ; ;;; ; ;; ;; ;; ;;; ;; ;; ; ;; ;;;;; ;; ;; ;;; ;; ; ;;;; ;;;; ;;; ; ;;; ; ; ;; ; ;;;;;; ; ;; ; ;;; ;;; ;;;; ;; ; ;; ; ;; ;; ;; ; ; ; ;; ;;;;; ; ;;; ;;; ;;;; ;;; ;; ; ; ; ;;; ;; ;;; ;; ;; ; ; ;; ;; ;;;; ; ;;; ;;; ;;;; ; ;;;; ;;; ; ;;; ;;;; ;; ; ; ; ; ;; ; ;;;;;;;;;;;; ;;;; ;;; ;;; ;; ;; ; ; ; ; ;; ;; ; ;;; ;;; ;;;; ;; ; ; ;;; ;; ; ;;; ; ;;;;; ;;; ;; ;;;; ;;;; ; ; ;; ; ;;;;; ;; ;; ; ; ;;; ;; ; ;; ;; ; ;; ; ; ;; ;; ;; ; ; ;; ; ;; ;;; ; ; ;; ; ;; ;; ; ; ; ;; ; ;;; ; ;;; ; ;; ;;;;;;; ; ;;;; ;; ;;;;;; ; ;; ; ; ;; ;;;; ;; ; ; ;; ; ;;;;; ;; ;;;; ;;; ;; ;; ; ;; ;;;; ;;;;; ; ;;; ;;;; ;; ;;; ;; ;;; ;; ;;;;; ; ; ;;; ; ;; ;;;; ;; ;;; ;; ; ;;; ;;;; ;;;;;; ;;; ;; ;;; ;;;;; ; ;; ;;; ;; ; ; ;; ;;;;;;;;;;;;;;;;;;; ;;;;;;; ;;;;; ;;;; ;; ;; ; ;;; ;; ;; ; ;; ;; ;;;;;;;;;;;;;;;;;;; ;;;; ;;; ;;; ;;; ;; ; ;;;; ;;;;;; ;; ;;; ;;;;; ;; ; ; ;;; ; ;; ; ; ;; ; ; ; ;; ;; ;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;; ;; ;;; ;;; ;; ; ;; ; ;;;; ;;; ; ;; ;;;;;;;;;;;;;;;;;;;;; ;; ;; ; ;; ;; ;;; ;; ;;;; ;;; ; ;;;;;;;;;;;;;;;;;;;; ;;; ;; ; ;;; ;;;; ;;; ;;; ; ;;; ; ;; ;; ; ;;;;;;;;;;;;;;;;;;; ;; ; ; ; ;;; ;;;;;; ;; ;;; ; ;;;;;;;;;;;;;;;;;;;;; ;;;; ;; ;;;;;;;;;;;;;;;;;;; ;; ;;;; ;; ;;;; ;; ;; ;;;; ; ;; ;;; ;; ; ;;;;; ;;;; ;; ; ;; ; ; ;; ;; ;;;;;;;;;;;;;;;;;;;;; ;;; ;;;;;;;; ;;;; ; ;;; ;; ; ;; ;;; ;;;; ;;;; ; ;;; ;; ; ;; ; ;; ;; ;; ;;; ; ;; ;; ; ;;;;;;;;;;;;;;;;;;;;; ;;;; ;;; ; ;;;;; ;;; ;; ;;; ; ;;;; ; ;; ; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;; ;; ;;; ;; ; ; ;; ;;;; ;;;;; ;;;; ;;;; ; ; ;; ;;; ;; ;;; ;;;;;; ;; ;; ;; ; ;;;; ;;; ; ;;;;; ; ;;; ; ;;;;; ; ; ;;; ; ; ;; ; ; ;; ;; ;; ;; ;; ; ;; ; ;; ;;; ; ;; ;; ;;;; ; ; ;; ;;; ; ;;; ;;; ; ;;; ; ;; ; ; ;;; ; ;;; ; ; ; ;; ;;; ;; ; ;;;;; ;;; ;; ; ;;;;;; ;; ;;; ;;;;; ;;;;; ; ;;;; ;; ;; ;; ; ; ;; ; ; ;;;;;;; ;;; ; ; ;;; ;;; ; ; ;; ;; ;;;;; ;; ;; ; ;; ; ;; ;; ;; ; ; ;; ; ; ; ; ;;;;;; ;; ;; ;;; ;;;; ;; ; ; ; ; ; ; ; ; ; ; ;;; ;; ;;;;; ; ;;;; ;; ;;; ;;; ;; ;;;;; ;;;;; ; ;;; ;; ; ;;;;;;;; ; ;;;; ;;; ;;; ;;; ;; ;; ;; ; ;; ;; ;;;; ; ;; ; ;; ;;;; ; ;; ; ;; ;; ; ; ;; ; ;;; ;; ; ;;;; ; ; ; ; ;D ; ;;;; ;

E

(With the upper outer frame removed) F ABB00555 AB

TSB Revision

WELDED PANEL REPLACEMENT

3-6

FRONT SIDEMEMBER (PARTIAL REPLACEMENT)

FRONT SIDEMEMBER (PARTIAL REPLACEMENT) M4030000100926

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

ABB00451AB

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

REPAIR WELDS (Right side)

(Left side)

180 mm (7.1 in)

115 mm (4.5 in)

Center of engine mounting insulator mounting hole

Center of transmission mounting insulator mounting hole

B

A Center of splash front shield mounting hole

Center of splash front shield mounting hole

70 mm (2.76 in)

60 mm (2.36 in)

B

A

ABB00640AB

TSB Revision

WELDED PANEL REPLACEMENT

3-7

FRONT PILLAR

FRONT PILLAR M4030005002102

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.)

ABB00452AB

Cutting position

REPAIR WELDS C B

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

A

Notch

150 mm (5.9 in)

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

F

H A

50 mm (1.97 in) Notch ; ;; ;;; ;;; ;;

E

G

(With the side outer panel removed) D

B

(With the side outer panel removed) D

C

TSB Revision

E

ABB00557AB

WELDED PANEL REPLACEMENT

3-8

FRONT PILLAR

(With the upper outer frame removed) F

;; ;; ; ;;; ;; ;;; 10 ± 4 N·m ;;; ; ;;; ;;;;;;;;; ;;;; ;;;;;;;; ;; ;;;; ; ;;; ;;;; ; ;; ;;; ; ;; ;;;;;;;;; ;;;;;;;;; ; ;;;; ;;; ; ;;; ; 89 ± 35 in-lb ;; ;; ;;; ;;; ;;;;;;; ;;; ;;;;;;;;;;; ; ;;;;; ; ;;; ;;; ;;; ;;; ;;;; ;;;;; ; ; ;;;;;;; ;;; ;; ;;;;;;;;; ;; ;;;;;;; ;;;;;;; ; ;; ;; ;;;; ;; ;;;;; ; ;;;;;;;;; ;;;; ; ;; ; ;;;;;;;;; ;; ;;;; ;; ;; ; ;; ; ; ;; ; ;;;; ; ; ; ;;;;;;;;; ;;;;;;;; ;;;;; ;;; ;;;; ;;; ;;;;; ;;;; ; ;; ;;; ;; ;;;; ;; ;; ;;; ;;;; ;; ;;;; ;;; ;;; ; ;; ;;; ;;; ;;;; ;;; ; ;;; ;;;;;; ; ;;; ;;; ;;;;;; ;; ;;; ;;; ;;; ;;; ; ;; ; ; ;; ;;;;; ; ;;;; ;;;; ; ;; ; ;; ;;; ;; ;;; ;;;;; ;;; ;;; ;;; ;; ;;;;; ;;;;;;;; ; ; ;; ;;;;;; ;;;;; ;; ; ;; ;; ; ; ;; ;;;;; ;;;;; ; ;; ;;; ;;;; ;; ; ;; ;;; ;; ; ;; ;; ;; ;; ;;; ;; ;;;; ;;;; ;; ;;; ;;; ; ;;;; ;; ; ;; ;;; ;;; ;; ; ; ; ; ;;;; ;;; ; ;;;;; ;;;; ;;;; ;; ;;;;;;;;;; ; ;; ;;; ;; ;;; ; ; ; ; ;;; ; ; ;;;;;;;;; ;;;;; ;; ;; ; ;;; ; ;; ; ;; ; ;;; ; ; ;;;;;; ; ;;;;;; ;; ; ;; ;;;;;;;; ;; ;;;;;;; ;; ;; ;; ;;;;;;;;;; ;; ; ; ; ;; ;; ;; ; ;; ;; ; ;;; ;; ; ;; ;; ; ; ;; ;; ; ;;;;;; ; ; ;; ; ; ;; ;;;;;;;; ;; ;;;; ;; ;;;; ; ;; ;;; ;;; ; ;;;; ;; ; ;; ;; ; ;;; ;; ; ;;;;; ;;; ;;;;; ; ;;; ; ; ;;;;;; ;;;;;;; ;; ;;;;; ; ;;;;;;;;;; ;;; ;; ;; ; ;; ; ;;;;;;;;; ;; ;;;; ; ;;; ;; ;;; ;;;;;;;;;;;; ;;;;;;;; ; ;;; ;;;;;;;; ;;; ;; ; ; ; ; ;;;;;;;;; ;;;; ;; ;;;;;;;;;; ; ; ;;; ;;;; ; ;;; ;; ;;;; ;;;;;;; ;;;; ;;; ;;; ;;; ; ;; ; ;; ;;;; ;;; ;;;;;;;;;;;;; ; ;;;;;;;;; ;; ;; ; ;; ; ;; ;; ; ;;; ; ; ; ; ;; ;;; ;;;;;; ;;;; ; ;;;;;;;;;;;; ;;; ;;;; ;;; ;; ;;;; ;;;; ;; ;; ; ;;;; ; ;;; ; ;;; ;;;; ;;; ;;;; ;;;; ; ;; ; ;;;;;;; ; ;; ;; ;; ; ;;;;;;; ;;;;;;;; ;;; ;;; ;;; ;; ; ;; ; ;; ;;;;; ;;; ;;; ; ;;; ; ; ;; ;;; ;; ;; ;; ;;;; ; ;;;;;;; ;;;;; ;; ;;;; ;;; ;;;; ;;; ;; ; ;;;; ;; ; ;; ;; ; ; ; ; ;; ;;;;;;;;;; ;; ;; ;; ; ;; ;;; ;;;;;;;;;;; ; ;;; ; ;;; ; ;; ; ;; ;;;;;; ; ;;;;;;;; ;;; ;; ; ;;; ;;;; ;; ; ;; ;;; ;;; ; ;; ;; ;;;; ;; ;; ;;; ; ;;;; ; ;; ; ;;; ;; ;;;; ;; ;;;;; ;;; ; ; ; ;;; ; ; ;;;;;; ;;;; ;; ;; ; ;; ;;; ; ; ; ;;;; ;; ; ;; ;;;; ;; ;;;; ;;;; ; ; ;; ; ;;;;; ;;;;; ;;; ;; ;; ; ; ; ;; ; ;;;; ;; ; ;;; ;; ; ;;;;; ;;;;;;;; ;;;;;;;;;;;; ;;;;; ; ;; ;;; ;;;; ;;; ; ;; ;; ;; ; ;; ;; ;;;; ; ;;;; ;;;; ;; ;;; ; ;;;; ; ;; ; ;;;;;;;; ; ;;;; ; ;;;;;;;; ;; ; ; ;; ;;;; ;; ; ;; ;; ;;;; ;; ;; ; ;; ;; ;;;;;; ;;;; ; ;;;; ;; ;;; ;;;; ; ;; ;;;; ;;; ;; ;; ;;; ;;;;; ; ; ;;; ;; ;; ;;; ; ;;;;; ;;; ;; ; ;;;;;;;;;;;;;;;;;;; ; ;;; ;;;; ;;;;; ;;; ;; ;;;;;; ; ;;; ;; ;; ; ; ;; ;; ;; ;;; ;;;;; ;; ;;; ;; ;;;;;; ;; ; ;; ; ; ;; ;; ;; ;;;;;;;;;;;;;;;;;;; ;;; ;;; ;;;; ;; ;; ; ;; ;;;;; ;;;;;;;;;;; ;; ; ;; ; ; ; ; ;; ;;;;;;;;;;;;;;;;;;; ;;;;; ;; ;;;; ; ;; ; ; ;; ;; ; ;;;;;;;; ; ;; ; ; ; ;; ;; ;; ;;;;; ;; ;;;;;;;;;;;;;;;;;;;;;;; ; ;;;;;;;;;;;;;;;;;;;; ; ; ;; ;; ;; ;; ;;; ; ;; ;; ;;;;;;;;;;;;;;;;;;; ;; ;; ;; ;;; ; ;;;;;;; ;;; ;;;; ;; ;;;;;;;;;;;;;;;;;;; ;; ;;; ;; ;;; ;;;; ; ;;; ;;; ;; ;; ; ;;;;;;; ;;;; ;; ;; ;; ;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;; ;;; ;;;; ;;;; ;; ; ; ;;; ;;;;;;; ; ;; ;;; ;;;; ;;;; ; ; ;;;;; ; ;; ;; ; ;; ; ;;;;;;;;;;;;;;;;;;;;; ;;; ;;; ;; ;; ;;;;; ; ;;;;;;;;;;;;;;;;;;;;; ;;;; ;;; ;; ; ;;;; ;;; ;; ;; ; ;;;; ;;;; ; ;;; ;; ;;;;;;;;;;;;;;;;;;;;;;;;;; ;; ;; ;;;;;; ;;;; ;; ;; ;;;;;;;; ;;; ;; ;;; ;;; ;;;;;; ;;; ; ;;;; ;; ;; ; ;;;;;;;;;;; ; ;;;;;; ;;;;;;; ;;;;; ;;; ;; ;;;; ; ; ;; ;;; ;;;; ;;; ;;;;; ;;;; ;;;; ;; ; ; ;;; ;; ;; ; ;;; ;;;; ;; ;; ;;; ; ; ;;;;;;;; ;; ;;;;; ;; ;;;; ; ;;; ;; ;; ;; ; ; ;; ;; ; ; ;;;; ;;;; ; ; ;;; ;;; ; ;; ; ;; ;; ;; ;;;;;;;; ;;; ; ;; ; ;;; ;; ; ;;;;;; ;; ;;;; ;; ; ;; ;;;; ;;; ;; ;;;;;;;; ; ;;; ;; ;;; ;; ; ; ;;; ; ;;; ;; ;;;;; ; ; ;;; ;;; ;; ;;; ;; ;;;;; ; ;;; ;;; ;;;; ;; ;;; ; ;; ; ;; ;;; ;;; ;; ;;; ; ; ; ;; ;;; ; ;; ;; ; ; ;; ;;;;; ;;;; ;; ; ;;;;; ;;; ;; ;;; ; ;; ;;;;;;; ;;; ; ;; ;;;; ;;;;;; ; ;;;; ; ;;;;; ; ;; ;; ;; ;; ;;;; ; ; ;;;; ; ;;; ;;;; ;; ; ;; ;; ;;; ; ;; ;; ;; ;;;;;;;;; ;;;; ;; ;;;;;;;;; ;;;;;; ; ;; ; ;;;; ;; ;;; ;;; ;;; ; ;;;; ; ;; ; ;;; ;;; ;; ; ; ;; ;; ;;;;;;;;; ;;;;;;;;; ;;;;;;;;;;; ;;;; ; ;;; ;;;; ; ;;;;; ;;; ; ;; ;;; ;;;;;;; ; ; ;; ;;;;;;;;;;;;;;; ;; ;; ;;; ; ;;;;;; ;;;;;;;;; ;; ; ;; ; ;; ; ;;; ; ;;; ;; ;; ;; ;; ;;;;;;;;;;;;; ;;;;;;;;;;;; ;; ;;; ;;;;;; ; ;; ;; ; ;; ;;;;;;;;; ;;; ;; ;;; ;;;;;;;;; ;;;;;;;;;; ;;;;; ;; ;;; ; ;;; ;;;;;; ;;;;; ;; ;; ; ; ;;; ;; ;;;;;;; ; ;; ; ;;;;;;;;; ; ;;; ; ; ;; ;;; ;;;;;;;;; ; ;;;;;;;;;; ;;;;;;;;;;; ;;;;;;;;;;;; ;;; ;;;;; ;;; ; ;; ;; ;; ;;; ; ;;; ;; ; ;; ;;; ;;;;;;;;; ;; ; ;;;;;;;;;; ; ; ;; ;; ; ;; ;;;;;;;;;;; ;; ;;;;;;;;;;;; ;;; ;;; ;;;;; ;;;;; ;;;;;;;;;;;; ;;;;;;;;;; ; ; ;;;; ;; ;;;;;;; ;;;;; ;; ;;;; ;;;;;;; ;;;;;;; ;;;;;;;;;;; ; ; ;; ;;;;;;;;;;;; ;;; ;;; ;;; ;;; ;;;;;;;;;;;; ;;;;;;;;;;;;; ;; ;;;; ;;;; ;;;;;; ;;;;;; ;; ; ;;; ;; ;;;;;; ;;; ; ;;; ; ;;;;; ;;; ;; ;;;;; ;; ;;; ;; ;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;; ;; ;; ; ;; ;; ;; ;;;;;; ;;; ;;;;;;;; ;; ;;;;;; ;;;;;; ;;;;; ;;;;; ; ;;; ;; ;; ;;;;;;;;;;; ;;;;;;;;;;;; ;; ;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;; ; ; ;; ;; ;; ;;;;;;; ;; ;; ;;;;; ; ; ;; ;; ;; ;;;;;;;; ; ;;; ; ;; ;;;; ; ;;; ;; ;; ;; ;; ;; ;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;; ;; ; ;; ;;;; ;; ;;;; ;;;;; ;; ;;;;; ;;; ;; ;;;; ;; ;; ;; ;;; ;;;;;;; ;; ;;; ;;; ; ; ;;; ;; ;;; ;;;;;;;;;;;;;;;;;;; ;; ;;; ;; ;; ;;;;;;;;;;;;;;;;;;;; ;;;; ;; ;; ;;;; ; ; ;;; ;;;;;; ; ;; ; ;;;; ;;; ;; ;;;; ;;; ; ;; ;;; ; ;; ;;;;; ; ;; ; ;; ;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;; ; ;; ;; ;; ;; ; ;;; ;; ;;;; ;;; ;;; ;;;; ;; ; ;;;;;; ;;; ; ; ;;;; ;; ; ;;; ;; ; ;; ;; ;; ;;;;;;;;;;;;;;;;;;;; ;; ;;;;;;;;;;;;;;;;;;;; ; ;; ; ;; ;; ; ;;;; ;; ;;; ; ;; ;;; ; ;;; ;;;;;; ;;;; ;;;;;; ; ;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;; ;;; ;; ;;;;;;;;;;;;;;;;;;;; ; ;;;;;;;;;;;;;;;;;;;; ; ;;; ; ;;; ; ;;; ;;;;;; ;;;;; ; ;;; ;;;; ; ;;;; ; ;;;; ;;; ;; ;;;; ; ;; ;;; ; ; ;; ;;;;; ; ;; ; ;;

H G

ABB00613AB

NOTE: Refer to the Fender Shield section on P.3-3 for the welding points with the upper outer frame.

TSB Revision

WELDED PANEL REPLACEMENT FRONT PILLAR

3-9

NOTE ON REPAIR WORK .

REMOVAL To cut the welding points between the front pillar reinforcement lower and side sill reinforcement, cut the side outer panel as shown.

Cutting position

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

ABB00461AB

.

INSTALLATION Cutting position B

1. To reinforce the strength in the front pillar cut area, cut the side outer panel at A point [100 mm (3.9 inches)] above the cut area and cut the front pillar reinforcement upper at B point [50 mm (1.97 inches)] above the cut area.

2. Assemble the new front lower inner pillar parts.

3. Assemble the new front upper inner pillar parts.

4. Assemble the new front pillar reinforcement upper part.

Cutting position A

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

50 mm (1.97 in)

100 mm (3.9 in) ABB00462 AB

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

NOTE: : Body sealant

ABB00463 AB

TSB Revision

WELDED PANEL REPLACEMENT

3-10

FRONT PILLAR (PARTIAL REPLACEMENT)

FRONT PILLAR (PARTIAL REPLACEMENT) M4030001200131

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.)

ABC00530AB

REPAIR WELDS

; ; ; ;

250 mm (9.8 in)

Cutting position

E

(With the side outer panel removed) B

50 mm (1.97 in)

Cutting position

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

A

Notch

A

D C

B

C

TSB Revision

ABC00393AB

WELDED PANEL REPLACEMENT

3-11

FRONT PILLAR (PARTIAL REPLACEMENT)

;; ; ; ;; ;; ; ;;;;;;;;; 10 ± 4 N·m ;;;;; ; ; ;;;;;; ;; ; ;; ;;;; ; ;;; ;;; ;; ;;;;;;;;; ;;; ;;;;;;;; ;; ;;;; ;;;; ;;;; ; ;;; ; ;;; ;; ;;;;;;;;; ;;;;;; 89 ± 35 in-lb ;;; ; ;;; ;; ;;; ;; ;;; ;;; ;;;;; ; ;;; ;;;;;;;;; ;;;;;; ;; ; ;;; ;;;;;;;;; ;;;;;; ;; ; ; ; ;;; ;;; ; ; ;;;;; ;; ;;;;; ;; ;; ;;;; ;;;;; ;;;; ;; ;;; ;;;;;;;;; ; ;;;;;;;;; ;;; ;;;;;; ;;; ;; ; ;; ;;;;; ; ;; ;;;;; ; ; ;; ;; ;;; ;;;;;; ; ;;;; ;; ; ;;; ;;;; ;;;; ;;;; ;; ;; ;;;; ;; ;;; ;;;; ;; ;; ;;;;; ; ;;; ;;;;; ; ; ;; ;;;; ; ;; ;;; ; ;;;;;; ;; ;;;;;; ; ;;; ;;; ;;;;;;; ;;;; ;;; ; ;; ; ; ;;; ; ;;; ;;;;;;;;;;; ;;;;;; ;;;;; ;; ; ; ;; ;;; ;; ;;;;;;;;;;;;;;;; ;;; ;;;; ; ; ; ;;; ; ;;;;;;;;;; ;;;;;;; ; ;; ; ;;; ;;;;;;;;;;;;;; ; ; ;; ;;; ;;;;; ;; ;;; ;;; ;;; ; ; ;;; ;;; ;;; ; ;;;;; ;; ;;; ;;; ;;;;;;; ; ;;;; ; ;; ; ;; ; ;;;;;;;; ; ;;;;;;;;;; ;;; ; ;;;; ;; ; ;;;; ;;;; ;;; ;;;;;;;; ;;;; ;;; ;;; ;; ;;;;;;;;;;;;;; ; ; ;; ; ;; ;;;;;;;;;; ;;;;;;; ;;; ; ;;;;;;;;;; ; ; ;;;; ;; ;;;;;;;;;; ;; ; ; ;;;;;;; ; ;;; ;; ;;;;;; ;;; ;;;; ;;; ;;;;;;;;;;; ;;;;;;;; ; ; ;; ; ;; ; ;;;;;;;;;;;;;;;;;;;; ; ; ;; ; ; ;; ;; ; ;; ;; ;;;;;;; ;; ; ;; ;; ; ;;; ; ;; ;; ; ;; ;; ;; ;;;;; ;;;;;; ; ; ;;; ; ;; ;;;; ;; ;;; ;;;;;; ; ;;;;; ;;; ;;;;;;;; ; ; ; ;; ;;;; ;;;;; ; ; ; ; ;;;;; ; ;;; ;;; ; ;; ;; ; ;; ; ; ; ;;; ;;; ;; ;; ;;;; ;;;;;;;;;; ;;;;;;;;; ; ;;;;;;;;; ;; ; ; ;;;; ;; ;;;;;;;;;; ;;;; ;; ;;;;; ;; ;;;; ;; ;;;; ;;; ;; ;;; ;;; ;; ; ;;;; ; ;; ;;;;;;;; ;; ;;; ;;; ;;; ;; ;;;;;;;;;;;; ;;;;;;;;; ; ;; ; ;;; ;;;; ;; ;; ;;;;; ;;;; ; ;; ; ;; ;;;;;;;;;;; ; ; ;; ;; ;;;;; ;;; ;;; ;; ; ;;;; ;;; ;;;;;;;;;;; ;;;; ; ;; ; ;;; ;; ; ; ;;;; ;; ; ;;;;; ;;;;; ; ;;; ; ;;;;;;;; ;; ;;; ;; ;; ; ; ; ; ;;;; ;;;;;; ;;;; ;;;; ;; ;; ;;;;;; ;;;;; ; ;;;;;; ;;; ;; ;;;;;;;;;; ;;;;; ;; ;; ; ; ; ;; ; ; ;; ; ; ;; ;; ; ;;; ; ;; ;;; ; ;;;; ;; ;;;;; ;; ;; ;; ;;;; ; ;; ;;; ;; ; ; ;; ; ; ; ;;;;; ; ;;; ; ;;; ;; ;;; ;; ; ;;;;;; ;;;; ;;;;;;; ; ;; ; ; ; ; ;;;;;; ;;;; ;;;; ;;; ;;;;; ; ;; ; ; ; ;;;;;; ;; ; ;;;; ;; ; ; ; ;; ; ; ;;;;;;;; ;;; ;;;;;; ; ; ;;;; ;; ; ; ;; ; ;; ; ;; ; ;;; ;;;;; ;;;;; ;;; ;; ;;; ;; ; ;;;; ; ; ;;;; ;;;; ;; ; ; ; ;; ;; ;;;; ;;;; ;; ;;;;; ;; ;;;;;; ;; ;; ;; ; ; ; ;; ;;; ;;; ;; ;; ; ;; ;; ; ;;;;;;; ;;;; ;;; ; ;;;;;;;;;;; ; ; ; ;; ;;; ; ; ;; ; ;; ;;; ;;; ; ;; ; ; ; ;;; ;; ; ;; ;;;;;;; ;;;; ;;;; ;; ;;;;;;;;;; ;; ;; ;;; ; ; ; ;; ;;; ;;; ;; ;;;;; ;; ;; ; ;;; ; ;;;; ;; ; ;;; ; ;; ;;;; ;;;; ; ;; ;; ;;; ;;; ;;;; ;;;; ;;; ;;;;;;;;;;;;;;;;;;; ; ; ;; ;;;;; ;;;;; ;;; ;; ;;;;; ; ; ;;; ;;;; ;; ; ; ;;;;;;; ;;; ;; ; ;;;;; ; ;; ;; ; ;; ;; ;; ;; ; ;;;;;;;;;;;;;;;;;;; ;;; ;;; ; ;; ; ;;;; ;; ;;;;;;;; ;;; ;; ;;;; ;;;;;; ;; ;; ; ;;;;;;;;;;;;;;;;;;; ;;;; ;;;; ;;;; ; ;;; ;;; ; ;;; ;;;; ;;;; ;; ;; ;; ;;;;;;;; ;;;;; ; ;; ;; ;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;; ;; ;; ;;; ;;; ;;;;;;;;;;;;;;;;;;;;;;; ; ;;; ;;;; ;; ;; ;; ; ; ;; Cutting ;;;; ;; ; ;;;; ;;;;;; ; ;;;; ;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;; ;; ;;;;;;;;;;;;;;;;;;; ; ;; ;;;; ; ;;; ;; ;; ; ; ;;;;;;;; ; ; ; ;; ;;;; ;;; ; ;;; ;;; ; ;;;; ;;; ;;; ;;;; ; ;;; ;;;; ; ;;;;;;;;; ;; ; ;; ;;;;; ;; ;;; ;;;;; ; ;;;;;;;;;;;;;;;;;;;; ;; ; ;; ;;; ;;;; ;;;; ;;; ;; ;; ;; ;;; ; ;; ;; ;; ; ;;;; ;;;;;;;;;;;;;;;;;;;; ;;; position ;;;;;;; ; ;; ;;;;;;;;;;;;;;;;;;;;;;;;; ;; ;; ;;;;; ; ;; ;; ;;; ;;;; ;;; ; ;;;;; ;;;;; ;;; ;; ;;; ; ;; ;;;;;;;;;;;;;;;;;;;; ; ;; ;;; ;; ;; ;;;; ; ; ;;; ;; ;; ;;;; ;;;; ;; ; ; ;;;;; ;;;; ;;; ;;;; ; ;; ;;; ;; ;;;; ;;;; ;; ;; ;; ; ;;;;;;;; ; ;; ; ;;;; ;;;; ; ;;; ; ; ; ;; ;;; ;; ;; ; ; ;;;; ;;;;;; ;;;; ;;;;; ; ; ;; ; ; ; ;;; ; ;;;; ;; ;; ;; ; ; ;;; ; ; ;; ; ;; ; ;; ; ;;; ;; ; ; ;;; ;; ; ;; ; ;;;;;; ;; ;;;; ;; ;; ;;; ;;;; ;;; ; ;;;; ; ; ;;;;;;; ;;;; ; ;; ;; ;;; ;; ; ;;; ; ; ;;; ;; ;;;;; ; ;;;;; ;; ;;;; ; ;; ; ; ;;; ;; ;;; ;;;; ;;;;;; ;;;;; ;; ;;;; ; ;;;; ;;; ; ;;;; ;;; ;; ; ; ;;;;;;;;;; ; ;; ; ;; ;;; ;; ;;;;;; ; ;; ;;; ;; ;;;;;; ;; ; ;;;; ;; ; ;; ; ;;; ;;; ;;;;;;;;; ;; ; ;; ; ; ; ;; ;;; ; ;;; ;;; ; ;; ;; ;; ; ;;;;;;;; ;;; ;; ;;; ;;;;;; ;;; ;; ; ;;; ; ;;; ;;; ;; ; ;;;;;;;;;;; ; ;; ;; ;;;;;;;;;;; ;;; ; ;;; ; ; ;;; ;; ;; ;;; ; ;;; ;; ;;;;; ; ;; ;;;; ; ;; ; ;;;;;;;;; ;;; ; ;;;;;; ;;;;;;;; ;;;;;;;;; ;;; ;;; ;;; ; ;;; ;;;;;; ; ;; ;; ;; ; ; ;; ;;;;; ;; ;; ;;;; ;; ;;;;;;;;;;;; ;;;;;; ;; ;; ;;;;;;;; ;; ;;;;;;;;;; ;;;;;;;;;;; ;;;;; ;;;; ;; ;;; ; ;;;;;; ; ; ;;;; ; ; ;; ;;; ; ;;;; ;; ;;; ;;; ;; ;; ;;;;;; ; ;;; ;; ;;;;;;;;;; ;;;;;;;;; ;; ; ;; ;;;;;;;;; ;; ;;;;;;;;;; ;;;;;;;;;;; ;;;;;;;;;;; ;;;;; ;;; ; ;;; ;;;; ;; ; ;; ; ;;;;;; ;;;;;;;;; ;; ; ; ;;;;;;;;;; ;; ;;;;;;;;;;; ;; ; ;; ; ;;; ;;;;;;;;;;; ;;;;; ;;;; ;;;;;;;;;;;; ;;;;;;;;;; ; ;; ;; ; ; ;; ;; ; ;; ;;;;;;;;;;; ; ; ;; ; ;; ; ; ; ; ; ;; ; ; ;; ; ;;; ; ;;;;;;;;;;; ;;;;; ;;;; ;;;; ;;; ;;; ;;;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;;;; ; ;;;; ;;;; ;;;;;;; ;; ;;;;; ;; ;; ;; ;;;;;; ;;;;; ;;;;;;;;;;; ;;; ;; ; ;;;; ;;; ;;; ; ;;;;;; ;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;; ;; ;;; ;;;; ;; ;;;;;; ;; ;; ;;; ; ; ;;;; ; ;;;;; ; ;;;; ; ;;;; ;; ;;; ; ;;; ;; ;;; ; ;;;;;;;;;;;; ;; ;; ;; ;; ;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;; ; ;;; ;; ;; ;;; ; ;; ;;; ;;;; ;; ;;; ;;;;; ;;; ;; ;;; ;;;;;;; ;;;;; ;;;;;;; ;;; ;;;; ;;;;;;; ;; ;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;; ; ;;;;;;;;;;;;;;;;;; ;;;; ;; ; ;; ; ;;; ;;;;; ;;; ;;; ;;;; ;; ;;;; ;;; ;;; ;; ; ;;; ;; ; ;; ; ;; ; ;; ;; ;; ;; ;; ;; ; ;;;;;;;;;;;;;;;;;;;; ;;;; ;;; ;;; ;; ;; ;; ;;; ;;; ;; ;; ;; ;; ;;;;;; ;;; ;; ;;; ;; ;; ;;; ; ; ;;;;;;;;;;;;;;;;;; ;;; ;; ;;; ;; ;;;;;;;;;;;;;;;;;;;; ;;;; ; ;;; ; ;;;;;; ;;;;;;; ;;; ;; ;;; ;;;; ;;; ;;; ; ;;;;; ;; ;;; ; ;; ;; ; ;; ;;; ;; ;;;;;;;;;;;;;;;;;;;; ; ;;;;;;;;;;;;;;;;;;;; ; ;;; ; ;;; ; ;;;; ;;; ;; ; ;; ; ;; ;;; ;;;;;; ; ;;; ;;; ;; ;;; ;;;;; ;;; ;; ;; ;; ;; ;; ;; ;; ; ;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;; ;; ; ;;; ;;; ;; ;; ;;; ;;; ;; ;;; ;;;; ;; ;;; ;;; ;;; ;;;;;; ;; ;; ; ;;; ;; ;;;;;;;;;;;;;;;;;;;; ; ;;;;;;;;;;;;;;;;;; ;;; ;; ; ;;;;;;;;;;;;;;;;;;;; ; ;;;;;;;;;;;;;;;;;;; ; ;;; ;; ; ; ; ;;;; ; ;; ; ; ;; ;;;

D

E ABC00394 AB

NOTE: Refer to the Fender Shield section on P.3-3 for the welding points with the upper outer frame.

NOTE ON REPAIR WORK .

REMOVAL Cutting position

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

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

2. Cut the side outer panel, front pillar reinforcement lower and front inner pillar lower and remove.

ABB00461AB

.

TSB Revision

3-12

WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT)

INSTALLATION Cutting position

50 mm (1.97 in)

1. To reinforce the strength in the front pillar cut area, cut the side outer panel and the front pillar reinforcement lower 80 mm (3.15 inches) above the cut area and cut the side outer panel 50 mm (1.97 inches) above the cut area.

2. Assemble the new front inner pillar lower parts.

3. Assemble the new front pillar reinforcement lower parts.

80 mm (3.15 in) ABC00531AB

4. When installing a new front outer pillar, cut the pillar along the remaining body side. Then, apply the body sealant in the area shown in the figure.

Cutting position

NOTE: : Body sealant

ABC00396AB

TSB Revision

WELDED PANEL REPLACEMENT

3-13

CENTER PILLAR

CENTER PILLAR M4030006001373

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.)

ABB00453AB

REPAIR WELDS

D

A Cutting position

150 mm (5.9 in)

Notch

A

E

F

The same position as the new center outer pillar part.

The same position as the new center outer pillar part.

B

C

B

C

TSB Revision

ABC00133 AB

WELDED PANEL REPLACEMENT

3-14

CENTER PILLAR

E

D

(With the side outer panel removed) F ABB00566AB

TSB Revision

WELDED PANEL REPLACEMENT CENTER PILLAR

3-15

NOTE ON REPAIR WORK .

REMOVAL Cutting position

Cutting position

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

ABB00468AB

2. Since the center inner pillar upper remaining on the body side is hard to remove, cut the roof side rail inner up to the position shown in the figure, and remove the center inner pillar upper by pulling it towards you.

Cutting position

Cutting position

Roof side rail inner Center inner pillar upper ABB00469AB

.

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

50 mm (1.97 in) Side outer Cutting panel position ABB00470 AB

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

ABB00471

TSB Revision

WELDED PANEL REPLACEMENT

3-16

SIDE SILL

SIDE SILL M4030007001699

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.)

ABB00454AB

REPAIR WELDS

The same position as the new front floor side sill outer part.

The same position as the new front floor side sill outer part.

C

A B

D

A

B

C

D ABB00136 AB

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WELDED PANEL REPLACEMENT

3-17

SIDE SILL

E

F

(With the side outer panel removed)

(With the center pillar reinforcement removed) E

F ABC00137AB

NOTE ON REPAIR WORK .

REMOVAL 90 mm (3.54 in)

Cutting position

1. When removing the side sill reinforcement, cut the center pillar reinforcement 90 mm (3.54 inches) downward from the installation hole of the rear door hinge because the center pillar reinforcement interferes with it.

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

Center pillar reinforcement ABB00472AB

.

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WELDED PANEL REPLACEMENT

3-18

SIDE SILL

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

ABB00471

2. When installing the new front floor side sill outer part, apply the body sealant and adhesives in advance to the areas shown in the figure.

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

NOTE: : Body sealant

: Adhesive ABB00674AB

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WELDED PANEL REPLACEMENT

3-19

QUARTER OUTER

QUARTER OUTER M4030008001409

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.)

ABB00455AB

REPAIR WELDS

B C 3 points on left side

D

A

The same position as the new quarter panel outer parts.

B

A

ABC00143 AB

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WELDED PANEL REPLACEMENT

3-20

QUARTER OUTER

50 mm (1.97 in)

50 mm (1.97 in)

D

C

ABB00572AB .

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

NOTE:

: Cuttable range

ABB00475AB

NOTE ON REPAIR WORK .

INSTALLATION When installing the new quarter panel outer parts, apply the body sealant and adhesives in advance to the areas shown in the figure.

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

Left side

NOTE: : Body sealant : Adhesive ABB00476AB

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WELDED PANEL REPLACEMENT

3-21

REAR END PANEL

REAR END PANEL M4030000300168

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.)

ABB00456AB

REPAIR WELDS

A

A ABB00538AB

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WELDED PANEL REPLACEMENT

3-22

REAR FLOOR

REAR FLOOR M4030010001376

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

ABB00457AB

REPAIR WELDS

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

D

A

B

C

B

A

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ABB00606AB

WELDED PANEL REPLACEMENT

3-23

REAR FLOOR

Cutting position

Cutting position

E

F

D

C

Cutting position

Cutting position

E

F ABC00527AB

NOTE: Refer to the Rear End Panel section on P.3-21 for the welding points with the rear end panel.

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WELDED PANEL REPLACEMENT

3-24

REAR FLOOR

NOTE ON REPAIR WORK .

REMOVAL 1. When removing the rear floor pan, cut it 60 mm (2.36 inches) behind the installation hole of the rear seat belt anchor.

2. To remove the rear floor sidemember extension and the rear floor sidemember reinforcement, follow the steps below:

60 mm (2.36 in)

ABB00639AB

(1) Cut off the rear floor sidemember extension together with the rear floor sidemember reinforcement 80 mm (3.15 inches) <left side> or 50 mm (1.97 inches) <right side> behind the edge of the extension.

(2) Remove the rear floor sidemember extension remaining on the body side.

80 mm (3.15 in) <left side> or 50 mm (1.97 in) <right side>

.

INSTALLATION Rear floor sidemember extension

ABC00518AB

1. Align the new rear floor sidemember reinforcement with the vehicle body, and cut out an excessive part. Then install it to the vehicle body.

2. Install the new rear floor sidemember extension.

Cutting position (left side) Cutting position (right side) ABC00528 AB

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WELDED PANEL REPLACEMENT

3-25

ROOF

ROOF M4030011001733

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

ABB00458AB

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

REPAIR WELDS

NOTE: : Adhesive

ABB00636AB

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

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3-26

WELDED PANEL REPLACEMENT QUARTER INNER

QUARTER INNER M4030012001435

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.)

ABB00459AB

REPAIR WELDS

B

C

A (With the quarter outer removed)

A ABB00630AB

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WELDED PANEL REPLACEMENT

3-27

QUARTER INNER

B

C ABB00632AB

NOTE: Refer to the Quarter Outer section on P.3-19 for the welding points with the quarter outer.

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3-28

WELDED PANEL REPLACEMENT QUARTER INNER LOWER

QUARTER INNER LOWER M4030001100327

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.)

ABB00460AB

REPAIR WELDS

A (With the quarter outer removed)

A

NOTE: Refer to the Quarter Outer section on P.3-19 for the welding points with the quarter outer.

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ABB00634AB

WELDED PANEL REPLACEMENT

3-29

FRONT DOOR OUTER PANEL (WELDED TYPE)

FRONT DOOR OUTER PANEL (WELDED TYPE) M4030001501050

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.)

ABB00410AB

REPAIR WELDS

A

50 mm (1.97 in)

A

NOTE: : Adhesive

ABB00403 AB

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

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WELDED PANEL REPLACEMENT

3-30

FRONT DOOR OUTER PANEL (ADHESION TYPE)

FRONT DOOR OUTER PANEL (ADHESION TYPE) M4030001701128

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.)

ABB00409AB

REPAIR WELDS

A

NOTE: : Adhesive 1 : Adhesive 2

A ABB00404AB

• 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

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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)

3-31

REAR DOOR OUTER PANEL (WELDED TYPE) M4030001600786

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.)

ABB00411AB

REPAIR WELDS

A

50 mm (1.97 in)

A

NOTE: : Adhesive

ABB00405 AB

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

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WELDED PANEL REPLACEMENT

3-32

REAR DOOR OUTER PANEL (ADHESION TYPE)

REAR DOOR OUTER PANEL (ADHESION TYPE) M4030001800768

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.)

ABB00411AB

REPAIR WELDS

A

NOTE: : Adhesive 1 : Adhesive 2

A

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

ABB00406 AB

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.

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WELDED PANEL REPLACEMENT

3-33

FRONT END CROSSMEMBER

FRONT END CROSSMEMBER M4030003100390

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.)

ABB00449 AB

7.0 ± 3.0 N·m 62 ± 26 in-lb

REPAIR WELDS 7.0 ± 3.0 N·m 62 ± 26 in-lb

10 ± 4 N·m 89 ± 35 in-lb

10 ± 4 N·m 89 ± 35 in-lb 7.0 ± 3.0 N·m 62 ± 26 in-lb

A

7.0 ± 3.0 N·m 62 ± 26 in-lb

A ABC00529AB

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NOTES

4-1

GROUP 4

CORROSION PROTECTION CONTENTS BODY SEALING LOCATIONS . . . . .

4-2

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

4-7

CORROSION PROTECTION

4-2

BODY SEALING LOCATIONS

BODY SEALING LOCATIONS M4040001002565

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.

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

FLOOR

2

3

1

ABC00401AB

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CORROSION PROTECTION

4-3

BODY SEALING LOCATIONS

UPPER BODY

4

7 6

8

5

ABB00598AB

SIDE BODY

12 10 13 9

14 11

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15 16 ABB00599AB

4-4

CORROSION PROTECTION BODY SEALING LOCATIONS

1

5

ABB00577AB

ABB00574AB

6

2

ABB00578AB

ABB00575AB

7

3

ABB00579AB

ABB00594AB

8

4

ABB00576AB

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ABC00398 AB

CORROSION PROTECTION BODY SEALING LOCATIONS

4-5

13

9

ABB00585AB

ABB00581AB

14

10

ABB00586AB

ABB00582AB

15

11

ABB00587AB

ABB00583AB

16

12

ABB00584 AB

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ABC00417AB

4-6

CORROSION PROTECTION BODY SEALING LOCATIONS

Rear door

Hood

ABB00589AB

ABB00591 AB

Tail gate

Front door

ABB00590AB

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ABB00592 AB

CORROSION PROTECTION UNDERCOAT APPLICATION LOCATIONS

4-7

UNDERCOAT APPLICATION LOCATIONS M4040003001698

• 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.

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

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• To avoid splashing of undercoat material during the coating, protect the plug holes and components installation holes with masking tape.

ABC00399AB

NOTES

5-1

GROUP 5

SYNTHETIC-RESIN PARTS CONTENTS LOCATION OF SYNTHETIC-RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . .

5-2

SYNTHETIC-RESIN PARTS

5-2

LOCATION OF SYNTHETIC-RESIN PARTS

LOCATION OF SYNTHETIC-RESIN PARTS M4050001002124

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

2

34 12

11 3

20

32

7

24

21

8 1, 5

25

4

23

22 6

ABC00204AB

14 13 26

29

28

30 15

27 16

33

10

19 9

18

31

17

ABC00205AB

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SYNTHETIC-RESIN PARTS

5-3

LOCATION OF SYNTHETIC-RESIN PARTS

No.

Part Name

Name Of Resin

Abbreviation

Heat-resistant Temp [°C (°F)]

1

Door mirror outer cover (color)

Acrylonitrile butadiene styrene

ABS

80 (176)

2

Liftgate spoiler

3

Rear view camera cover

4

Front delta garnish

Acrylonitrile styrene acrylate

ASA

80 (176)

5

Door mirror outer cover (black)

6

Front side air dam

Ethylene Propylene diene terpolymer

EPDM

80 (176)

7

Headlight

Polycarbonate

PC

120 (248)

8

Door outside handle

Polycarbonate+Polyethylene terephthalate

PC+PET

120 (248)

9

Front wheelhouse splash shield

High density polyethylene

PE-HD

10

Rear wheelhouse splash shield

70 − 90 (158 − 194)

11

Rear wiper arm

Polyethylene terephthalate

PET

80 (176)

12

Antenna base

Polypropylene

PP

80 (176)

13

Inside rear view mirror

14

Lower center pillar trim

15

Quarter trim lower

16

Rear end trim

17

Rear scuff plate

18

Front scuff plate

19

Cowl side trim

20

Front deck garnish cover

Polypropylene+Ethylene Propylene diene terpolymer

PP+EPDM

80 (176)

21

Rear bumper face

PP+E/P-TD10

80 (176)

22

Front bumper face

Talc filled rubber modified polypropylene (10%)

23

Front bumper under grille

24

Front bumper grille

25

Side air dam

Talc filled rubber modified polypropylene (30%)

PP+E/P-TD30

110 (230)

26

Front pillar trim

Talc filled polypropylene (10%) PP-TD10

27

Front door trim

110 − 120 (230 − 248)

28

Upper center pillar trim

29

Rear door trim

30

Quarter trim upper

31

Floor console assembly

32

Front deck garnish

Talc filled polypropylene (20%) PP-TD20

33

Instrument panel

120 − 130 (248 − 266)

34

Roof drip molding

Polyvinyl chloride

80 (176)

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PVC

5-4

SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS

NOTE: .

• 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 COLOR

6-2

BODY COLOR CODE

BODY COLOR CODE M4060001001531 .

AC700308

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

MODEL

ENGINE TRANS AXLE COLOR,TRIM OPT

Body color code ABC00418 AB

BODY COLOR CHARTS M4060002004180

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 code

Color number

Color name

Coating film Composition of film structure

DARK GRAY

A02

CMA10002 Eisen Gray Mica

2P

Pearl

SILVER

A66

CSA10066

Cool Silver Metallic

2M

Metallic

GREEN

F24

CSF10024

Pop Green Metallic

2M

Metallic

RED

P19

CSP10019

Red Metallic

2M

Metallic

MEDIUM BLUE

T69

CST10069

Cerulean Blue Mica

2P

Pearl

PURPLE

V08

CSV10008

Cassis Purple Metallic

2M

Metallic

WHITE

W19

AC11319

White Solid

2S

Solid

BLACK

X08

AC11008

Black Mica

2P

Pearl

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.

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9-1

GROUP 9

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

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . . . . . .

9-2

9-2

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

9-3

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

9-3

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

9-27

USING A FRAME STRAIGHTENER . . . . . .

9-28

FRAME REPAIR PROCEDURES . . . . . . . .

9-29

NOTES REGARDING REPAIR WORK . . . .

9-32

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

9-35

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

9-37

CORROSION PROTECTION . . . . . . .

9-38

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

9-38

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

9-41

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

9-3

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

9-9

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

9-13

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

9-15

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

9-15

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

9-24

ATTACHMENT OF SILENCERS . . . . . . . .

9-25

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

9-45

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

9-26

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

9-45

BASE OF BODY REPAIR

9-2

GENERAL

GENERAL M4090000100018

Group 9 is applicable for all models.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) M4090000500016

WARNING • Improper service or maintenance of any

component of the SRS and any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering the SRS inoperative).

• The SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, air bag modules, clock spring, front seats, impact sensor and seat belt with pre-tensioner before drying or baking the vehicle after painting.

• SRS-ECU, air bag modules, clock spring, front seats, impact sensor: 93° C (199° F) or more • Seat belt with pre-tensioner 90°C (194° F) or more • Service or maintenance of any SRS component and SRS-related component must be performed only at an authorized MITSUBISHI dealer.

• MITSUBISHI dealer personnel must thoroughly review workshop manual, and especially its GROUP 52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the SRS and any SRS-related component.

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BASE OF BODY REPAIR

9-3

WELDING

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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M4090002000040

ADVANTAGES OF ELECTRIC RESISTANCE SPOT WELDING • 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

9-4

WELDING

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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BASE OF BODY REPAIR

9-5

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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BASE OF BODY REPAIR

9-6

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

BASE OF BODY REPAIR

9-7

WELDING

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

Factory welds (F)

8 Points

Repair welds (R)

8 Points

11 Points

11 Points

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

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

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

AB200031AE

Safety equipment 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

9-8

WELDING

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

Panel thickness* [mm (in)] 0.9 (0.035 or Safety equipment less area 1.0 (0.04) 1.2 (0.047) or more Other area 0.9 (0.035) or less

Number of repair weld (percentage of factory weld)

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

100% Same number as factory welds; plug welding 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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BASE OF BODY REPAIR WELDING

9-9

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

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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.

BASE OF BODY REPAIR

9-10

WELDING

MIG SPOT WELDING Wire Gas cup

Gas outlet

AB200036AE

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

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

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BASE OF BODY REPAIR

9-11

WELDING

Item

Mig spot welding

Electric resistance spot welding

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

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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BASE OF BODY REPAIR

9-12

WELDING

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

AB200041 .

Torch angle and welding technique

15 – 30˚

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

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

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

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

15 – 30˚

Backhand technique

Forehand technique

AB301457AD .

Preventing warping Anti-Warp Welding Techniques 1.

5

4

3

2

1

Backhand technique 4

2

1

3

2.

Symmetrical technique 3.

1

4

2

5

3

"Stepping stone" technique AB200043AD

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

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

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

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BASE OF BODY REPAIR WELDING

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

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

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

9-13

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.

BASE OF BODY REPAIR

9-14

WELDING

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.

BASE OF BODY REPAIR BODY REPAIR

9-15

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.9-28 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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BASE OF BODY REPAIR

9-16

BODY REPAIR

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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BASE OF BODY REPAIR BODY REPAIR

9-17

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

AB200058

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

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

AB200059

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

AB200060

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

AB200061AD

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

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

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

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BASE OF BODY REPAIR

9-18

BODY REPAIR

Twolayer construction

Outer panel Approx. 50 mm (1.97in)

Inner panel

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

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

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

AB200062 AD

Three-layer construction

Inner panel

Inner panel cut line Outer panel and reinforcement cut line

Inner panel cut line

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

AB200063AD

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

AB200064

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BASE OF BODY REPAIR BODY REPAIR

AB200065

9-19

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 butt 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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BASE OF BODY REPAIR

9-20

BODY REPAIR

AB200070

AB200070

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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BASE OF BODY REPAIR BODY REPAIR

9-21

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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BASE OF BODY REPAIR

9-22

BODY REPAIR

AB200077

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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BASE OF BODY REPAIR BODY REPAIR

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.

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. .

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).

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

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9-23

.

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

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

BASE OF BODY REPAIR

9-24

BODY REPAIR

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

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

9-25 M4090009000052

Dash panel interior side

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

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

AB200097AD

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

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

AB200098

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BODY REPAIR

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

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

AB200099

POSITIONING DIMENSIONS FOR OPENINGS

M4090010000045

Porta power

AB200100 AD

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

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STANDARD PROCEDURES FOR SHEET METAL WORK

9-27 M4090012000030

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

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

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

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

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

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

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

(2) Next repair the areas of moderate damage.

(3) Finally, smooth the surface out.

(1)

(2)

(3)

AB200101

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BODY REPAIR

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.

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

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

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

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

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M4090013000044

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

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

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

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

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

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

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

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9-29

FRAME STRAIGHTENING NOTES Wires for protection

AB200103AD

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

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

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

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

FRAME REPAIR PROCEDURES

M4090014000047

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.

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

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BODY REPAIR

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

Crack-stop hole

Crack

Approx.

1 mm (0.04 in)

Approx.

90˚

A

Approx.

8 mm (0.31 in)

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

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

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

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

A

A

A : 30 – 45˚

AB301461AB

10 mm (0.39 in)

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.

Welded point AB200133 AD

(1)

(2)

AB200134 AB

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

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

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

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BODY REPAIR

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.

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

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

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

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

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

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

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

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

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

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

HANDLING ELECTRONIC PARTS AND SEMICONDUCTORS WARNING

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

AB200105

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

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

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

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

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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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BODY REPAIR

HEAT-WITHSTAND TEMPERATURES OF RESIN-PLASTIC PARTS

M4090016000054

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)

Where mainly used

Acrylonitrile styrene acrylate

ASA

80 (176)

Door mirror, Pillar garnish, License garnish, Radiator grille

Acrylonitrile butadiene styrene

ABS

80 (176)

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

Cellulose acetate

CA

50 − 90 (122 − 194)

-

Cellulose acetate butylate

CAB

60 − 100 (140 − 212)

Door trim molding

Polyamide

PA

140 − 160 (284 − 320)

Harness connector, Wheel cover, Cooling fan, Fuel strainer

Talc filled polyamide

PA-TD

190 − 200 (374 − 392)

Hood garnish, Door outside handle

Polybutylene terephthalate

PBT

120 (248)

Dome light lens, Headlight lens

Polyethylene

PE

100 (212)

Heater duct, Fender liner, Washer tank

High density polyethylene

PE-HD (HDPE)

70 − 90 (158 − 194)

Fuel tank, Splash shield

Phenole formaldehyde

PF

170 − 190 (338 − 374)

Ashtray

Polymethyl methacrylate

PMMA

80 − 100 (176 − 212)

Light lens

Polyacetal

POM

120 (248)

Door regulator handle, Ball joint seat

Polypropylene

PP

80 (176)

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

Polyphenylene ether

PPE (PPO)

130 − 140 (266 − 284)

Accelerator pedal pad, Wheel cover, Speaker garnish

Talc filled polypropylene

PP-TD (PPF)

100 (212)

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

Talc filled polypropylene (10%)

PP-TD10 (PPF)

110 − 120 (230 − 248)

Center pillar trim

Talc filled polypropylene (15%)

PP-TD15 (PPF)

110 − 120 (230 − 248)

Front pillar trim, Center pillar trim, Rear pillar trim

Talc filled polypropylene (20%)

PP-TD20 (PPF)

120 − 130 (248 − 266)

Beltline trim, Front deck garnish, Front pillar trim

Talc filled polypropylene (30%)

PP-TD30 (PPF)

130 − 140 (266 − 284)

Quarter trim, Rear side trim

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BODY REPAIR

Material name

Abbreviation

Heat-deformation temperature °C (°F)

Where mainly used

Polyurethane

PUR

80 − 100 (176 − 212)

Bumper, Steering wheel

Polyurethane (formed)

PUR-E

80 − 100 (176 − 212)

Seat cushion, Arm rest, Door trim, Instrument panel

Glass fiber reinforced RIM urethane

PUR-GF [RIM]

100 − 120 (212 − 248)

Air dam panel

Polyvinyl alcohol

PVAL

*1

-

Polyvinyl butyral

PVB

Polyvinyl chloride

PVC

80 (176)

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

Thermoplastic TPO (TEO) elastomer (olefine)

80 (176)

Mud guard, Side air dam

Urea formaldehyde UF

120 − 145 (248 − 293)

-

Glass fiber reinforced unsaturated polyester

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

200 (392)

Rear air spoiler

Ethylene vinyl acetate

E/VAC (EVA)

60 (140)

Mud guard

Talc filled polypropylene

PP + E/P-TD [HMPP]

80 − 100 (176 − 212)

Bumper face, Side air dam, Side protector molding

Polyvinyl chloride, Polyurethane

PVC, PUR-E

*2

Instrument panel pad

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

100 − 120 (212 − 248)

Side splash

Polycarbonate + Acrylonitrile butadiene

PC + ABS

120 − 125 (248 − 257)

Door outside handle

Polycarbonate + Polyethylene terephthalate

PC + PET

120 (248)

Door outside handle

Polycarbonate + Polybutylene terephthalate

PC + PBT

130 − 140 (266 − 284)

Door outside handle

Polyphenylene ether + Polyamide 6

PPE (PPO) + PA6 150 − 160 (302 − 320)

Wheel cover

Polyphenylene ether + Polyamide 66

PPE (PPO) + PA66

160 − 170 (320 − 338)

Wheel cover

120 − 130 (248 − 266)

Wheel cover

Polyphenylene PPE (PPO) + PS ether + Polystyrene

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BODY REPAIR

NOTE: .

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

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

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

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

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

HOW TO DISTINGUISH TYPES OF PLASTICS

M4090017000035

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

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

Plastic name

Abbrevi Flame color ation

Combustion 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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CORROSION PROTECTION

CORROSION PROTECTION ANTICORROSION TREATMENT AT THE FACTORY

M4090019000064

Anticorrosion treatment at the time of production includes the following measures.

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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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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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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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. .

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CORROSION PROTECTION

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

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

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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

• 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

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CORROSION PROTECTION

UNDERCOATING

: Undercoating application locations

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

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

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AB301464 AD

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

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REPAIR OF SYNTHETIC-RESIN PARTS

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

M4090000300090

Bumper is taken as a repair work example for explanation.

FLOWCHART

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

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

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

1. Cleaning

2. Reshaping of damaged area

3. Fixing of glass cloth (backing)

4. Adhesive application

5. Base surface preparation (surface grinding)

6. Rough grinding

7. Filling (putty application)

8. Surface grinding

9. Surface preparation for primer-surfacer

10. Cleaning and degreasing

11. Masking

12. Primer-surfacer coating

13. Primer-surfacer grinding

14. Coating

AB401319 AB

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BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS

REPAIR JUDGMENT .

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

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

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

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

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

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

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

REPAIR PROCEDURE .

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

AB401311AB

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BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS

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

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

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

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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

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Old paint layer AB401316AE AB401316

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BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS

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 Sand 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

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

AB401297AB

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

AB401297AB .

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

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

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

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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

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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