DOWNLOAD PDF Mitsubishi Outlander 2007 Body Repair Manual

2007 MITSUBISHI OUTLANDER

BODY REPAIR MANUAL FOREWORD This manual has been prepared for the use of all service mechanics engaged in the body repair service.

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

One especially important point is the welding method.

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

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

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

TECHNICAL INFORMATION MANUAL MSSP-207B-2007 SERVICE MANUAL CD MSCD-007B-2007 PARTS CATALOG BUM6W507A_

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.

2006 Mitsubishi Motors Corporation All Rights, Reserved Printed in USA MSSP-407B-2007

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

1

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

2

WELDED PANEL REPLACEMENT. .

3

CORROSION PROTECTION . . . . . .

4

SYNTHETIC-RESIN PARTS . . . . . . .

5

BODY COLOR . . . . . . . . . . . . . . . . . .

6

REFERENCE MATERIAL . . . . . . . . .

8

BASE OF BODY REPAIR . . . . . . . . .

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

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

1-1

GROUP 1

BODY CONSTRUCTION CONTENTS

BODY COMPONENTS..................1-2 BODY MAIN CROSS-SECTIONAL VIEWS .................................1-4 MAINTENANCE, SERVICEABILITY......1-6 BODY CONSTRUCTION CHARACTERISTICS .................................1-8 FRONT BODY.......................1-8 SIDE BODY.......................1-15 REAR BODY.......................1-18 ROOF............................1-19 UNDER BODY......................1-20 DOOR............................1-24

SILENCER APPLICATION LOCATIONS ................................1-25 LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL...................1-26 STIFFENER AND DAMP SHEET APPLICATION LOCATIONS.......................1-26

BODY CONSTRUCTION

1-2

BODY COMPONENTS

BODY COMPONENTS M40100000010USA0000010001

AB501519 ZB500405 ZB500404

32

37

33

31 72

71 38

74

73

36

29

39

34 75

35 70

30 69* 28

40

94

27

95

68 26

96

67**

25 24

76

92 91

66

41

93*

42

23

43 44 65**

90 46

64*

22

98

18*

97

89

19

47

77

48

20* 21

17

63**

8

16 15

61**

12

78 79 80 82 81

88 62

87

9

13

60 7* 59

14 11

86*

6

10* 4

45

50 51*

83* 85

5 58 57

3

49

52

84* 53* 54

2

55**

1 56 : Anti-corrosion steel panels : High-tensile steel panels (*: Indicates 590MPa-high-tensile steel panels.) (**: Indicates 980MPa-ultra-high-tensile steel panels.)

ZB5003710000

1.

Front bumper reinforcement

BODY CONSTRUCTION BODY COMPONENTS 2.

Front bumper bracket lower

50.

Rear bumper bracket lower

3.

Front end crossmember

51.

Rear floor sidemember extension

4.

Headlight support panel

52.

Rear wheel house inner panel

5.

Front end upper bar

53.

Rear floor sidemember lower

6.

Front sidemember inner

54.

Rear floor sidemember upper

7.

Front sidemember rear

55.

Front floor side sill inner

8.

Front sidemember brace lower

56.

Front fender

9.

Front sidemember outer

57.

Backbone crossmember front

10.

Front sidemember outer front

58.

Backbone crossmember rear

11.

Front fender shield front

59.

Front floor pan

12.

Front wheel house inner panel

60.

Backbone reinforcement

13.

Fender bracket rear

61.

Front floor crossmember front

14

Fender bracket front

62.

Front floor crossmember rear

15.

Front end upper bar side

63.

Side sill reinforcement

16.

Engine mounting gusset

64.

Front pillar reinforcement lower

17.

Front upper frame inner

65.

Front pillar reinforcement upper

18.

Dash panel crossmember upper

66.

Front pillar inner lower

19.

Dash panel crossmember lower

67.

Front pillar inner upper

20.

Dash panel

68.

Center pillar inner

21.

Upper frame to front pillar brace

69.

Roof side rail inner

22.

Upper frame outer

70.

Quarter inner extension front

23.

Front deck

71.

Gate pillar reinforcement

24.

Front deck crossmember

72.

Third seat belt reinforcement upper

25.

Hood inner panel

73.

Gate pillar inner

26.

Hood outer panel

74.

Gate pillar inner reinforcement

27.

Front door panel inner

75.

Gate pillar inner reinforcement upper

28.

Front door side door beam

76.

Quarter inner extension lower

29.

Front door panel outer

77.

Shipping hook reinforcement

30.

Rear door side door beam lower

78.

Rear bumper bracket

31.

Rear door side door beam upper

79.

Rear bumper bracket center

32.

Rear door panel outer

80.

Rear floor crossmember rear

33.

Rear door panel inner

81.

Rear floor crossmember center

34.

Roof panel

82.

Rear floor crossmember front

35.

Roof bow center

83.

Front stringer

36.

Roof carrier bracket

84.

Rear floor (rear seat) crossmember

37.

Rear roof rail

85.

Front floor crossmember front lower

38.

Liftgate panel inner upper

86.

Front floor sidemember front

39.

Liftgate panel outer upper

87.

Rear floor extension panel

40.

Liftgate panel outer lower

88.

Rear floor pan front

41.

Liftgate panel inner lower

89.

Fender bracket

42.

Quarter extension outer

90.

Center pillar reinforcement

43.

Quarter outer extension lower

91.

Rear door catch reinforcement

44.

Fuel filler door panel

92.

Rear pillar reinforcement lower

45.

Rear bumper beam

93.

Roof side rail reinforcement

46.

Rear end crossmember outer

94.

Roof side reinforcement support

47.

Rear end inner panel side

95.

Rear quarter inner panel

48.

Rear end crossmember inner

96.

Rear pillar reinforcement

49.

Gate pillar reinforcement lower

97.

Rear floor pan rear

1-3

BODY CONSTRUCTION

1-4 98.

BODY MAIN CROSS-SECTIONAL VIEWS Side outer panel

BODY MAIN CROSS-SECTIONAL VIEWS M40100000020USA0000010001

B

C

D

E F

A

ZB5003720000

Front end crossmember upper

A Front end crossmember reinforcement

Side outer panel

Front pillar upper reinforcement

Front end crossmember plate Front end crossmember lower

B

C

Towing hook reinforcement ZB500373 0000

Front pillar reinforcement plate Roof side reinforcement support

D Roof panel

Belt anchor reinforcement

Center pillar inner reinforcement lower Front roof rail upper Front roof rail lower ZB5003740000

Center pillar inner

Roof side rail reinforcement Side roof rail inner ZB5003750000 Center pillar reinforcement

Side outer panel Rear door hinge reinforcement ZB6010260000

BODY CONSTRUCTION

1-5

BODY MAIN CROSS-SECTIONAL VIEWS

E

F

Front door hinge reinforcement lower Front pillar inner lower

Side outer panel

Side sill bulkhead A Side sill outer reinforcement front

Front floor side sill inner

Side sill outer reinforcement rear

Front pillar reinforcement lower

Side outer panel ZB5003780000

ZB5003770000

J G

H I

K

L ZB5003790000

G Side outer panel

Front pillar upper reinforcement

Front pillar inner upper

Gate pillar inner upper

I

Quarter inner panel

Side outer panel Gate pillar reinforcement

reinforcement upper

Side outer panel

Second seat belt reinforcement upper

Quarter inner panel

ZB5003810000

Quarter outer extension ZB5003820000

ZB5003800000

H Rear pillar

Side seat belt reinforcement upper

J

Roof panel

Roof extension panel Rear roof rail outer Rear roof rail inner

ZB5003830000

BODY CONSTRUCTION

1-6 K

MAINTENANCE, SERVICEABILITY Rear door catch reinforcement Rear wheel house panel inner

Rear pillar reinforcement lower

Rear end panel outer

Rear floor pan Shipping hook bulkhead

Side outer panel

Quarter inner front extension

Rear end panel inner

L

Quarter inner plate front ZB6010270000

Shipping hook reinforcement

ZB5003850000

MAINTENANCE, SERVICEABILITY M40100000030USA0000010000

FENDER SHIELD

A positioning hole, lug, marking, and cut-out have been added on the front side member, front side member rear, and headlight support panel to improve assembling workability during panel replacement.

BODY CONSTRUCTION

1-7

MAINTENANCE, SERVICEABILITY

ZB5003880000

SIDE STRUCTURE

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

Panel positioning notch ZB5003890000

BODY CONSTRUCTION

1-8

BODY CONSTRUCTION CHARACTERISTICS

ZB5003900000

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 pillar outer

Front pillar outer Rear quarter outer panel

Floor side sill outer ZB5003910000

BODY CONSTRUCTION CHARACTERISTICS FRONT BODY M40100000100USA0000010000

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.

BODY CONSTRUCTION

1-9

BODY CONSTRUCTION CHARACTERISTICS ｠The bolt-on front bumper reinforcement, bolt-on hood lock stay, and bolt-on front end upper bar are

used to improve maintainability.

9.0 ± 2.0 N·m 80 ± 17 in-lb 20 ± 5 N·m 15 ± 3 ft-lb

9.0 ± 2.0 N·m 80 ± 17 in-lb

6

17 16

7 15

31 30 29

9.0 ± 2.0 N·m 80 ± 17 in-lb

5 20 ± 5 N·m 15 ± 3 ft-lb

9

8

14 13 12

18 32

28

19 20

10

21 4

3

2

27

20 ± 5 N·m 15 ± 3 ft-lb

11

18 ± 7 N·m 13 ± 5 ft-lb

1

22 26

25

24

23 ZB601024 0000

1.

Front bumper reinforcement plate front

17.

Front end crossmember gusset

2.

Front bumper reinforcement plate side

18.

Front end crossmember reinforcement

3.

Horn bracket

19.

Radiator bracket lower (A)

4.

Bumper bracket

20.

Radiator bracket lower (B)

5.

Front bumper reinforcement center

21.

Front end crossmember lower

6.

Front end upper bar

22.

Front end crossmember extension

7.

Sensor bulkhead

23.

Towing hook bracket

8.

Radiator bracket upper (Sensor)

24.

Towing hook

9.

Front bumper reinforcement plate rear

25.

Towing hook reinforcement

10.

Front bumper reinforcement plate

26.

Bumper bracket lower

11.

Front bumper reinforcement bracket lower

27.

Shipping reinforcement front

12.

Front bumper reinforcement bracket upper

28.

Shipping hook front

13.

Air guide plate

29.

Front end crossmember plate

14.

Hood lock stay reinforcement

30.

Front No. 2 crossmember pipe

15.

Hood lock stay

31.

Front end crossmember bulkhead

16.

Front end crossmember upper

32.

Front end crossmember reinforcement lower

FENDER SHIELD

The front frame structure is supported in three directions by the dash crossmember center, dash

crossmember lower, and front sidemember rear in order to improve the frontal collision characteristics, and increase the vehicle body rigidity.

BODY CONSTRUCTION

1-10

BODY CONSTRUCTION CHARACTERISTICS

Right side 8

9

10 11 12

6

13 21 23

4

7

12

14 17 18

16

21 25

15

27 26

22 19

24 3

6

13

20 5

11 10

22

19

8

9

Left side

7

5

2 1

2 1

3

4

A ZB500393 0000

1.

Front sidemember

15.

Spring house harness bracket

2.

Fender gusset

16.

Suction hose bracket

3.

Front corner bracket

17.

Engine mounting bracket upper

4.

Fender bracket lower

18.

Condense tank reinforcement

5.

Front end upper bar side

19.

Front fender shield

6.

Fender bracket front

20.

Engine mounting gusset

7.

Upper frame center bulkhead

21.

Fender bracket rear

8.

Upper frame rear bulkhead

22.

Spring house panel

9.

Front upper frame inner

23.

Power steering reservoir tank bracket

10.

Spring house bracket reinforcement

24.

Engine-ECU bracket

11.

Spring house bracket front

25.

Relay box bracket

12.

Spring house corner gusset

26.

Relay box bracket rear

13.

Spring house panel rear

27.

Transmission mounting gusset

14.

Horn bracket

A

Front sidemember inner

Front sidemember outer ZB5003940000

The front part of the front sidemember has hexagonal section that efficiently absorbs energy upon impact.

BODY CONSTRUCTION

1-11

BODY CONSTRUCTION CHARACTERISTICS

FRONT SIDEMEMBER REINFORCEMENT Right Side

9

4

10

3

14

7

15

18 17 16

5 20

2

19

21 1

13

11

8 6

12

22

23

ZB6010220000

7

13

18 6

15 A

9 19

B

14

12

ZB5003960000

1.

Front sidemember plate rear

13.

Front sidemember rear reinforcement lower

2.

Headlight bracket

14.

Front sidemember rear bulkhead

3.

Front sidemember outer front

15.

Front sidemember rear

4.

Front sidemember outer

16.

Dash crossmember extension lower

5.

Upper bar bracket

17.

Front sidemember brace lower

6.

Front sidemember bulkhead front

18.

Front sidemember inner

7.

Engine mounting bulkhead

19.

Front suspension crossmember bracket front

8.

Front brake hose bracket

20.

Pipe nut

9.

Front suspension crossmember bulkhead

21.

Engine mount bracket

10.

Front sidemember brace upper

22.

Engine mount reinforcement

11.

Tie down reinforcement front

23.

Headlight support panel

12.

Height sensor bracket

BODY CONSTRUCTION

1-12

BODY CONSTRUCTION CHARACTERISTICS

B

A

21 6

4

10

4 18

18 9 ZB5003980000

ZB6010210000

Left Side

10 11

12 13

15

14

16 17

9 8

19 18

5 7

6

1 4

3

2 ZB500399 0000

14

9

4

10 6

17

A

B

11

ZB5004000000

1.

Headlight bracket

11.

Front sidemember rear bulkhead

2.

Front sidemember plate rear

12.

Tie down reinforcement front

3.

Headlight support panel

13.

Front sidemember brace upper

4.

Front sidemember inner

14.

Front suspension crossmember bulkhead

5.

Pipe nut

15.

Front sidemember outer

6.

Front suspension crossmember bracket front

16.

Front brake hose bracket

7.

Dash crossmember extension lower

17.

Transmission mounting bulkhead

8.

Front sidemember brace lower

18.

Upper bar bracket

9.

Front sidemember rear

19.

Front sidemember outer front

10.

Front sidemember rear reinforcement lower

BODY CONSTRUCTION

1-13

BODY CONSTRUCTION CHARACTERISTICS

A

B

13

15

15 4

14

4

17 ZB5004010000

ZB5004020000

FRONT DECK

The impact absorbing opening on the cowl top outer panel has been added to efficiently absorb energy upon impact and improve the pedestrian protection capability.

5 3 4

6 7

12

8 2

9

11

10

1 ZB500403 0000

1.

Cowl top lower panel

7.

Cowl top bulkhead side

2.

Brake pedal reinforcement upper

8.

Upper frame extension inner

3.

Cowl top inner panel

9.

Upper frame outer

4.

Wiper bracket

10.

Upper frame to front pillar brace

5.

Cowl top outer panel

11.

Deck crossmember stay bracket

6.

Fender bracket

12.

Brake pedal support bracket

BODY CONSTRUCTION

1-14

BODY CONSTRUCTION CHARACTERISTICS

DASH PANEL 8

5 7 4

9

6 10

3 14 2

11

12 1

13

ZB500404 0000

1.

Brake tube bracket

8.

Dash crossmember lower

2.

Dash panel crossmember center

9.

Dash crossmember lower bulkhead

3.

Dash crossmember extension

10.

Steering shaft bracket

4.

Dash heat protector bracket

11.

Dash crossmember side

5.

Backbone reinforcement front

12.

Dash panel

6.

Accelerator pedal bracket

13.

Dash panel reinforcement

7.

Dash panel lower

14.

Canister bracket

BODY CONSTRUCTION

1-15

BODY CONSTRUCTION CHARACTERISTICS

SIDE BODY M40100000110USA0000010000

SIDE STRUCTURE 14 13

12

15

11

17

10

54

18 19

51

9

52

53

61

57

58 43

1

24

59

45 44

5 4 3 2

25

60

49 48 47 46

22 23

55

50

6

21

20

56

8

7

16

26

62 63

27 28 33 32

42 41 40

64

29 34

65 39

36

35

38

30 37

31 ZB6010280000

1.

Front door hinge reinforcement lower

16.

Gate inner pillar lower

2.

Front pillar reinforcement bulkhead center

17.

Third seat belt reinforcement lower (Left side) <7 person>

3.

Front door check reinforcement

18.

Quarter inner lower extension

4.

Front door hinge reinforcement upper

19.

5.

Front pillar reinforcement lower support

Third seat belt reinforcement lower (Right side) <7 person>

6.

Front pillar inner lower

20.

Roof side rail reinforcement

7.

Harness bracket

21.

Third seat belt reinforcement upper <7 person>

8.

Front pillar inner upper

22.

Gate pillar reinforcement

9.

Roof side rail inner

23.

Second seat belt reinforcement upper

10.

Assist grip bracket front

24

Liftgate lower cable reinforcement

11.

Quarter inner panel

25.

Quarter outer extension upper

12.

Side outer reinforcement rear (Right side)

26.

Quarter outer extension rear

13.

Gate inner pillar upper

27.

Rear bumper bracket side

Gate pillar inner reinforcement upper <7 person>

28.

Quarter outer extension lower

Gate pillar inner reinforcement <7 person>

29.

Filler neck bracket (Left side)

14.

15.

1-16

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

30.

Side sill outer reinforcement rear

48.

Deck crossmember bracket (Right side)

31.

Side sill outer reinforcement front

49

Center inner pillar lower

32.

Side sill bulkhead C

50.

Center inner pillar upper

33.

Side sill reinforcement support center

51.

Center pillar inner reinforcement lower

34.

Side sill bulkhead A

52

Quarter inner plate front

35.

Side sill reinforcement support front

53.

Quarter inner front extension

36.

Side sill bulkhead front

54.

Jack bracket (Right side)

37.

Side sill inner support front

55.

Splash shield bracket

38.

Fender bracket

56.

Roof side reinforcement support

39.

Front pillar reinforcement lower

57.

Front pillar reinforcement plate

40.

Deck support pipe (Left side)

58.

Rear door catch reinforcement

41.

Rear door hinge reinforcement

59.

Rear pillar reinforcement lower

42.

Center pillar seat belt reinforcement lower

60.

Second seat belt reinforcement lower (Right side)

43.

Center pillar seat belt reinforcement upper

61.

Second seat belt reinforcement lower (Left side)

44.

Front pillar upper reinforcement

62.

Rear pillar reinforcement upper

45.

Side sill end plate

63.

Liftgate lower striker reinforcement

46.

Hood opener bracket (Left side)

64.

Center pillar reinforcement

47.

Cowl side trim bracket

65.

Side outer panel

BODY CONSTRUCTION

1-17

BODY CONSTRUCTION CHARACTERISTICS

SIDE STRUCTURE REINFORCEMENT

The ring structure of the side structure reinforcement has been adopted to improve the

collision characteristics and the rigidity of the whole vehicle.

Roof side rail reinforcement

Front pillar reinforcement upper

Rear pillar reinforcement upper Rear pillar reinforcement lower

Side sill reinforcement rear outer Front pillar reinforcement lower

Center pillar reinforcement Side sill reinforcement front outer ZB500406 0000

BODY CONSTRUCTION

1-18

BODY CONSTRUCTION CHARACTERISTICS

REAR BODY M40100000120USA0000010000

REAR END CROSSMEMBER 20 ± 5 N·m 15 ± 3 ft-lb

13 15

17

20 ± 5 N·m 15 ± 3 ft-lb

14 12

8 1

6

9

7

11

10

5

2

19

3

20

13 14 18

12

16

21

4 3 2

17

1

ZB5004070000

1.

Rear end inner panel side

12.

Rear end bulkhead

2.

Liftgate lower striker reinforcement

13.

Gate pillar reinforcement lower

3.

Rear end inner panel corner

14.

Rear bumper beam reinforcement

4.

Rear end crossmember inner

15.

Rear bumper beam

5.

Shipping hook reinforcement lower

16.

Bumper bracket lower

6.

Third seat striker reinforcement

17.

Rear floor side brace

7.

Pipe nut

18.

Spare tire bracket

8.

Towing hook bracket pipe

19.

Rear bumper bracket center

9.

Shipping hook bulkhead

20.

Shipping hook reinforcement upper

10.

Rear bumper bracket lower

21.

Shipping hook

11.

Rear end crossmember outer

BODY CONSTRUCTION

1-19

BODY CONSTRUCTION CHARACTERISTICS

ROOF M40100000130USA0000010000

｠A roof panel made of aluminum alloy has been adopted to reduce the weight of vehicle and improve handling stability.

｠The closed section structure has been adopted to the front roof rail, roof bow center, and rear roof rail to reduce vibration and noise, and to improve the rigidity.

Standard roof

6

5

7 8 31

9

30 11 10

13 12 14 4

17 18

26 27

28

6

29 7

15 16 8

3 2

30 1

Sunroof

20

5

12

21

4

3

25 2

23 24

19 29

9 31 26 27 10 11 28

22

1

ZB500408 0000

1.

Sunvisor bracket

12.

Roof bow B

2.

Holder bracket

13.

Dome light bracket (Vehicles without roof rail)

3.

Roof front rail lower

14.

Roof bow A

4.

Roof front rail upper

15.

Center roof bow lower

5.

Roof panel

16.

Center roof bow upper

6.

Roof extension panel

17.

Head lining bracket

7.

Roof rear rail inner

18.

Roof bow front

8.

Roof rear rail outer

19.

Sunroof bracket rear

9.

Liftgate hinge reinforcement

20.

Dome light bracket (Vehicles with roof rail)

10.

Roof bow D

21.

Roof reinforcement

11.

Roof bow C

22.

Sunroof bracket

BODY CONSTRUCTION

1-20

BODY CONSTRUCTION CHARACTERISTICS

23.

Set bracket rear

28.

Roof rack bracket center (Vehicles with roof rail)

24.

Set bracket front

29.

Roof rack bracket front (Vehicles with roof rail)

25.

Set bracket front

30.

Roof carrier bracket (Vehicles without roof rail)

26.

Roof rail bracket (Vehicles with roof rail)

31.

Roof bracket (Vehicles without roof rail)

27.

Roof rack bracket rear (Vehicles with roof rail)

UNDER BODY M40100000140USA0000010000

FRONT FLOOR 5

7

6

8

4

3

9

10 2 1 41 ± 10 N·m 30 ± 8 ft-lb

12

13

11 ZB5004090000

1.

Backbone brace front <2WD>

8.

Front floor sidemember plate

2.

Backbone crossmember front

9.

Front floor sidemember front

3.

Front floor pan

10.

Front floor crossmember rear

4.

Parking brake lever reinforcement

11.

Front floor side sill inner

5.

Backbone reinforcement

12.

Front floor reinforcement lower

6.

Barking brake cable reinforcement

13.

Front floor crossmember front

7.

Backbone crossmember rear

BODY CONSTRUCTION

1-21

BODY CONSTRUCTION CHARACTERISTICS

REAR FLOOR 18 ± 7 N·m 13 ± 5 ft-lb 11 ± 4 N·m 98 ± 35 in-lb

7 25 ± 6 N·m 19 ± 4 ft-lb 41 ± 10 N·m 30 ± 8 ft-lb

8 6 4

9

5

10 11 12

13 3

14 15 16

27 28

2

26 1

17

29 7

25 30

24

6

19

21 23

18

20

22

ZB5004100000

1.

Rear floor extension

16.

Rear floor crossmember center extension lower

2.

Rear seat reinforcement front side

17.

Rear floor sidemember

3.

Second seat hinge bracket side

18.

Rear wheel house panel inner

4.

Rear floor pan front

19.

Rear spring house panel

5.

Rear floor crossmember upper extension

20.

Rear spring house bracket

6.

Rear spring house reinforcement

21.

Rear seat crossmember

7.

Rear wheel house reinforcement

22.

Rear seat crossmember bulkhead side

8.

Rear floor pan rear

23.

Sidemember front floor extension

9.

Rear floor crossmember rear

24.

Rear seat crossmember bulkhead inner

10.

Third seat bracket center

25.

Second seat hinge reinforcement

11.

Rear floor crossmember extension rear upper

26.

Second seat striker center reinforcement

12.

Rear floor crossmember extension rear

27.

Rear floor crossmember front

13.

Third seat hinge front bracket

28.

Rear floor crossmember extension front

14.

Rear floor crossmember center

29.

Fuel tank rear bracket

15.

Rear floor crossmember extension center

30.

Front stringer

BODY CONSTRUCTION

1-22

BODY CONSTRUCTION CHARACTERISTICS

REAR FLOOR SIDEMEMBER REINFORCEMENT

9

8

10

13

12

11

23 24

7 4 6

5

3

16

15

34

34

19

25 14 22 27 26

20

29 31

28 30

1

ZB5004110000

30

13

18

21

33 32

2

1

17

15

23

21

8

19

2 31

29

22

33

18

B

20

A

3

7

ZB500412 0000

1.

Rear floor side sill inner

18.

Rear floor sidemember extension

2.

Rear floor sidemember extension front

19.

Rear floor sidemember extension bracket

3.

Rear tie down plate

20.

Trailer hitch plate

4.

Front No. 2 crossmember pipe

21.

Rear floor sidemember extension bulkhead

5.

Spring sheet support

22.

Rear suspension bracket rear

6.

Spring sheet

23.

Rear floor sidemember bulkhead rear

7.

Trailing arm bracket

24.

Rear parking brake cable rear bracket (Right side)

8.

Rear floor sidemember upper

25.

Rear parking brake cable rear bracket (Left side)

9.

Muffler hanger hook (Right side)

26.

Rear brake hose bracket

10.

Seat under frame reinforcement

27.

Rear floor sidemember rear reinforcement (Right side)

11.

Bracket

28.

Rear floor sidemember front reinforcement (Right side)

12.

Canister bracket

29.

Rear floor sidemember rear reinforcement (Left side)

13.

Rear floor sidemember reinforcement

30.

Rear floor sidemember front reinforcement (Left side)

14.

Pipe nut

31.

Rear suspension bracket front

15.

Third seat anchor reinforcement

32.

Pipe nut

16.

Muffler hanger rear (Right side)

33.

Rear floor sidemember lower

17.

Third seat hinge reinforcement

34.

Rear floor sidemember bulkhead

BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS

A

8

30 29 33

31 ZB500413 0000

B

8 21

19 20

18 ZB500414 0000

1-23

BODY CONSTRUCTION

1-24

BODY CONSTRUCTION CHARACTERISTICS

DOOR M40100000150USA0000010000

An uneven thickness steel sheet* has been used for the front and rear door inner panels to make the

forward part of the vehicle thicker for reduction in vehicle weight and higher rigidity.

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

Front Door

6

5

8

7

9 4

10

3 2

11

1

12

Rear Door

ZB500415 0000

21

20

22

23 24 25

19

14

18 17 16 15

26

13 12

ZB500416 0000

1.

Front door check reinforcement

9.

Front door latch reinforcement

2.

Front door mirror reinforcement

10.

Front door side door beam

3.

Front door window sash front

11.

Front door inner panel

4.

Front door outer panel

12.

Nut plate

5.

Front door window sash upper

13.

Nut plate

6.

Front door window sash rear

14.

Nut plate

7.

Front door beltline outer reinforcement

15.

Rear door side door beam lower

8.

Front door beltline inner reinforcement

16.

Rear door side door beam upper

BODY CONSTRUCTION

1-25

SILENCER APPLICATION LOCATIONS 17.

Rear door beltline inner reinforcement

22.

Rear door beltline outer reinforcement

18.

Rear door window sash front

23.

Rear door inner rear reinforcement

19.

Rear door outer panel

24.

Rear door sash reinforcement

20.

Rear door window sash upper

25.

Rear door latch reinforcement

21.

Rear door window sash rear

26.

Rear door inner panel

SILENCER APPLICATION LOCATIONS M40100000050USA0000010001

A silencer (MD-12) has been affixed on the upper surface of the floor for vibration damping.

NOTE: MD-12 is a high-performance sheet made of asphalt, to which mica, heat cured resin, and so on are added to improve damping performance.

: 1.6 mm thick melting sheet : 3.6 mm thick MD-12 [Place three 1.6 mm melting sheet one on top of another.]

NOTE: ( ) indicates the number of melting sheets that are used for repair.

ZB5004170000

1-26

BODY CONSTRUCTION LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL

LOCATIONS USING URETHANE FOAM AND FOAM MATERIAL M40100000180USA0000010000

1. Foam noise absorbing materials have been adopted to the upper and lower sections of the front pillar, center pillar lower section, rear pillar, gate pillar, and wheel house arch inside to shield from external noise.

2. Urethane foam has been inserted into the quarter inner lower section to shield from external noise.

The foam materials may burn when heated.

Always observe the following instructions: ｠Never use a gas burner to burn the areas where foam materials are used. ｠When cutting the parts which are provided with foam materials, ensure to use tools (air saw, etc.) that do not generate fire. ｠If there are residual foam materials remaining on the cut section (body side), remove the foam materials from periphery of the welding area before welding work.

1

1 1 2

ZB6010200000

STIFFENER AND DAMP SHEET APPLICATION LOCATIONS M40100000181USA0000010000

Spray-type stiffeners on the inner side of the side outer panel, sheet-type stiffeners on the inner side of the liftgate outer panel, and a damp sheet on the

BODY CONSTRUCTION

1-27

STIFFENER AND DAMP SHEET APPLICATION LOCATIONS

interior side of the front deck have been used for higher surface rigidity.

NOTE: ｠The spray-type stiffener is mainly made from epoxy resin and contains filler. The sheet-type one is additionally reinforced with glass fiber. The stiffener

is cured by heating in the paint drying furnace during the production. ｠No spare part of the stiffener for repair is available in the field. If the stiffener is damaged, replace it together with the panel. ｠The spare part for the panel provided with the stiffener has a sheet-type stiffener affixed.

Stiffener Stiffener ZB5004220000

Liftgate

Front deck Damp sheet

Stiffener

ZB5004210000

1-28 MEMO

BODY CONSTRUCTION

2-1

GROUP 2

BODY DIMENSIONS CONTENTS

BODY DIMENSIONS AND MEASUREMENT METHODS..........................2-2 TYPE A (PROJECTED DIMENSIONS)....2-3 UNDER BODY.......................2-3 SUSPENSION INSTALLATION DIMENSIONS .................................2-5

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)......................2-8 UNDER BODY.......................2-8 SUSPENSION INSTALLATION DIMENSIONS ................................2-10 FRONT BODY......................2-12 SIDE BODY.......................2-14 REAR BODY.......................2-17 INTERIOR........................2-18

BODY DIMENSIONS

2-2

BODY DIMENSIONS AND MEASUREMENT METHODS

BODY DIMENSIONS AND MEASUREMENT METHODS M40200000010USA0000010000

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

Projected dimension

NOTE: The height indicates a distance from the assumed

Height

standard line established 100 mm below the lowest measurement point. ｠Type B (actual-measurement dimensions) is the actual distance between the measurement points. Measure using a tracking gauge or a measuring tape, etc.

Probe

ZB6001710000

Ac

tua

l-m ea su

red

dim

en s

A

ion

A'

ZB6001720000

Center of hole

ZB6001730000

ZB6001740000

NOTE: ｠Make the lengths of the tracking gauge probes the same (A=A’). ｠Do not bend or twist the measuring tape. ｠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. ｠When using a notch for dimension measurement, set the measuring point at the center of the notch. ｠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.

BODY DIMENSIONS

2-3

TYPE A (PROJECTED DIMENSIONS) Bolt

Measurement point ZB6001750000

TYPE A (PROJECTED DIMENSIONS) UNDER BODY M40200000050USA0000010000

AB501333

Center line of the vehicle 651

mm (in)

(25.6)

833

701

2

(32.8)

(27.6)

960 (37.8)

875 (34.4 )

540

510

(21.3)

(20.0)

3

5

4

111

(29.6)

462 13 (18.2)

894 (35.2) 375 12 (14.8) 350 (13.8)

6

7

1,056 (41.6) 877 (34.5)

1,262 (49.7)

1,050 (41.3)

(4.4)

1,022 (40.2)

894 (35.2) 197 (7.8) 564 (22.2)

910 (35.8)

967 (38.0)

1

624 (24.6)

1,009 (39.7)

752

374

440

(14.7)

(17.3)

393

628

(15.5)

9

(24.7)

10 11

8

ZB5004330000

Center line of the vehicle

mm (in)

2 763 (30.0)

1,079 (42.5)

972 (38.3)

1,394 (54.9) 1,140 (44.9)

967 (38.1)

13

1,138 (44.8) 1,028 (40.5)

1,272 (50.1)

641 (25.2 ) 960

3

4

5

1,342 (52.8)

1,448 (57.0)

(37.8)

686 (27.0 )

1,218 (48.0)

544 (21.4 )

12

1,149 (45.2) 1,025 (40.4)

1,126 (44.3)

1,144 (45.0)

1

1,217 (47.9)

6

7

9 8

10 11 ZB5004340000

BODY DIMENSIONS

2-4

TYPE A (PROJECTED DIMENSIONS)

No. Standard measurement point

Hole Size mm (in) shape

1

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

Round 8 (0.3)

2

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

Round 8 (0.3)

3*

Center of front sidemember inner positioning hole

Round 25 (1.0)

4*

Center of front suspension crossmember mounting hole

Round 15.5 (0.6)

5*

Center of front sidemember rear water draining hole

Round 16 (0.6)

6*

Center of front floor sidemember front positioning hole

Round 16 (0.6)

7*

Center of front floor sidemember front positioning hole

Round 16 (0.6)

8*

Center of rear floor sidemember lower positioning hole

Oblong 33.9×18 (1.3×0.7)

9*

Center of rear floor sidemember lower water draining hole

Round 18 (0.7)

10*

Center of rear floor sidemember lower positioning hole

Round 25 (1.0)

11*

Center of trailer hitch mounting hole

Round 15 (0.6)

12

Center of center bearing mounting hole

Round 11 (0.4)

13

Center of center bearing mounting hole

Round 11 (0.4)

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

AB501337 mm (in)

486 (19.1)

2

3

280 (11.0) 279 (11.0)

9

4

1 347 (13.7) 294 (11.6)

13 5

12

100 (3.9)

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

510 (20.1) Standard line

230 (9.1)

716 (28.2)

1,049 (41.3) 1,160 (45.7)

6

11

8

7

154 (6.1)

105 (4.1) 350 (13.8)

10

286 (11.3)

354 (13.9)

357 (14.1)

326 (12.8) 750 (29.5) 1,136 (44.7) 1,758 (69.2) ZB5004350000

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

BODY DIMENSIONS

2-5

TYPE A (PROJECTED DIMENSIONS) AB501571

1, 2

1

AB501572

3

4

2

5

ZB5004360000

ZB5004370000

ZB5004380000

AB501574

ZB500440 AB501576

AB501577

6

7

ZB5004400000

ZB5004390000

ZB5004410000

SUSPENSION INSTALLATION DIMENSIONS M40200000130USA0000010000

510 (20.1)

AB501335

Center line of the vehicle

822

(11.4)

603

695

(23.7)

1,129 (44.4)

886 (34.9) 910 (35.8)

(27.4)

1,000 (39.4)

894 (35.2)

875 (34.4)

1,288 (50.7)

5 16

1,093 (43.0) 903 (35.6)

1,092 (43.0)

4

579

7

18

(22.8)

441

19

(17.4)

293

217

98

(11.5)

(8.5)

(3.9)

20

714 (28.1)

14

mm (in)

289

(32.4)

17

15

254 (10.0)

ZB5004420000

BODY DIMENSIONS

2-6

TYPE A (PROJECTED DIMENSIONS) AB501336

Center line of the vehicle

mm (in)

1,028 (40.5)

945

1,145 (45.1)

(37.2)

1,231 (48.5)

907

4

16

5

7

1,294 (50.9)

1,171 (46.1)

(35.7)

18 17

1,048 (41.3)

1,212 (47.7)

1,253 (49.3)

19

20 1,076 (42.4) ZB5004430000

No. Standard measurement point

Hole shape

Size mm (in)

4

Center of front suspension crossmember mounting hole

Round

15.5 (0.6)

5

Center of front sidemember rear water draining hole

Round

16 (0.6)

7

Center of front floor sidemember front positioning hole

Round

16 (0.6)

14

Center of front shock absorber mounting hole

Round

80 (3.1)

15

Center of rear shock absorber mounting hole

Round

64 (2.5)

16

Center of front suspension crossmember mounting hole

Round

15.5 (0.6)

17

Center of trailing arm mounting hole

Round

14 (0.6)

18

Center of trailing arm mounting hole

Round

14 (0.6)

19

Center of rear suspension crossmember mounting hole

Round

27 (1.1)

20

Center of rear suspension crossmember mounting hole

Round

15 (0.6)

BODY DIMENSIONS

2-7

TYPE A (PROJECTED DIMENSIONS) AB501338

A

AB501388 Center of vehicle

B

Center of vehicle AB501387

6°54´ 6°30´

ZB500445

ZB500444

539 (21.2)

1,122 (44.2)

3°06´

14

0°

A

16

Standard line

294 (11.6)

162 (6.4)

5

217 (8.5) 510 (20.1)

19 20

7 222 (8.7)

105 (4.1)

100 (3.9)

1,066 (42.0)

B

15

18 17

4 782 (30.8)

mm (in)

570 (22.4) 820 (32.3) 1,258 (49.5)

284 (11.2)

354 (13.9)

462 (18.2)

ZB500446 0000

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

4

AB501575

5, 16

14

AB501324

16

5 ZB5004380000

ZB5004470000

ZB5004480000

BODY DIMENSIONS

2-8

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) AB501325

15

AB501582

17, 18, 19

AB501581

20

17 18 19

ZB5004500000

ZB5004490000

ZB5004510000

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) UNDER BODY M40200000050USA0000010001

AB501333

mm (in)

651 (25.6)

856

702

2

(33.7)

(27.6)

644 (25.4)

960 (37.8) 910 (35.8)

875 (34.4)

967 (38.0) 542

546

(21.3)

(21.5)

3

1

5

4

130

222 (8.7) 567 (22.3)

(30.5)

487

13 (19.2) 894 894 (35.2) (35.2)

1,262 (49.7)

1,022 (40.2)

378 12 (14.9) 350 (13.8)

6

7

1,079 (42.5)

(5.1)

1,011 (39.8)

774

378

460

(14.9)

(18.1)

399

628

(15.7)

9

1,056 (41.6)

877 (34.5)

(24.7)

10 11

8

ZB5004330001

mm (in)

2 765 (30.1)

1,081 (42.6)

975 (38.4)

1,415 (55.7) 1,140 (44.9)

970 (38.2)

13

1,138 (44.8) 1,046 (41.2)

1,273 (50.1)

643 (25.3 ) 960

3

4

5

1,356 (53.4)

1,450 (57.1)

(37.8)

704 (27.7 )

1,225 (48.2)

566 (22.3 )

12

1,149 (45.2) 1,027 (40.4)

1,127 (44.4)

1,144 (45.0)

1

1,230 (48.4)

6

7

9 8

10 11 ZB5004340001

BODY DIMENSIONS

2-9

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole Size mm (in) shape

1

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

Round 8 (0.3)

2

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

Round 8 (0.3)

3

Center of front sidemember inner positioning hole

Round 25 (1.0)

4

Center of front suspension crossmember mounting hole

Round 15.5 (0.6)

5

Center of front sidemember rear water draining hole

Round 16 (0.6)

6

Center of front floor sidemember front positioning hole

Round 16 (0.6)

7

Center of front floor sidemember front positioning hole

Round 16 (0.6)

8

Center of rear floor sidemember lower positioning hole

Oblong 33.9×18 (1.3×0.7)

9

Center of rear floor sidemember lower water draining hole

Round 18 (0.7)

10

Center of rear floor sidemember lower positioning hole

Round 25 (1.0)

11

Center of trailer hitch mounting hole

Round 15 (0.6)

12

Center of center bearing mounting hole

Round 11 (0.4)

13

Center of center bearing mounting hole

Round 11 (0.4)

AB501571

1, 2

1 5

8

3

AB501572

4

2 ZB5004360000

ZB5004370000

ZB5004380000

AB501574

ZB500440 AB501576

7

AB501577

10

6

ZB5004390000

ZB5004400000

ZB5004410000

AB501578

AB501584

AB501579

ZB5004520000

9

ZB5004530000

ZB5004540000

BODY DIMENSIONS

2-10 11

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) AB501583

12, 13

AB501580

12

13

ZB5004560000 ZB5004550000

SUSPENSION INSTALLATION DIMENSIONS M40200000130USA0000010001

546

AB501335

(21.5)

841

(11.6)

614

707

(24.2)

886 (34.9) 910 (35.8)

875 (34.4)

1,288 (50.7)

590

4

5

16

(27.8)

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

894 (35.2)

18

903 (35.6)

446

19

(23.2)

7

(17.6)

727

20

(28.6)

322

226

98

(12.7)

(8.9)

(3.9)

mm (in)

295

(33.1)

17

262 (10.3)

ZB5004420001 AB501336

mm (in)

1,046 (41.2) 954

1,151 (45.3)

(37.6)

909

1,265 (49.8)

1,237 (48.7)

4

16

5

7

1,300 (51.2)

1,173 (46.2)

(35.8)

18 17

1,050 (41.3)

1,219 (48.0)

19

20 1,077 (42.4) ZB5004430001

No. Standard measurement point

Hole shape

Size mm (in)

4

Round

15.5 (0.6)

Center of front suspension crossmember mounting hole

BODY DIMENSIONS

2-11

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm (in)

5

Center of front sidemember rear water draining hole

Round

16 (0.6)

7

Center of front floor sidemember front positioning hole

Round

16 (0.6)

16

Center of front suspension crossmember mounting hole

Round

15.5 (0.6)

17

Center of trailing arm mounting hole

Round

14 (0.6)

18

Center of trailing arm mounting hole

Round

14 (0.6)

19

Center of rear suspension crossmember mounting hole

Round

27 (1.1)

20

Center of rear suspension crossmember mounting hole

Round

15 (0.6)

4

AB501575

5, 16

7

AB501577

16

5 17, 18, 19

ZB5004380000

ZB5004470000

AB501582

AB501581

20

17 18 19

ZB5004500000

ZB5004510000

ZB5004410000

BODY DIMENSIONS

2-12

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

FRONT BODY M40200000060USA0000010000

AB501479

mm (in)

1,202 (47.3)

35 935 (36.8)

Body center point 1,494 (58.8)

512 (20.2)

416 (16.4) 28

909 (35.8)

470 (18.5)

1,634 (64.3)

1,069 (42.1)

1,450 (57.1)

34

33

369

32

(14.5)

31

423 (16.7)

27

30

472 (18.6)

1,026 896 (40.4) (35.3)

26

23

Body center point

25

1,060 (41.7) 450 (17.7)

332 (13.1)

29

24

343 (13.5)

22

21

33 880 (34.6)

28

Body center point

1,228 (48.3)

1,084 (42.7)

999 (39.3) 763 (30.0)

Body center point

773 (30.4)

28 30 26

789

235 (9.3)

23

34

33

(31.1)

642 (25.3)

223 (8.8)

27

884 (34.8)

32 31

29 25

984 (38.7)

21 883 (34.8)

1,466 (57.7)

1,217 (47.9)

641 1,094 30 (25.2) (43.1)

26

34

1,559 1,457 (61.4) (57.4)

775 (30.5)

24

22

Body center point

548 744 (29.3)

(21.6)

820 (32.3) 1,516 (59.7)

737 (29.0) 32 1,524 (60.0)

790 (31.1) 906 906 784 (35.7) (35.7) 557 (30.9) (21.9) 576 561 (22.7) (22.1)

880 (34.6)

25 29 24

23 Body center point

27 826 (32.5)

31

21

22 ZB500457 0000

BODY DIMENSIONS

2-13

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

No. Standard measurement point

Hole shape

Size mm (in)

21

Front end crossmember upper positioning lug (Body center point)

-

-

22

Center of front bumper bracket positioning hole

Round

13 (0.5)

23

Center of front bumper bracket positioning hole

Round

13 (0.5)

24

Center of front bumper beam mounting hole

Round

9 (0.4)

25

Center of front bumper beam mounting hole

Round

9 (0.4)

26

Center of front bumper beam mounting hole

Round

9 (0.4)

27

Center of front end upper bar mounting hole

Round

6.6 (0.3)

28

Center of front end upper bar mounting hole

Round

6.6 (0.3)

29

Front sidemember inner positioning lug

-

-

30

Front sidemember inner positioning lug

-

-

31

Center of front end upper bar side positioning hole

Round

5 (0.2)

32

Center of front strut mounting hole

Round

11.5 (0.5)

33

Cowl top lower panel positioning notch (Body center point)

-

-

34

Center of hood hinge mounting hole

Round

9 (0.4)

35

Corner of roof panel

-

-

21, 22

AB501562

23

AB501521

24, 25

AB501563

25

22 24 21

26

ZB500458 0000

ZB5004590000

ZB5004600000

AB501522

AB501564

AB501565

ZB5004610000

27

ZB5004620000

28

ZB5004630000

BODY DIMENSIONS

2-14 29

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) AB501533

AB501493

30

31

AB501566

34

ZB5004640000

ZB5004650000

ZB5004660000

32

AB501567

AB501568

AB501569

35

AB501570

33

ZB5004670000

ZB5004680000

ZB5004690000

ZB5004700000

SIDE BODY M40200000070USA0000010000

AB501356

mm (in)

42

38 36

707 (27.8) 1,208 861 (33.9) (47.6)

747 (29.4)

37

869 (34.2)

1,105 (43.5)

39

40 855 (33.7) 966 (38.0)

44 1,144 (45.0)

645 (25.4)

727 (28.6)

41

45

1,122 762 (44.2) (30.0)

43 ZB5004710000

BODY DIMENSIONS

2-15

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) AB501357

mm (in)

42

38

979 (38.5)

46 379 (14.9)

48

1,113 1,116 (43.8) 1,194 321 (47.0) (43.9) (12.6) 1,090 (42.9)

47

711 (28.0) 901 (35.5) 985 (38.8)

50

49

ZB500472 0000

No. Standard measurement point

Hole shape

Size mm (in)

36

Front pillar positioning notch (upper)

-

-

37

Front pillar positioning notch (lower)

-

-

38

Side roof rail positioning notch (front)

-

-

39

Side sill positioning notch (front)

-

-

40

Center pillar positioning notch (upper)

-

-

41

Center pillar positioning notch (lower)

-

-

42

Side roof rail positioning notch (rear)

-

-

43

Side sill positioning notch (rear)

-

-

44

Quarter panel positioning notch (upper)

-

-

45

Quarter panel positioning notch (lower)

-

-

46

Center of front door hinge mounting hole (upper)

Round

11 (0.4)

47

Center of front door hinge mounting hole (lower)

Round

11 (0.4)

48

Center of rear door hinge mounting hole (upper)

Round

11 (0.4)

49

Center of rear door hinge mounting hole (lower)

Round

11 (0.4)

50

Center of rear door switch mounting hole

Round

5 (0.2)

36

AB501539

37, 47

AB501545

38

AB501546

37 47

ZB5004730000

ZB500474 0000

ZB500475 0000

BODY DIMENSIONS

2-16 40

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) AB501547

41, 43, 49

AB501548

42

AB501549

46

41 49 43

44

48

ZB5004760000

ZB5004770000

ZB5004780000

AB501550

45

AB501551

AB501553

ZB5004790000

ZB5004800000

AB501553

50

AB501544

ZB5004820000

ZB5004830000

ZB5004810000

BODY DIMENSIONS

2-17

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)

REAR BODY M40200000080USA0000010000

mm (in)

51

51

700 (27.6)

1,073 (42.2)

518 (20.4)

1,102 (43.4)

1,352 (53.2)

52

52

1,522 (59.9) 680 (26.8)

53 1,364 (53.7) 1,014 (39.9)

54

951 (37.4)

1,259 (49.6)

1,354 (53.3)

1,139 (44.8)

53

1,282 (50.5)

960 (37.8) 974 (38.3)

54 55 Body center point

56

1,003 (39.5)

508 (20.0)

55 Body center point

56

ZB5004840000

No. Standard measurement point

Hole shape

Size mm (in)

51

Center of liftgate hinge mounting hole

Round

12 (0.5)

52

Center of liftgate gas spring mounting hole

Round

12 (0.5)

53

Center of rear combination light mounting hole

Round

8 (0.3)

54

Center of liftgate lower striker mounting hole

Round

14 (0.6)

55

Rear end crossmember outer body center point

-

-

56

Center of rear bumper beam mounting hole

Round

12 (0.5)

51

AB501534

AB501535

52, 53

54

AB501538

52

53 ZB5004850000

ZB500486 0000

ZB5004870000

BODY DIMENSIONS

2-18 55

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) AB501537

AB501536

56

ZB5004880000

ZB5004890000

INTERIOR M40200000090USA0000010000

1,260 (49.6) 1,385 (54.5)

1,430 (56.3)

1,439 (56.7)

42 1,377 (54.2)

38

1,387 (54.6)

44

40

36

1,430 (56.3)

mm (in)

1,211 (47.7)

1,430 (56.3)

1,430 (56.3)

45

41

37

43 39 ZB500490 0000 AB501483

mm (in)

42

38 36 1,232 (48.5)

Body center point 1,205 (47.4)

795

1,002 (39.4) 783 (31.3)

37

(30.8)

39

(48.1) 1,180 (46.5)

1,187 (46.7)

58

57

44

40 1,221

767 (30.2)

45

726 (28.6)

41

43 Body center point ZB5004910000

BODY DIMENSIONS

2-19

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) AB501484

mm (in)

Body center point

59 1,093 (43.0)

60

675 (26.6)

954 (37.6)

1,159 (45.6) 812 (32.0)

61

ZB500492 0000

No. Standard measurement point

Hole shape

Size mm (in)

36

Front pillar positioning notch (upper)

-

-

37

Front pillar positioning notch (lower)

-

-

38

Side roof rail positioning notch (front)

-

-

39

Side sill positioning notch (front)

-

-

40

Center pillar positioning notch (upper)

-

-

41

Center pillar positioning notch (lower)

-

-

42

Side roof rail positioning notch (rear)

-

-

43

Side sill positioning notch (rear)

-

-

44

Quarter panel positioning notch (upper)

-

-

45

Quarter panel positioning notch (lower)

-

-

57

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

Round

11 (0.4)

58

Rear floor pan front body center point

-

-

59

Rear floor pan rear notch (Body center point)

-

-

60

Center of rear shock absorber mounting hole

Round

14 (0.6)

61

Center of rear end trim mounting hole

Round

7 (0.3)

36

AB501539

ZB5004730000

57

AB501554

ZB5004930000

58

AB501555

ZB500494 0000

BODY DIMENSIONS

2-20

TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) AB501556

59

AB501557

60

ZB500495 0000

AB501558

61

ZB500497 0000

ZB500496 0000

ZB501485

mm (in)

Body center point

62 756 (29.8)

63 130 (5.1)

786 (30.9)

1,436 (56.5)

64

1,428 (56.2)

788 (31.0)

767 (30.2)

65 140 (5.5)

1,433 (56.4)

1,429 (56.3)

66

ZB5004980000

No. Standard measurement point

Hole shape

Size mm (in)

62

Tip of instrument panel bracket center (Body center point)

-

-

63

Center of deck crossmember mounting hole (left-upper)

Round

9 (0.4)

64

Center of deck crossmember mounting hole (left-lower)

Round

9 (0.4)

65

Center of deck crossmember mounting hole (right-upper)

Round

13 (0.5)

66

Center of deck crossmember mounting hole (right-lower)

Round

13 (0.5)

62

AB501559

ZB500499 0000

63, 64

AB501560

65, 66

AB501561

63

65

64

66

ZB500500 0000

ZB5005010000

3-1

GROUP 3

WELDED PANEL REPLACEMENT CONTENTS

ULTRA HIGH STRENGTH STEEL PLATE .................................3-2

QUARTER INNER (PARTIAL REPLACEMENT) ................................3-40

FRONT END CROSSMEMBER............3-3

FRONT DOOR OUTER PANEL (WELDED TYPE) ................................3-43

FENDER SHIELD....................3-4 FRONT SIDEMEMBER (PARTIAL REPLACEMENT).....................3-8

FRONT DOOR OUTER PANEL (ADHESION TYPE)...........................3-45

FRONT PILLAR....................3-10

REAR DOOR OUTER PANEL (WELDED TYPE) ................................3-46

FRONT PILLAR (PARTIAL REPLACEMENT) ................................3-14

REAR DOOR OUTER PANEL (ADHESION TYPE)...........................3-48

CENTER PILLAR...................3-17

ALUMINUM PANEL..................3-49

SIDE SILL.......................3-20

ALUMINUM PANEL CHARACTERISTICS. .3-49 ALUMINUM PANEL LOCATIONS........3-50 ALUMINUM PANEL REPAIR...........3-50 ALUMINUM PANEL PAINT............3-56

QUARTER OUTER...................3-23 ROOF (ALUMINUM ROOF)............3-26 REAR END CROSSMEMBER............3-31 REAR FLOOR......................3-34 QUARTER INNER...................3-36

3-2

WELDED PANEL REPLACEMENT ULTRA HIGH STRENGTH STEEL PLATE

ULTRA HIGH STRENGTH STEEL PLATE M40300000151USA0000010000

ULTRA HIGH STRENGTH STEEL PLATE APPLICATION

: High-tensile steel panel in 590Mpa-class : Ultra-high-tensile steel panel in 980MPa-class

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).

ZB600358 0000

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. ｠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.

WELDED PANEL REPLACEMENT

3-3

FRONT END CROSSMEMBER ｠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 overpulling 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 inches) 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.

FRONT END CROSSMEMBER M40300000152USA0000010000

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding AB501520 ZB600165 0000

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

WELDED PANEL REPLACEMENT

3-4

FENDER SHIELD

REPAIR WELDS

A

B

AB501492

A

B ZB600068 0000

FENDER SHIELD M40300000040USA0000010000

AB501344

AB501088

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding

ZB600144 0000

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

WELDED PANEL REPLACEMENT

3-5

FENDER SHIELD

REPAIR WELDS

ZB600023

A

Acoustic foam

A

ZB600451

ZB600069 0000

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

When repairing the area using foam materials do not use firing tools since the foaming materials may burn.

WELDED PANEL REPLACEMENT

3-6

FENDER SHIELD

B

Acoustic foam

B

(With the front upper frame outer removed) B

E

D

ZB600024

C Acoustic foam AB501449

ZB600450

AB501603

C ZB600070 0000

WELDED PANEL REPLACEMENT

3-7

FENDER SHIELD

AB501604

AB501450

E

D

ZB6000710000

NOTE: Partial replacement of the front upper frame is 180 mm (7.1 in)

90 mm (3.5 in)

Front upper frame inner

possible depending on the range of damage. For partial replacement, cut the front upper frame outer at 90 mm (3.5 inches) forward of the vehicle from its positioning hole, and front upper frame inner at 180 mm (7.1 inches).

Front upper frame outer ZB600437 0000

NOTE ON REPAIR WORK REMOVAL 1.Turn up the front sidemember outer as shown to cut off the welded point between the front sidemember rear bulkhead and the front sidemember brace lower.

AB501661

Front sidemember outer ZB600168 0000

3-8

WELDED PANEL REPLACEMENT FRONT SIDEMEMBER (PARTIAL REPLACEMENT)

INSTALLATION 1.After installation of the upper frame outer, press in sponge from the hole up to the dotted line shown in the figure as a temporary measure to fill the inside of the upper frame outer.

AB501419

ZB600155 0000

FRONT SIDEMEMBER (PARTIAL REPLACEMENT) M40300000001USA0000010000

AB501353

AB501088

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding

ZB600153 0000

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

WELDED PANEL REPLACEMENT

3-9

FRONT PILLAR

REPAIR WELDS A

B

270 mm (10.6 in)

310 mm (12.2 in)

230 mm (9.0 in)

150 mm (5.9 in)

A

B

AB501606

ZB600072 0000

NOTE: ｠Refer to the Front End Crossmember section on P. 3-3for the welding point with front end crossmember. ｠Refer to the Fender Shield section on P.3-4for the welding points with the fender shield.

WELDED PANEL REPLACEMENT

3-10

FRONT PILLAR

FRONT PILLAR M40300000050USA0000010000

AB501346

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding

ZB600146 0000

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

WELDED PANEL REPLACEMENT

3-11

FRONT PILLAR

REPAIR WELDS

120 mm (4.7 in) A

E ZB600672A

B

ZB600022 ZB600018

C

210 mm (8.3 in)

B (With the side outer panel removed)

Acoustic foam (With the front upper frame outer removed) D

AB501289

ZB600676 AB501508

C

AB501398

D

E

ZB600073 0000

NOTE: For the welding points of upper frame outer and upper pillar-to-front pillar brace, refer to P.3-4Fender Shield.

When repairing the area using foam materials do not use firing tools since the foaming materials may burn.

WELDED PANEL REPLACEMENT

3-12

FRONT PILLAR

NOTE ON REPAIR WORK

Side sill inner support front

side outer panel 350 mm (13.7 in)

REMOVAL Because partial replacement of the side sill outer reinforcement front is impossible, remove the side sill outer reinforcement front on the body side. Cut and remove the side outer panel at 350 mm (13.7 inches) behind the side sill cutting section.

Side sill outer reinforcement front ZB600021 0000

INSTALLATION 1.When installing the side sill outer reinforcement front and front pillar reinforcement lower, weld them in advance as shown in the figure.

AB501286

Front pillar reinforcement lower

Side sill outer reinforcement front ZB600135 0000

WELDED PANEL REPLACEMENT FRONT PILLAR

3-13

2.When installing the front pillar outer, apply body sealant as shown in the figure.

AB501220

: Body sealant

ZB600128 0000

3.When installing the new front pillar outer, affix urethane foam as shown in the figure as a temporary measure to fill the inside of the front pillar.

Urethane foam

ZB600362 0000

4.After installing the front pillar outer, seal the hole and flange with bolt and aluminum tape, and then fill the hole with foam materials as shown in the figure.

Foam: 3M™ AAD ULTRAPRO Panel foam-Yellow

AB501291

ZB600138 0000

WELDED PANEL REPLACEMENT

3-14

FRONT PILLAR (PARTIAL REPLACEMENT) 5.Wait 2 hours after filling the foam materials to remove the bolt and aluminum tape, then melt the foam materials with a soldering gun to ensure that a clip, etc. can be inserted in the hole filled with foam materials.

AB200418

ZB600112 0000

FRONT PILLAR (PARTIAL REPLACEMENT) M40300000158USA0000010000

AB501346

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding

ZB600348 0000

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

WELDED PANEL REPLACEMENT

3-15

FRONT PILLAR (PARTIAL REPLACEMENT)

REPAIR WELDS ZB600670 AB501507 ZB600019

A

200 mm (7.9 in)

ZB600022

E A

210 mm (8.3 in)

B

(With the side outer panel removed) Acoustic foam

ZB600676

C

C

B D

ZB600020 AB501508

AB501289

D

E ZB600293 0000

When repairing the area using foam materials do not use firing tools since the foaming materials may burn.

WELDED PANEL REPLACEMENT

3-16

FRONT PILLAR (PARTIAL REPLACEMENT)

NOTE ON REPAIR WORK

Side sill inner support front

side outer panel 350 mm (13.7 in)

REMOVAL Because partial replacement of the side sill outer reinforcement front is impossible, remove the side sill outer reinforcement front on the body side. Cut and remove the side outer panel at 350 mm (13.7 inches) behind the side sill cutting section.

Side sill outer reinforcement front ZB600021 0000

side outer panel 120 mm (4.7 in)

INSTALLATION 1.To assure the strength of the front pillar cutting section, cut the front pillar reinforcement lower 60 mm (2.4 inches) upward from the front pillar cutting section, and the side outer panel at 120 mm (4.7 inches) upward.

60 mm (2.4 in) Front pillar reinforcement lower ZB600459 0000

Front pillar reinforcement lower

Side sill outer reinforcement front

2.When installing the side sill outer reinforcement front and front pillar reinforcement lower, weld them in advance as shown in the figure.

ZB6003490000

3.When installing the new front pillar outer, affix urethane foam as shown in the figure as a temporary measure to fill the inside of the front pillar.

Urethane foam

ZB600362 0000

WELDED PANEL REPLACEMENT

3-17

CENTER PILLAR

4.When installing the front pillar outer, apply body sealant as shown in the figure.

ZB600128

: Body sealant

ZB600347 0000

5.After installing the front pillar outer, seal the hole and flange with bolt and aluminum tape, and then fill the hole with foam materials as shown in the figure.

Foam : 3M™ AAD ULTRAPRO Panel foam-Yellow

AB501291

ZB600138 0000

6.Wait 2 hours after filling the foam materials to remove the bolt and aluminum tape, then melt the foam materials with a soldering gun to ensure that a clip, etc. can be inserted in the hole filled with foam materials AB200418

ZB600112 0001

CENTER PILLAR M40300000060USA0000010000

AB501348

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding ZB600148 0000

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

WELDED PANEL REPLACEMENT

3-18

CENTER PILLAR

REPAIR WELDS

ZB600678

70 mm (2.75 in) A

D A

E AB501509

The same position as the new center pillar outer C B

30 mm (1.2 in) D

ZB600104

AB501510

F

Acoustic foam AB501652 AB501511

ZB600679

E

ZB600677

F

(With the side outer panel removed) B

C

When repairing the area using foam materials do not use firing tools since the foaming materials may burn.

ZB600074 0000

WELDED PANEL REPLACEMENT CENTER PILLAR

3-19

NOTE ON REPAIR WORK REMOVAL After cutting the center pillar inner from the side outer panel, remove the center pillar inner upper remaining on the body.

AB501423

Center inner pillar upper

ZB600158 0000

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

AB501421

50 mm (1.97 in)

Side outer panel Center pillar reinfoecement ZB600156 0000

Center inner pillar upper

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

2.Remove the center inner pillar upper and center inner pillar lower from a new center pillar inner.

Center inner pillar lower

AB501217

ZB600296 0000

3.When installing the new center pillar outer, affix urethane foam as shown in the figure as a temporary measure to fill the inside of the center pillar.

Urethane foam AB501288

ZB6001370000

WELDED PANEL REPLACEMENT

3-20

SIDE SILL 4.After installing the new center pillar reinforcement, seal the hole and flange with bolt and aluminum tape, and then fill the hole with foam materials as shown in the figure.

Foam : 3M™ AAD ULTRAPRO Panel foam-Yellow

ZB600105 0000

5.Wait 2 hours after filling the foam materials to remove the bolt and aluminum tape, then melt the foam materials with a soldering gun to ensure that a clip, etc. can be inserted in the hole filled with foam materials.

AB200418

ZB600112 0000

SIDE SILL M40300000070USA0000010000

AB501351

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding ZB6001510000

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

WELDED PANEL REPLACEMENT

3-21

SIDE SILL

REPAIR WELDS 260 mm (10.2 in) D

50 mm (1.97 in)

F

50 mm (1.97 in) C

Acoustic foam

B

AB501207

F

Acoustic foam A

ZB600106

(With the side outer panel removed)

A ZB600669

ZB600675

ZB600849

D

C

B

AB501205

E

When repairing the area using foam materials do not use firing tools since the foaming materials may burn.

F

ZB600075 0000

WELDED PANEL REPLACEMENT

3-22

SIDE SILL

NOTE ON REPAIR WORK INSTALLATION 1.Remove the center inner pillar upper and center inner pillar lower from a new center pillar inner.

Center inner pillar lower

AB501218

Center inner pillar upper

ZB600126 0000

Side sill outer reinforcement rear

2.Remove the side sill outer reinforcement front and side sill outer reinforcement rear from a new side sill reinforcement.

Side sill outer

AB501219 reinforcement front

ZB6001270000

3.When installing a new side sill outer reinforcement rear, lift the side sill end plate up to the point shown in the figure, cut the quarter inner extension front at a position shown in the figure, and remove it. Install the side sill outer reinforcement rear, and next install and weld the quarter inner extension front.

Cut position AB501694

Quarter inner extension front

Side sill end plate ZB600169 0000

4.When installing the new floor side sill outer, affix urethane foam as shown in the figure as a temporary measure to fill the inside of the center pillar.

AB501287

Urethane foam

ZB600136 0000

WELDED PANEL REPLACEMENT

3-23

QUARTER OUTER

5.After installing the new floor side sill outer, seal the hole and flange with bolt and aluminum tape, and then fill the hole with foam materials as shown in the figure.

Foam: 3M™ AAD ULTRAPRO Panel foam-Yellow

ZB600105 0000

6.Wait 2 hours after filling the foam materials to remove the bolt and aluminum tape, then melt the foam materials with a soldering gun to ensure that a clip, etc. can be inserted in the hole filled with foam materials.

AB200418

ZB600112 0000

QUARTER OUTER M40300000080USA0000010000

AB501347

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding

ZB600147 0000

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

WELDED PANEL REPLACEMENT

3-24

QUARTER OUTER

REPAIR WELDS 190 ± 50 mm (7.5 ± 1.97 in) 40 ± 20 mm (1.57 ± 0.78 in)

A

B

C

3 points left side

Right side The same position as the new quarter outer panel

F

3 points right side

Acoustic foam AB501494

A

E

AB501496

D ZB600671

ZB600684 ZB600683

B

C D ZB600076 0000

When repairing the area using foam materials do not use firing tools since the foaming materials may burn.

WELDED PANEL REPLACEMENT

3-25

QUARTER OUTER

AB501495

AB501497

F

E

ZB600685 0000

NOTE ON REPAIR WORK INSTALLATION 1.To reinforce the strength of the rear gate pillar cut-off area, cut off the side outer panel 50 mm (1.97 inches) above the cut-off position.

AB501428

50 mm (1.97 in)

ZB600160 0000

2.When assembling the new quarter outer extension lower, apply in advance the body sealant to the area shown in the figure. (Right side only) Adhesive : Epoxyayresin adhesive Brand : 3M™ AAD Part No.8115 or equivalent

AB501498

: Adhesive AB501427

Urethane foam

: Body sealant

ZB600164 0000

Left side

ZB6001590000

3.When assembling the new rear quarter outer panel, apply in advance the body sealant to the area shown in the figure. Affix urethane foam so that it fills the wheel arch inside to prevent the foam material from dripping.

WELDED PANEL REPLACEMENT

3-26

ROOF (ALUMINUM ROOF) 4.After installing the rear quarter outer panel, seal the hole and flange with bolt and aluminum tape, and then fill the hole with foam materials from the hole as shown in the figure.

Foam : 3M™ AAD ULTRAPRO Panel foam-Yellow

AB501429

ZB6001610000

5.Wait 2 hours after filling the foam materials to remove the bolt and aluminum tape, then melt the foam materials with a soldering gun to ensure that a clip, etc. can be inserted in the hole filled with foam materials.

AB200418

ZB600112 0000

ROOF (ALUMINUM ROOF) M40300000153USA0000010000

AB501350

Symbol

Operation description Spot weldin g MIG plug welding

t wo panels to be welde d ( :: indicates indicates three panels to be welde d )

MIG spot weldin g MIG arc welding (conti nuous )

Rivet ZB600149 0000

Anti-corrosion agent application locations (Use access holes to apply libe rally to butt- welded joint s.)

WELDED PANEL REPLACEMENT

3-27

ROOF (ALUMINUM ROOF)

REPAIR WELDS Vehicles without sunroof

1

A

C

E D

F

B

2

AB501305

Vehicles with roof rail Vehicles with sunroof

1 C

E D

F B

2 1 2

: Adhesive 1

AB501306

Vehicles with roof rail

: Adhesive 2

｠Adhesive 1: Urethane body sealer Brand: 3M™ AAD Part No.8542 equivalent

ZB600077 0000

or

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

or

WELDED PANEL REPLACEMENT

3-28

ROOF (ALUMINUM ROOF)

A

ZB600674

BZB600673

ZB600850

C

5.5 ± 1.5 N·m

5.5 ± 1.5 N·m 49 ± 13 in-lb

AB501433

49 ± 13 in-lb AB501300 5.5 ± 1.5 N·m 49 ± 13 in-lb

5.5 ± 1.5 N·m 49 ± 13 in-lb

D

(Vehicles without sunroof)

D (Vehicles with sunroof)

5.5 ± 1.5 N·m 49 ± 13 in-lb AB501380 AB501307

5.5 ± 1.5 N·m 49 ± 13 in-lb

E

F

ZB600088 0000

WELDED PANEL REPLACEMENT ROOF (ALUMINUM ROOF)

3-29

NOTE ON REPAIR WORK REMOVAL 1.Place supporting bars in the vehicle to prevent the side panels from expanding or tilting when removing the roof panel assembly.

AB501312

AB302193

ZB600140 0000

Self piereing rivet

AB501298

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

Roof panel Foot

Belt sander ZB600129 0000 AB501299

Roof panel

Self piereing rivet

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

Punch ZB600143 0000

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

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

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

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

WELDED PANEL REPLACEMENT

3-30

ROOF (ALUMINUM ROOF) 4.Use the recommended tool to tighten the roof lid rivet by the following procedure.

(1)Insert the rivets into the roof.

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

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

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

Recommended tool Rivet diameter 4.8 mm (0.18 in)

AB501393

ZB600154 0000

Recommended tool

Roof panel

Recommended tool

AB302218 AC205918 A

Flange surface

Roof lid rivet 1

2

3

4 ZB600142 0000

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

AB302189

A

Roof panel

Body sealing AB302205

Rivet

A ZB6001410000

WELDED PANEL REPLACEMENT

3-31

REAR END CROSSMEMBER

REAR END CROSSMEMBER M40300000150USA0000010000

AB501352

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding

ZB600152 0000

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

WELDED PANEL REPLACEMENT

3-32

REAR END CROSSMEMBER

REPAIR WELDS

C

D

A

B

AB501253

AB501254

AB501255

A

B

AB501258 ZB6000870000

WELDED PANEL REPLACEMENT

3-33

REAR END CROSSMEMBER

AB501256

AB501257

AB501275

D (With the quarter outer extension rear removed) C

ZB6002970000

NOTE ON REPAIR WORK Quarter outer extension rear

AB501245

Quarter outer extension lower

Rear end inner panel side

AB501246

AB501243

ZB600119 0000

REMOVAL When removing the rear end crossmember, remove the quarter outer extension rear, quarter outer extension lower, and rear end inner panel side.

WELDED PANEL REPLACEMENT

3-34

REAR FLOOR

INSTALLATION 1.Remove the rear end inner panel side from the new rear end crossmember.

AB501244

Rear end inner panel side ZB600130 0000

2.After the installation of the rear end crossmember, seal both the holes of the rear end crossmember with body tape to prevent intrusion of exhaust gas.

AB501651 AB501253

Body tape ZB600167 0000

REAR FLOOR M40300000100USA0000010000

AB501349

Symbol

Operation description Spot weldin g MIG plug welding

t wo panels to be welde d ( :: indicates indicates three panels to be welde d )

MIG spot weldin g MIG arc welding (conti nuous ) Braze weldin g

ZB6001500000

Anti-corrosion agent application locations (Use access holes to apply libe rally to butt- welded joint s.)

WELDED PANEL REPLACEMENT

3-35

REAR FLOOR

REPAIR WELDS

A

C

B

AB501293

AB501303

A (With the rear floor pan removed)

NOTE: Refer to the Rear End Crossmember Section on P.3-31for the welding points with the rear end crossmember.

ZB600080 000

WELDED PANEL REPLACEMENT

3-36

QUARTER INNER

ZB600025

ZB600026

B

C ZB600079 0000

NOTE ON REPAIR WORK REMOVAL When removing the rear floor side member upper, cut at 60 mm (2.36 inches) behind the rear floor crossmember upper extension mounting hole shown in the figure.

60 mm (2.36 in)

Rear floor crossmember upper AB501304 extension mounting hole

ZB600139 0000

QUARTER INNER M40300000120USA0000010000

AB501345

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding

ZB6001450000

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

WELDED PANEL REPLACEMENT

3-37

QUARTER INNER

REPAIR WELDS D

E Acoustic foam Left side Right side

C

Acoustic foam

B

Left side A

(With the side outer panel removed)

AB501467

AB501407

A

AB501599

B

(With the side outer panel removed) ZB6000810000

When repairing the area using foam materials do not use firing tools since the foaming materials may burn.

NOTE: ｠Refer to the Quarter Outer section on P.3-23for the welding point with quarter outer. ｠Refer to the Roof section on P.3-26for the welding points and riveting points with the roof.

WELDED PANEL REPLACEMENT

3-38

QUARTER INNER

Seven-people Seven-people AB501468 AB501469

C

C

(Right side)

(Left side)

AB501472

D

AB501600 AB501470

E

ZB600087 0000

WELDED PANEL REPLACEMENT QUARTER INNER

3-39

NOTE ON REPAIR WORK INSTALLATION 1.When installing the new gate pillar reinforcement, affix urethane foam so that it fills the gate pillar bottom to prevent the foam material from dripping.

Five-people

Urethane foam AB501598

Seven-people

AB501605

Urethane foam AB501431

ZB6001660000

2.Because foam materials cannot be filled into the rear pillar inside after the installation of the quarter inner panel, press in sponge as a temporary measure to fill the rear pillar inside from the hole to the dotted line shown in the figure.

AB501696

ZB600170 0000

3.After installing the gate pillar reinforcement, seal the hole and flange with bolt and aluminum tape, and then fill the hole with foam materials from the hole as shown in the figure.

Foam: 3M™ AAD ULTRAPRO Panel foam-Yellow

AB501430

ZB600162 0000

3-40

WELDED PANEL REPLACEMENT QUARTER INNER (PARTIAL REPLACEMENT) 4.Wait 2 hours after filling the foam materials to remove the bolt and aluminum tape, then melt the foam materials with a soldering gun to ensure that a clip, etc. can be inserted in the hole filled with foam materials.

AB200418

ZB600112 0000

QUARTER INNER (PARTIAL REPLACEMENT) M40300000002USA0000010000

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding

ZB600048 0000

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

WELDED PANEL REPLACEMENT

3-41

QUARTER INNER (PARTIAL REPLACEMENT)

REPAIR WELDS

B C

AB501599

AB501467 A

(With the rear pillar reinforcement lower removed)

AB501407

A

B

(With the rear pillar reinforcement lower removed) ZB600294 0000

NOTE: Refer to the Quarter Outer section on P.3-23for the welding points with the quarter outer.

WELDED PANEL REPLACEMENT

3-42

QUARTER INNER (PARTIAL REPLACEMENT)

AB501469

C ZB600969 0000

NOTE ON REPAIR WORK REMOVAL AB501285 Acoustic

foam 100 mm (3.9 in) Rear pillar reinforcement

ZB600353 0000

When repairing the area using foam materials do not use firing tools since the foam materials may burn.

1.When removing the quarter inner extension front, remove the rear pillar reinforcement lower in advance and cut the rear pillar reinforcement at 100 mm (3.9 inches) below the positioning notch. The cut area of the quarter inner panel is clogged by the rear pillar reinforcement. Therefore, cut and remove the rear pillar reinforcement 100 mm (3.9 inches) below the positioning notch.

NOTE: Refer to the Quarter Inner section on P.3-36for the welding points with the rear pillar reinforcement.

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

Tape

AB501283 ZB6003510000

WELDED PANEL REPLACEMENT

3-43

FRONT DOOR OUTER PANEL (WELDED TYPE)

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

AB501282ZB600350 0001 AB501284

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

40 mm (1.57 in) ZB600352 0000

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

AB501283 Body sealing ZB6003510001

FRONT DOOR OUTER PANEL (WELDED TYPE) M40300000154USA0000010000

AB501251

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding

ZB600133 0000

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

WELDED PANEL REPLACEMENT

3-44

FRONT DOOR OUTER PANEL (ADHESION TYPE)

REPAIR WELDS AB501238

50 mm (1.97 in)

ZB600680

A

AB201368 AB501390

A

B

BAB501342

ZB600681

ZB600682

C

: Adhesive

D

Adhesive application point

Adhesive : Urethane body sealer

C

D

ZB600082 0000

Brand : 3M™ AAD Part No.8542 or equivalent

NOTE: After hemming the front door outer panel, MIG spot weld the flange overlap section at a pitch of 50 mm (1.97 inches).

WELDED PANEL REPLACEMENT

3-45

FRONT DOOR OUTER PANEL (ADHESION TYPE)

FRONT DOOR OUTER PANEL (ADHESION TYPE) M40300000155USA0000010000

Symbol

AB501252

Operation description Spot weldin g MIG plug welding

t wo panels to be welde d ( :: indicates indicates three panels to be welde d )

MIG spot weldin g MIG arc welding (conti nuous ) Braze weldin g Anti-corrosion agent application locations (Use access holes to apply libe rally to butt- welded joint s.)

AB401287

ZB600134 0000

REPAIR WELDS

AB501237

A

A

ZB600942

B

ZB600680

C

C AB501241

B

D : Adhesive 1

E

ZB600682

Adhesive application point

: Adhesive 2

｠Adhesive 1: Urethane body sealer

ZB600681

D

E

ZB600083 0000

AB501389

Brand: 3M™ equivalent

AAD

Part

No.8542

or

3-46

WELDED PANEL REPLACEMENT REAR DOOR OUTER PANEL (WELDED TYPE)

｠Adhesive 2: Epoxyayresin adhesive

Brand: 3M™ equivalent

AAD

Part

No.8115

or

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

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

REAR DOOR OUTER PANEL (WELDED TYPE) M40300000156USA0000010000

AB501249

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding

ZB6001310000

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

WELDED PANEL REPLACEMENT

3-47

REAR DOOR OUTER PANEL (ADHESION TYPE)

REPAIR WELDS

50 mm (1.97 in)

AB501240

AB201368

A A

Adhesive application point AB501341

B

ZB600680 ZB600681

B

C

C AB501392

: Adhesive

Adhesive : Urethane body sealer

ZB600084 0000

Brand: 3M™ AAD Part No.8542 or equivalent

NOTE: After hemming the front door outer panel, MIG spot weld the flange overlap section at a pitch of 50 mm (1.97 inches).

WELDED PANEL REPLACEMENT

3-48

REAR DOOR OUTER PANEL (ADHESION TYPE)

REAR DOOR OUTER PANEL (ADHESION TYPE) M40300000157USA0000010000

AB501250

Symbol

Operation description Spot welding MIG plug welding

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

MIG spot welding MIG arc welding (continuous) Braze welding ZB600132 0000

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

AB401287

REPAIR WELDS

AB501239

A A

B

AB501242

ZB600680

B

ZB600681

C

C AB501391

: Adhesive 1 : Adhesive 2

Adhesive application point

｠Adhesive 1: Urethane body sealer

ZB600085 0000

WELDED PANEL REPLACEMENT ALUMINUM PANEL

Brand : 3M™ AAD Part No.8542 or equivalent ｠Adhesive 2: Epoxyayresin adhesive

3-49

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

NOTE ON REPAIR WORK

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

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

ALUMINUM PANEL ALUMINUM PANEL CHARACTERISTICS M40300000005USA0000010000

Description of aluminum panel

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

Advantage of aluminum panel

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

However, it requires 1.4 times in thickness to obtain

the same rigidity as the steel panel, resulting in one half in weight.

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

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

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

WELDED PANEL REPLACEMENT

3-50

ALUMINUM PANEL

ALUMINUM PANEL LOCATIONS M40300000006USA0000010000

Roof panel

ZC501829

ZB600163 0000

Application

Thickness

Roof panel

1.3 mm (0.05 inches)

ALUMINUM PANEL REPAIR M40300000007USA0000010000

Precautions upon sheet metal processing 1.Major difference in processing between sheet metal and steel sheet (On the basis of general body shop) Work Aluminum alloy panel Steel sheet descript ion Hammeri Mallet or plastic hammer Sheet metal ng hammer Washer welding

Not possible

Possible

Gas welding

Not good workability but Possible possible

Spot welding

Not possible

Possible

WELDED PANEL REPLACEMENT ALUMINUM PANEL

3-51

Work Aluminum alloy panel Steel sheet descript ion MIG welding

Possible by a welding Possible by a machine for aluminum general and argon gas welding machine and CO2gas

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

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

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

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

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

Material Melting point

Aluminum

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

Steel sheet

1500 to 2500 °C (2732 to 4532 °F)

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

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

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

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

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

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

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

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

WELDED PANEL REPLACEMENT

3-52

ALUMINUM PANEL 1.Repair of sheet metal (1)Heat with a burner. ｠Heat-up the panel until you feel heat with a keplar work glove on the reverse side of the panel. ｠Keep moving the burner evenly to prevent heat from concentrating in one point.

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

AB202119

ZB600117 0000

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

ZB600118 0000

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

AB202113

ZB6001110000

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

AB202116

ZB600114 0000

｠The heating temperature should be approximately 250° C (482°F). ｠Pay particular attention to heating, because it is melted without discolouration by heat. ｠Cover the vicinity of the area to be heated with a wet rag or the like to prevent temperature rise and influence of heat (distortion). ｠Do not use a draw hammer for steel sheets because it may cause the panel crack.

WELDED PANEL REPLACEMENT ALUMINUM PANEL

3-53

4.Sanding: Grind the surface with a disk sander or a doubleaction sander. ｠Disk sander: #100 to #120 ｠Double-action sander: #150 to #180

Aluminum plates are softer than steel sheets, therefore select an appropriate abrasive to prevent the surface from deeply scratched. The heating temperature should be approximately 250°C (482°F).

ZB6001100000

AB302173

Correction of cuts and cracks If cuts, cracks, or holes occur in a steel sheet panel, MIG welding with CO2is used for repair. However, for an aluminum panel, use MIG or TIG welding with argon gas (inert gas) as shielding gas for repair.

ZB6001210000

DEGREE OF DISTORTION CAUSED BY WELDING Gas welding (a large amount of distortion) TIG welding MIG welding (a small amount of welding). This manual explains the operation procedure of MIG welding which causes a small amount of distortion by welding heat.

Operation procedure of MIG welding ｠Be careful to avoid excessive stretch of or damage to the panel. ｠Minimize the gap of the butt joint.

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

ZB600118 0000

WELDED PANEL REPLACEMENT

3-54

ALUMINUM PANEL

AB202118 ZB600116 0000

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

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

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

(2)Remove the oxide coat from the welding area, including its back, with a stainless steel wire brush just before welding.

Welding shall be started as soon as the oxide coat is removed.

Do not over-grind the base of the panel.

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

AB202117

ZB600115 0000

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

AB202113

ZB6001110000

｠The heating temperature should be approximately 250°C (482°F). ｠Pay particular attention to heating, because it is melted without discolouration by heat. ｠Cover the vicinity of the area to be heated with a wet rag or the like to prevent temperature rise and influence of heat (distortion). ｠Do not use a draw hammer for steel sheets because it may cause the panel crack.

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

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

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

AB302174 ZB600122 0000

WELDED PANEL REPLACEMENT ALUMINUM PANEL

3-55

ZB6001100000

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

Wire diameter: 1.6 mm (0.063 inches).

AB202108

｠Be careful to avoid excessive stretch of or damage to the panel. ｠Minimize the gap of the butt joint.

ZB600109 0000

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

Wire diameter: 1.6 mm (0.063 inches).

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

AB302175

ZB600123 0000

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

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

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

AB302176

ZB600124 0000

WELDED PANEL REPLACEMENT

3-56

ALUMINUM PANEL

Finish with putty 1.Grind the putty-applied area with a 150-to 180-grit doubleaction sander.

2.Degrease and clean the putty-applied area.

3.Apply 2-liquid type epoxy primer or a pretreatment agent for aluminum.

4.Grind with a 180-grit double-action sander for cutting action.

5.Degrease and clean the putty-applied area.

6.Apply putty for metal sheets, and dry it naturally.

AB202114

ZB600113 0000

Do not dry it forcibly at 60°C (140°F) or higher.

7.Grind with a 180-grit sander.

AB302177

ZB600125 0000

ALUMINUM PANEL PAINT M40300000008USA0000010000

Painting in production line Same as painting for normal steel sheets.

Precautions upon sheet metal processing ｠Avoid hasty grinding and minimize grinding heat. ｠Do not dry it forcibly at higher than 60°C (140°F).

1.Peel-off of paint film 2.Cleaning and degreasing

Apply 2-liquid type epoxy primer or a pretreatment agent for aluminum to the aluminum base surface.

3.Application of wash primer 4.Drying <60°C (140°F) or lower> 5.Application of primer surfacer 6.Drying <60°C (140°F) or lower> 7.Grinding 8.Cleaning and degreasing 9.Finish coating 10.Drying <60°C (140°F) or lower>

NOTE: ｠Refer to paint manufacturers' paint specifications for details.

WELDED PANEL REPLACEMENT ALUMINUM PANEL

3-57

｠The procedure is almost the same as the repair painting procedure of anti-corrosion steel panel.

3-58 MEMO

WELDED PANEL REPLACEMENT

4-1

GROUP 4

CORROSION PROTECTION CONTENTS

BODY SEALING LOCATIONS...........4-2 UNDERCOAT APPLICATION LOCATIONS .................................4-6

CORROSION PROTECTION

4-2

BODY SEALING LOCATIONS

BODY SEALING LOCATIONS M40400000010USA0000010000

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

1

6

2 5 4

3 ZB500345 0000

UPPER BODY

7

8

9

10 ZB5003460000

CORROSION PROTECTION

4-3

BODY SEALING LOCATIONS

SIDE BODY

14

15 11

12

13 ZB500347 0000

1

2

ZB500509 0000

3

4

ZB500510 0000

4-4

CORROSION PROTECTION BODY SEALING LOCATIONS

5

6

0000 ZB5005110000

7

8

ZB500354

9

ZB500512 0000

10

ZB5005130000

CORROSION PROTECTION BODY SEALING LOCATIONS

11

4-5

12

ZB500514 0000

13

14

ZB5005150000

15

Hood

ZB500516 0000

4-6

CORROSION PROTECTION UNDERCOAT APPLICATION LOCATIONS

Front door

Rear door

ZB500517 0000

Liftgate upper(outer)

Liftgate upper(inner)

ZB500518 0000

Liftgate lower

ZB5005190000

UNDERCOAT APPLICATION LOCATIONS M40400000030USA0000010000

The under parts of the body is undercoated for anticorrosive, anti-rust, anti-chipping, and anti-vibration performance.

After correcting the body, restore as shown in the instructions of the figure, if necessary.

CORROSION PROTECTION

4-7

UNDERCOAT APPLICATION LOCATIONS

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

areas.

*

*

*

: Undercoat [Film thickness is at least 0.5 mm]

* ZB5003690000

4-8 MEMO

CORROSION PROTECTION

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 M40500000010USA0000010000

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

12 6

11 5

2

8

3

7 4

26

27 28

1

25 10

29 19

9 34 38 33

30 15 32

17 18

16

35 31

20

23 14 21 13

22 24

37

36 ZB6005660000

SYNTHETIC-RESIN PARTS

5-3

LOCATION OF SYNTHETIC-RESIN PARTS

No.

Part name

Material

Abbreviat Heation of resistant material temperat ure [°C (° F)]

1

Radiator grille

Acrylonitrile butadiene styrene

ABS

80 (176)

2

Door mirror

3

Rear roof garnish

4

Liftgate spoiler

5

Roof rack cover front

6

Roof rack cover center

7

Roof rack cover rear

8

Roof antenna base center

Acrylonitrile ethylene styrene

AES

80 (176)

9

Fog light bezel

Acrylonitrile styrene acrylate

ASA

80 (176)

10

Headlight

Polycarbonate

PC

120 (248)

11

Front door outside handle

PC+PET

120 (248)

12

Rear door outside handle

Polycarbonate+Polyethylene terephthalate

13

Front splash shield

Polyethylene

PE

100 (212)

14

Rear splash shield

High density polyethylene

PE-HD (HDPE)

70 - 90 (158 - 194)

15

Inside rear view mirror

Polypropylene

PP

80 (176)

16

Lower quarter trim

17

Upper liftgate trim

18

Liftgate trim side

19

Liftgate trim

20

Lower liftgate trim

21

Rear scuff plate

22

Front scuff plate

23

Rear end trim

24

Cowl side trim

25

Front bumper face

Rubber denatured polypropylene

PP+E/P

80 (176)

26

Front deck garnish

27

Rear bumper face

28

Rear corner bumper

29

Side air dam

Talc filled rubber polypropylene (20%)

modified PP+E/PTD20

110 (230)

30

Front door trim

Talc filled polypropylene (10%)

31

Rear door trim

32

Lower center pillar trim

PP-TD10 (PPF)

110 - 120 (230 - 248)

SYNTHETIC-RESIN PARTS

5-4

LOCATION OF SYNTHETIC-RESIN PARTS

No.

Part name

Material

Abbreviat Heation of resistant material temperat ure [°C (° F)]

33

Front pillar trim

Talc filled polypropylene (20%)

34

Upper center pillar trim

PP-TD20 (PPF)

35

Upper quarter trim

36

Floor console rear

37

Floor console front

38

Instrument panel

NOTE: ｠If the material symbols designated by the ISO differ from the old symbols, both are given, with the old symboling enclosed in brackets.

ISO: International Standardization Organization. ｠A slash (/) in the material symbol indicates that two different materials make two-layer construction. A plus sign (+) indicates that the two different materials mix each other. ｠The indicated heat-resistant temperature for parts which are composed of two or more types of material is the value for the material with the lowest heat-resistant temperature. ｠The material symbols for synthetic-resin parts are embossed on the parts in hidden places.

120 - 130 (248 - 266)

6-1

GROUP 6

BODY COLOR CONTENTS

BODY COLOR CODE..................6-2 BODY COLOR CHARTS................6-2 BODY COLORING....................6-3 RADIATOR GRILLE..................6-3 WHEELHOUSE.......................6-4

BODY COLOR

6-2

BODY COLOR CODE

BODY COLOR CODE M40600000010USA0000010000

Body color code is stamped on the name plate, which is attached on the underside of the center pillar (right side).

Body color code ZB5004280000

BODY COLOR CHARTS M40600000020USA0000010002

Color

Color code

Color number

Color name (Previous name)

Composition of film

SILVER

A31

CMA10031

Cool Silver Metallic

Metallic

MEDIUM A39 PURPLISH GRAY

CMA10039

Medium Purplish Gray Mica

Metallic Interferenced Pearl

+

GREENISH SILVER

A86

CMA10086

Aqua Metallic

Metallic Interferenced Pearl

+

DEEP BLUE

T65

CMT10065

Deep Blue Mica

Interferenced Pearl

BEIGE

S18

CMS10018

Beige Metallic (Fraser Beige)

Metallic Interferenced Pearl

BLACK

X42

AC11342

Black Mica (Amethyst Black)

Interferenced Pearl

WHITE

W13

CMW10013

White Pearl

Pearl

RED

P23

CMP10023

Red Solid

Solid

NOTE: For painting, inner panel colors should be similar to the outer panel colors.

+

BODY COLOR

6-3

BODY COLORING

BODY COLORING RADIATOR GRILLE M40600000070USA0000010002

2

2

B

1 A

1 A

1 2 B

1

Silver

(CMH50061)

2

Dark Gray

(CMH18031) ZB5004290000

BODY COLOR

6-4

BODY COLORING

WHEELHOUSE M40600000120USA0000010002

Front wheelhouse

Rear wheelhouse

: Black (AC10657)

ZB5004310000

8-1

GROUP 8

REFERENCE MATERIAL CONTENTS

BOLTED PANEL FIT AND ADJUSTMENT .................................8-2 HOOD.............................8-2 FRONT DOOR FIT ADJUSTMENT........8-3 LIFTGATE ALIGNMENT...............8-5 FUEL FILLER LID..................8-6

INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS.......................8-7 GARNISH..........................8-7 SIDE AIR DAM.....................8-8

ADJUSTMENT OF OTHER PARTS.......8-10 FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT......................8-10 REAR WHEEL ALIGNMENT CHECK AND ADJUSTMENT......................8-11 HEADLIGHT AIMING................8-12 FOG LIGHT AIMING................8-14

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - AIR BAG.......................8-16

REFERENCE MATERIAL

8-2

BOLTED PANEL FIT AND ADJUSTMENT

BOLTED PANEL FIT AND ADJUSTMENT HOOD M40800000050USA0000010000

Hood adjustment

1.When the clearance between the hood and the body is uneven Remove the front deck garnish, and loosen the hood hinge mounting bolts shown in the figure but do not remove them.

Then move the hood hinge up/down and left/right to adjust the clearance around the hood. After adjustment, install the front deck garnish.

Hood hinge mounting bolt tightening torque: 23 ± 6 N·m (17 ± 5 ft-lb)

Hood hinge

ZB6004230000

Hood latch ZB6004240000

2.When adjusting hood level and hood striker linkage Remove the headlight support upper panel cover, and loosen the hood latch mounting bolts shown in the figure but do not remove them. Then move the hood latch up/down and left/ right to adjust the hood level and hood striker linkage. After adjustment, install the headlight support upper panel cover.

Hood latch mounting bolt tightening torque: 9.0 ± 1.0 N·m (80 ± 9 in-lb)

REFERENCE MATERIAL

8-3

BOLTED PANEL FIT AND ADJUSTMENT

ADJUSTMENT OF HOOD HEIGHT

Turn the damper to the dimension shown in the figure to adjust the hood height. If the hood height is still not even, turn the damper again until the height is even. The damper height is altered by roughly 3 mm (0.1 inch) when the damper is rotated once.

A A

NOTE: If a rattling noise is heard due to the vibration of the hood when the vehicle is being driven, adjust the damper height until the damper is seated on the hood.

Section A – A

20.4 mm (0.8 inch)

Damper ZB6004250000

FRONT DOOR FIT ADJUSTMENT M40800000060USA0000010000

Required Special Tools: ｠MB990211: Slide Hammer ｠MB990243: Body Puller ｠MB990900 or MB991164: Door adjusting Wrench ｠MB990939: Brass Bar

MB990900 or MB991164

ZB600426 0000

｠Do not rotate special tool MB991164 with a torque of over 98 N·m (72 ft-lb).

1.When the clearance between the door and the body is uneven (1)Apply protective tape to the fender around the hinge installation position and door edge.

(2)Remove the splash shield front <Front door only>.

(3)Remove the center pillar trim <Rear door only>.

(4)Use special tool MB990900 or MB991164 to loosen the hinge mounting bolts on the body side, and then adjust the clearance around the door so that it is uniform on all sides.

(5)Move the door to adjust until the clearance around the door is even.

Door hinge mounting bolt tightening torque: 26 ± 6 N·m (19 ± 5 ft-lb)

REFERENCE MATERIAL

8-4

BOLTED PANEL FIT AND ADJUSTMENT 2.When the door is not flush with the vehicle body surface.

(1)Loosen the door-side hinge mounting bolts.

(2)Move the door to adjust so that the door is flush with the vehicle body.

(3)If adjustment is not possible, replace the door-side door hinge mounting bolt with the adjustment bolt (MU001031).

Bolt Door hinge

NOTE: If the adjustment bolt has been already Bolt ZB6004270000

<Non adjustable bolt>

installed, reuse it.

(4)Move the door to adjust so that the door is flush with the vehicle body.

(5)Tighten the door-side door hinge mounting bolt to the specified torque.

Tightening torque: 26 ± 6 N?m (19 ± 5 ft-lb)

<Adjusting bolt (MU001031)>

ZB6004280000

MB990939 Temporary bolts

Striker ZB6004290000

MB990243 MB990211

Striker ZB6004300000

Shim Striker

ZB6004310000

3.When the door is stiff to close and open (1)Adjustment using the striker (toward the inside of the vehicle and vertical direction) Install a temporary bolt instead of the striker mounting bolt, and use special tool MB990939 and a hammer to tap the bolt in the desired direction.

(2)Adjustment by using the striker (toward the outside of the vehicle) Use special tools MB990211 and MB990243 to pull the striker toward the outside of the vehicle.

(3)Adjustment using shims (forward and rearward) Increase or decrease the number of shims so that the striker engages with the door latch properly.

Door striker mounting bolt tightening torque: 20 ± 5 N·m (15 ± 3 ft-lb)

REFERENCE MATERIAL BOLTED PANEL FIT AND ADJUSTMENT

8-5

LIFTGATE ALIGNMENT M40800000070USA0000010000

Required Special Tool: ｠MB990939: Brass Bar

LIFTGATE UPPER ALIGNMENT

1.If the striker is not engaged with the latch properly, adjust by loosening the striker mounting screws.

ZB6004320000

2.If the clearance between the liftgate and the body is uneven, loosen the liftgate-side liftgate hinge mounting bolts to adjust it.

Liftgate hinge mounting nut tightening torque: 7.0 ± 3.0 N·m (43 ± 26 in-lb)

Liftgate hinge ZB6004330000

LIFTGATE LOWER ALIGNMENT

1.If the striker is not engaged with the latch properly, remove the quarter trim lower. Replace the striker mounting screw with an adequate bolt, and use the special tool MB990939 and a hammer to tap the bolt head in the desired direction to adjust the striker.

MB990939 Temporary bolts

Striker ZB6004340000

REFERENCE MATERIAL

8-6

BOLTED PANEL FIT AND ADJUSTMENT

Liftgate hinge

2.If the clearance between the liftgate and the vehicle body is uneven, remove the rear bumper assembly and loosen the body-side liftgate hinge mounting nuts to adjust the liftgate lower so that the clearance between the liftgate and body becomes even.

Liftgate hinge mounting nut tightening torque: 20 ± 5 N·m (15 ± 3 ft-lb)

ZB6004350000

ADJUSTMENT OF LIFTGATE HEIGHT

Rotate the damper by using the arrow mark on the damper as a guide to adjust the liftgate height. The damper height is altered by roughly 3 mm (0.12 inch) when the damper is rotated once.

A

NOTE: If a rattling noise is heard due to the vibration of A

the liftgate when the vehicle is being driven, adjust the damper height until the damper is seated on the vehicle body. The damper should be seated on the vehicle body regardless of a rattling noise.

Section A – A Damper

15 mm (0.59 inch) ZB6004360000

FUEL FILLER LID M40800000190USA0000010000

FUEL FILLER LID ADJUSTMENT

If the leveling and clearance of the fuel filler lid is uneven, loosen the fuel filler lid mounting bolt, then move and adjust the fuel filler lid.

Fuel filler lid mounting bolt tightening torque: 7.0 ± 3.0 N·m (43 ± 26 in-lb)

ZB6004220000

REFERENCE MATERIAL

8-7

INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS

INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS GARNISH M40800000120USA0000010000

Rear roof garnish

ZB6004130000

Double-sided tape affixed location Rear roof garnish

Double-sided tape

Double-sided tape

Double-sided tape: 10 mm (0.39 in) width and 1.2 mm (0.05 in) thickness ZB600414 0000

8-8

REFERENCE MATERIAL INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS

REAR ROOF GARNISH REMOVAL BOTH-SIDE TAPE The removal and adherence procedures of the both-side tape are the same as for the side air dam.

SIDE AIR DAM M40800000002USA0000010000

Side air dam

Double-sided tape affixed location

Double-sided tape

Side air dam

Double-sided tape: 4 mm (0.16 in) width and 1.2 mm (0.05 in) thickness ZB6004150000

REFERENCE MATERIAL INSTALLATION AND REMOVAL OF ADHESIVE COMPONENTS

8-9

REMOVAL SERVICE POINT A SIDE AIR DAM REMOVAL Gently lift and remove the side air dam. If there is any doublesided tape remaining on the side air dam, remove according to the following instructions.

Remove double-sided tape remaining on the body surface 1.Attach protection tape all the way along the edges of the double-sided tape which is still adhering to the body.

Double-sided tape

Protection tape

ZB6004180000

2.Scrape off the double-sided tape with a resin spatula as much as possible.

3.Peel off the protection tape.

4.Wipe the body surface and clean it with a rag moistened with isopropyl alcohol.

Double-sided tape ZB6004190000

Remove double-sided tape remaining on side air dam and adhere double-sided tape (when re-using side air dam) 1.Scrape off the double-sided tape on the side air dam with a resin spatula as much as possible.

2.Wipe the side air dam surface and clean it with a rag moistened with isopropyl alcohol.

3.Remove only a small portion of the residual adhesive.

4.Adhere the double-sided tape as specified on the side air dam.

ZB6004200000

REFERENCE MATERIAL

8-10

ADJUSTMENT OF OTHER PARTS

INSTALLATION SERVICE POINT A SIDE AIR DAM INSTALLATION 1.Tear off the double-sided tape backing paper.

Backing paper

NOTE: If attach the adhesive tape to the edge of the backing paper, it will be easy to tear off.

2.Install the side air dam.

NOTE: If the double-sided tape is difficult to affix in

Adhesive tape ZB6004210000

cold temperature, etc., warm the bonding surfaces of the body and side air dam to about 40- 60°C before affixing the tape.

3.Firmly press in the side air dam.

ADJUSTMENT OF OTHER PARTS FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT M40800000090USA0000010000

Measure wheel alignment with alignment equipment on a level surface. The front suspension, steering system, wheels, and tires should be serviced to normal condition before measuring wheel alignment.

TOE-IN Standard value: 1 ± 2 mm (0.04 ± 0.09 inch) 1.Adjust the toe-in by undoing the clip and jam nut, and turning the left and right tie rod turnbuckles by the same amount (in opposite directions).

Bellows clip

NOTE: The toe will move out as the left turnbuckle is

Jam nut

ZB6006960000

turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle.

2.Install the clip and tighten the jam nut to the specified torque.

Tightening torque: 52 ± 2 N·m (38 ± 2 ft-lb) 3.Confirm that the toe-in is at the standard value.

4.Use a turning radius gauge to check that the steering angle is at the standard value.

STEERING ANGLE Standard value: 38°40' ± 1°30’ Inner wheel 32°20' Outer wheel (reference)

CAMBER, CASTER AND KINGPIN INCLINATION Required Special Tool: ｠MB991004: Wheel Alignment Gauge Attachment

REFERENCE MATERIAL

8-11

ADJUSTMENT OF OTHER PARTS

Vehicles with aluminum wheels Standard value: Camber 0°20' ± 0°30’ (Left/right deviation within 30’) Caster 2°57' ± 0°30’ (Left/right deviation within 30’) Kingpin inclination 12°44’ ± 1°30’ NOTE: Camber and caster are preset at the factory and cannot be adjusted.

MB991004

Never subject the wheel bearings to the vehicle load when the drive shaft nuts are loosened.

NOTE: For vehicles with aluminum type wheels, attach the camber/caster/kingpin gauge to the driveshaft by using the special tool MB991004. Tighten the special tool MB991004 to the same torque 245 ± 29 N·m (181 ± 21 ft-lb) as the driveshaft nut.

160 ± 16 N·m ZB600967AA00

REAR WHEEL ALIGNMENT CHECK AND ADJUSTMENT M40800000100USA0000010000

1.Before the wheel alignment measurement, adjust the rear suspension, wheel, and tires in good condition.

2.Park the vehicle on a level surface to measure the wheel alignment.

TOE-IN Standard value: 3 ± 2 mm (0.12 ± 0.08 inch) If it is out of the standard range, adjust as follows: Turn the toe adjusting bolt (the mounting bolt inside the body on the control link) to adjust.

Left wheels: Clockwise → (+) Toe in Right wheels: Clockwise → (-) Toe in Toe-in varies approximately 2.6 mm (0.10inch) (equivalent to 0° 16' of the toe angle for one side) for each scale mark.

Toe adjusting bolt

ZB6006980000

CAMBER

Standard value: -0°25' ±0°30' (left/right difference 0°30' max)

REFERENCE MATERIAL

8-12

ADJUSTMENT OF OTHER PARTS

NOTE: Compensator

｠For FWD vehicles with aluminum wheels, attach the camber/ caster/kingpin gauge by using a compensator. ｠For AWD vehicles with aluminum wheels, tighten the wheel alignment gauge attachment (Special tool: MB991004) to the specified torque, then measure the camber. ｠The camber is pre-adjusted at factory and is not adjustable.

ZB6006990000

MB991004

160 ± 16 N·m 118 ± 11 ft-lb

ZB6007000000

HEADLIGHT AIMING M40800000110USA0000010000

PRE-AIMING INSTRACTIONS (LOW-BEAM) 1.Inspect for badly rusted or faulty headlight assemblies.

2.These conditions must be corrected before a satisfactory adjustment can be made.

3.Inspect tire inflation, and adjust if it is necessary.

4.If the fuel tank is not full, place a weight in the trunk of the vehicle to simulate weight of a full tank [3 kg (6.6 pounds) per gallon].

5.There should be no other load in the vehicle other than driver or substituted weight of approximately 68 kg (150 pounds) placed in driver's position.

6.Thoroughly clean headlight lenses.

7.Place the vehicle on a level floor, perpendicular to a flat screen 7.62 m (25.0 ft) away from the bulb center-marks on the headlight lens.

8.Rock vehicle sideways to allow vehicle to assume its normal position.

9.Bounce the front suspension through three (3) oscillations by applying the body weight to hood or bumper.

REFERENCE MATERIAL ADJUSTMENT OF OTHER PARTS

(1) Screen

Headlight center line (3)

(2)

Vehicle center line (3) 6.72 m

Light center

8-13

10.Set the distance between the screen and the bulb center marks of the headlight as shown in the illustration.

11.Four lines of adhesive tape (or equivalent markings) are required on screen or wall: (1)Position a vertical tape or mark so that it is aligned with the vehicle center line.

(2)Measure the distance from the center-marks on the headlight lens to the floor [ reference value: 828 mm (3.26 inches)]. Transfer the measurement to the screen.

Horizontal tape or mark on the screen is for reference of vertical adjustment.

(3)Measure the distance from the center line of the vehicle to the center of each headlight. Transfer the measurement to the screen. Vertical tape or mark on the screen with reference to the center line of each headlight bulb.

ZB6010290000

HEADLIGHT ADJUSTMENT (LOW-BEAM) NOTE: When adjusting headlight, disconnect the other headlight harness.

1.The low beam headlight will project on the screen upper edge of the beam (cut-off).

REFERENCE MATERIAL

8-14

ADJUSTMENT OF OTHER PARTS 2.Turn the adjusting screws to achieve the specified low-beam cut-off location on the aiming screen.

Vertical direction adjustment

Standard value: (Vertical direction) Horizontal line (H) ± 50.5 mm (± 2.0 inches) (0.38 degrees angle) (Horizontal direction): ± 126.4 mm (± 5.0 inches) (± 0.95 degrees angle) from the axis, which is 266.1 mm (10.5 inches) (2 degrees angle) rightward from the vertical line (V) ZC603337

<Halogen headlight>

Do not cover a headlight for more than three minutes to prevent the plastic headlight lens deformation.

Vertical direction adjustment

NOTE: High-beam pattern should be correct when the lowbeams are adjusted properly.

Adjustment screw

ZC603076

<Discharge headlight> Vertical direction adjustment

ZC604537

Adjustment screw

ZB6010300000

(V)

266.1 (10.5) Hot zone

Cutoff line 50.5 (2.0) 50.5 (2.0)

(H)

mm (in)

126.4 (5.0) 126.4 (5.0)

ZB6010310000

FOG LIGHT AIMING M40800000130USA0000010001

PRE-AIMING INSTRUCTIONS

1.Inspect for badly rusted or faulty front fog light assemblies.

2.These conditions must be corrected before a satisfactory adjustment can be made.

REFERENCE MATERIAL ADJUSTMENT OF OTHER PARTS

8-15

3.Inspect tire inflation, and adjust if necessary.

4.If the fuel tank is not full, place a weight in the trunk of the vehicle to simulate weight of a full tank [3 kg (6.5 pounds) per gallon].

5.There should be no other load in the vehicle other than driver or substituted weight of approximately 68 kg (150 pounds) placed in driver's position.

6.Thoroughly clean the front fog light lenses.

7.Place the vehicle on a level floor, perpendicular to a flat screen 7.62 meters (25.0 ft) away from the bulb center-marks on the fog light lens.

8.Rock the vehicle sideways to allow the vehicle to assume its normal position.

9.Bounce the front suspension through three (3) oscillations by applying the body weight to the hood or bumper.

10.Measure the center of the front fog lights as shown in the illustration.

Fog light center

ZB6009800000

(1) Screen (2)

Fog light center (3) Vehicle center line

(3)

7.62 m (25.0 ft) ZB6009810000

11.Four lines of adhesive tape (or equivalent markings) are required on screen or wall: (1)Position a vertical tape or mark so that it is aligned with the vehicle center line.

(2)Measure the distance from the center of the front fog light lens to the floor. Transfer the measurement to the screen.

Horizontal tape or mark on the screen is for reference of vertical adjustment.

(3)Measure the distance from the center line of the vehicle to the center of each front fog light. Transfer the measurement to the screen. Vertical tape or mark on the screen is for reference to the center line of each front fog light.

FOG LIGHT ADJUSTMENT (V) Cutoff line (H) 153.0 (6.02)

53.2 (2.09) Hot zone

mm (in)

99.8 (3.93)

599.7 (23.6) 599.7 (23.6)

ZB6009820000

1.Check if the beam shining onto the screen is at the standard value.

Standard value: (Cutoff line direction): The horizontal line 153.0 mm (6.02 inches) (1.15 degrees angle) below the horizontal line (H)

REFERENCE MATERIAL

8-16

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - AIR BAG Limit: (Vertical direction): Area from 53.2 mm (2.09 inches) (0.4 degrees angle) above the cutoff line to 99.8 mm (3.93 inches) (0.75 degrees angle) below the cutoff line (Horizontal direction): Vertical line (V) ± 599.7 mm (± 23.6 inches) (± 4.5 degrees angle) 2.If it is not within the standard value range, adjust by turning the adjusting screw.

NOTE: The horizontal direction is non-adjustable. If deviation of the light beam axis exceeds the standard value, check that the mounting location or some other points are not faulty.

Vertical adjustment ZB6009830000

Vertical direction ZB6009840000

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - AIR BAG M40800000160USA0000010000

｠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 pretensioner should not be subjected to heat, so remove the SRS-ECU, driver's and front passenger's air bag modules, clock spring, side-airbag modules, Curtain air bag modules, front and side impact sensor and seat belt pretensioner before drying or baking the vehicle after painting. ｠SRS-ECU, air bag modules, clock spring, impact sensor: 93° C (200° 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.

9-1

GROUP 9

BASE OF BODY REPAIR CONTENTS

GENERAL..........................9-2

REPAIR OF SYNTHETIC-RESIN PARTS ................................9-42

WELDING..........................9-2

SYNTHETIC-RESIN PARTS REPAIR PROCEDURES......................9-42

WELDING..........................9-2 ELECTRIC RESISTANCE SPOT WELDING .................................9-2 GAS SHIELD ARC WELDING...........9-8 OTHER TYPES OF WELDING..........9-11

BODY REPAIR.....................9-13 STANDARD BODY REPAIR PROCEDURES ................................9-13 THEFT PROTECTION................9-22 ATTACHMENT OF SILENCERS.........9-24 POSITIONING DIMENSIONS FOR OPENINGS ................................9-25 STANDARD PROCEDURES FOR SHEET METAL WORK............................9-25 USING A FRAME STRAIGHTENER......9-27 FRAME REPAIR PROCEDURES.........9-28 NOTES REGARDING REPAIR WORK. . . . .9-30 HEAT-WITHSTAND TEMPERATURES OF RESINPLASTIC PARTS...................9-33 HOW TO DISTINGUISH TYPES OF PLASTICS ................................9-35

CORROSION PROTECTION............9-36 ANTICORROSION TREATMENT AT THE FACTORY.........................9-36 ANTICORROSION TREATMENT AT THE TIME OF BODY REPAIR WORK.............9-39

BASE OF BODY REPAIR

9-2

GENERAL

GENERAL M40900000001USA0000010000

Group 9 is applicable for all models.

WELDING WELDING M40900000010USA0000010001

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

Pressure methods Electric resistance spot welding [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) ZB6001910000

FUSION WELDING

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.

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.

BRAZING

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.

ELECTRIC RESISTANCE SPOT WELDING M40900000020USA0000010000

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

ADVANTAGES OF ELECTRIC RESISTANCE SPOT WELDING

｠Because the time required for welding at each point is brief, the work can be done quickly and at reduced cost. ｠Because both metals are fused and pressure applied to make the weld, the strength and reliability are both high. ｠Because the time required to make the welds is short, there is little occurrence of distortion of the panel due to heat.

BASE OF BODY REPAIR WELDING

9-3

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

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

ZB600192 0000

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.

ZB6001930000

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.

ZB600194 0000

BASE OF BODY REPAIR

9-4

WELDING

NUGGET FORMATION

Weak ← Shear strength per point → Strong

Cooling water

More than 1.6 mm (0.06 in)

C D C' D'

B' B

A' A

1.6 mm (0.06 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 ZB600195 0000

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 (0.06 inch)] continues to increase proportionately (between points B and C); however, for thin panels [1.6 mm (0.06 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.

BASE OF BODY REPAIR

9-5

WELDING

NOTES REGARDING WELDING

D

t

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

ZB6001960000

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.

WELDING REQUIREMENTS Standard steel plate (SPCC, etc.)

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.

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. ｠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.

Example ｠Center pillar (outer): plate thickness 1.4 mm (0.06 inch), material SPCC ｠Center pillar (inner): plate thickness 1.5 mm (0.06 inch), material SPCC

BASE OF BODY REPAIR

9-6

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 (1.0 inch) or more cannot be maintained, the plug welding method (eight weld points) should be used.

ZB6001970000

Panel thickness* [mm (in)] Safety equipme nt area

Number of repair weld (percentage of factory weld)

1.0 (0.04) or 100% Same number as factory welds less 1.2 (0.05)

150% Maintain pitch of at least 22 mm (0.9 inch); if not possible, plug weld.

1.4 (0.06) or 100% Same number as factory welds; plug welding more Other area

1.2 (0.05) or 100% Same number as factory welds less 1.4 (0.06)

130% Maintain pitch of at least 26 mm (1.0 inch); if not possible, plug weld.

1.6 (0.06) or 100% Same number as factory welds; plug welding more

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

BASE OF BODY REPAIR WELDING

9-7

Galvanized steel plate (SECC) If the total thickness of the plates at the weld places is 3 mm (0.1 inch) or more, use plug welding, because spot welding will not provide sufficient welded strength.

Panel Number of repair weld (percentage of factory weld) thickness* [mm (in)] Safety equipme nt area

0.9 (0.04) or 100% Same number as factory welds less 1.0 (0.04)

200% Maintain pitch of at least 18 mm (0.7 inch); if not possible, plug weld.

1.2 (0.05) or 100% Same number as factory welds; plug welding more Other area

0.9 (0.04) or 100% Same number as factory welds less 1.0 (0.04)

140% Maintain pitch of at least 18 mm (0.7 inch); if not possible, plug weld.

1.2 (0.05) or 100% Same number as factory welds; plug welding more

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

USING A TEST PIECE TO CHECK NUGGET FORMATION Weld 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 1 Weld point diameter.

Using the weld point as an axis, apply force in the direction indicated by the arrows in the illustration, and determine the 2 strength of the weld.

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

2. and 3.

3 The weld conditions are unsatisfactory; adjust the welding current, the current application time, and/or the applied ZB6001980000 pressure.

CHECKING NUGGET STRENGTH FOLLOWING SPOT WELDING

3 mm (0.1 in)

ZB6001990000

｠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 (1.2 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.

BASE OF BODY REPAIR

9-8

WELDING ｠The nugget diameter should be 3 mm (0.1 inch) or more.

GAS SHIELD ARC WELDING M40900000030USA0000010000

Wire Nozzle Contact tip Shield gas

Metal vapor

ZB600200 0000

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

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

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

MIG SPOT WELDING Wire Gas cup

Gas outlet

ZB6002010000

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

Procedure ｠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.

BASE OF BODY REPAIR

9-9

WELDING ｠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

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.

Electric resistance spot welding

Working characteristics

｠Light weight ｠Although the torch with separate ｠Welding possible at various transformer is lightweight, the torch positions (no limit upon welding combined with transformer type is heavy. ｠The arm must be exchanged to conform to positions) the weld location.

Weld time/point

Slow (0.5 second or more)

Treatment welding

Fast (0.5 second or less)

after 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

｠50 - 60 points Weld points/10 ｠25 points or less ｠Arc instability and contact tip burn ｠Welding rod deformation and transformer minutes (rate of use) if rate of use is exceeded. overheating if rate of use is exceeded.

Distortion caused by Occurs easily welding

Rare

Welding strength

Depends on strength of welding wire ｠Same as base material ｠Little oxidation itself. ｠Uniform welding quality

Weld traces

Button head (slightly convex)

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

Swivel tip

ZB6002020000

Re-repairability Difficult Easy (cutting away welded (Much welding trace High hardness (Can be separated by spot cutter.) area) of weld points)

BASE OF BODY REPAIR

9-10

WELDING

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.

ZB600203 0000

PLUG WELDING

Torch

5 – 6 mm (0.2 in) diameter hole

Perfect contact

ZB600204 0000

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 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.

CONTINUOUS WELDING

ZB6002050000

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.

Torch angle and welding technique 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.

BASE OF BODY REPAIR WELDING

15 – 30°

Forehand technique

15 – 30°

9-11

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 (0.2 - 0.4 inch) from the surface being welded.

Backhand technique ZB600206 0000

Preventing warping 1. Backhand technique Anti-warp welding techniques Because the direction for each weld pass and that for the 5 4 3 2 1 fusion progression are opposite, the residual stress is evenly 1. distributed.

Backhand technique 2.

Symmetrical technique 4 2 1 3 2.

Because the welds are made in symmetrical positions in Symmetrical technique relation to the center of the joint, the residual stress is also 1 4 2 5 3 symmetrical.

3.

3. "Stepping stone" technique "Stepping stone" technique Because the welds are made at random positions, the ZB6002070000 residual stress is the most evenly distributed; however, the possibility of flaws at the starting and stopping points is relatively high.

3. Select a welding current to match the thickness of NOTES REGARDING MIG WELDING the panels being welded.

Note the following notes regarding MIG welding.

4. For continuous welding, maintain a constant weld 1. The surface to be welded must be perfectly clean; speed and keep both the height and the width of be sure to remove any non-conductive paint. the bead constant.

2. If the end of the wire forms into a ball, it will In addition, the tack welding pitch and the welding adversely affect the formation of the arc; cut the bead should be shorter as the thickness of the end off with a pair of wire snips or a similar tool. panels being welded decreases.

OTHER TYPES OF WELDING M40900000040USA0000010000

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.

BASE OF BODY REPAIR

9-12

WELDING

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 ZB600208 0000

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

｠When doing brass brazing, if the panels and the filler metal are heated excessively, a weak ironcopper 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.

GAS WELDING Oxy-acetylene flame

Welding rod

Base metal

Deposite

ZB600209 0000

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.

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

BASE OF BODY REPAIR

9-13

BODY REPAIR

2. Standard flame

1. Carburizing flame Flame core

Acetylene cone

Flame core

Outer flame

Outer flame

3. Peroxide flame Flame core

Outer flame ZB600210 0000

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.

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.

BODY REPAIR STANDARD BODY REPAIR PROCEDURES M40900000060USA0000010000

The following is an explanation of the standard repair procedures for the monocoque body and the frametype 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.9-27concerning repair procedures for the frame of frame-type vehicles.

BASE OF BODY REPAIR

9-14

BODY REPAIR

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

ZB6002110000

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.

｠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 (1.2 - 2.0 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.

ZB6002120000

ZB6002130000

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.

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.

BASE OF BODY REPAIR BODY REPAIR

9-15

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.

ZB6002140000

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).

ZB6002150000

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

ZB600216 0000

ZB6002170000

BASE OF BODY REPAIR

9-16

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

ZB600218 0000

ZB6002190000

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.

9.Rough cutting of new parts Cut off the unnecessary portions of new parts. Allow an overlap of approximately 30 - 50 mm (1.2 - 2.0 inches) when performing overlap cutting of the pillars, side sills, or other locations.

ZB6002200000

Edge of the new part

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.

Edge of the panel on the body

ZB6002210000

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.

BASE OF BODY REPAIR BODY REPAIR

Two-layer construction Outer panel Inner panel

Approx. 50 mm (2.0 in)

ZB6002220000

Three-layer construction

Inner panel cut line Outer panel and reinforcement cut line Inner panel cut line

Inner panel

ZB6002230000

9-17

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 twolayer construction but no reinforcement, make the cutting of the inner panel and that of the outer panel approximately 50 mm (2.0 inches) apart in order to obtain maximum strength. ｠Three-layer construction When cutting a front pillar or center pillar which has a threelayer (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.

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.

ZB6002240000

ZB600225 0000

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.

BASE OF BODY REPAIR

9-18

BODY REPAIR

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.

ZB6002260000

Weld completely so that there are no pinholes.

14.Butt welding For burr welding, make a 10 - 15 mm (0.4 - 0.6 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.

ZB6002270000

ZB6002280000

ZB6002290000

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.

BASE OF BODY REPAIR BODY REPAIR

9-19

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 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 ZB6002300000

AB401287

Section A–A

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.

(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.

A AB401282

A ZB6002310000

Hemming tool ZB6002320000

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.

(2)After completing the hemming work, make MIG spot welds at 50 - 60 mm (2.0 - 2.4 inches) intervals on the inside.

Hemming tool ZB6002320000

BASE OF BODY REPAIR

9-20

BODY REPAIR

ZB6002330000

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.

ZB6002340000

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.

ZB6002350000

ZB6002360000

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.

BASE OF BODY REPAIR BODY REPAIR

9-21

ZB6002370000

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).

ZB6002380000

CAUTIONS REGARDING BODY REPAIR

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

STRENGTH AND RIGIDITY 1. The suspension installation part plays an important role, determining the wheel alignment.

Wheel misalignment is of course potentially very dangerous because it can lead to driving instability, one-sided braking, abnormal tire wear, abnormal vibration, etc.

At the time of repair, it is particularly necessary to take measurements at the components noted below, and to make all welds and installations with special care. ｠Front sidemember ｠Rear floor sidemember ｠Front wheelhouse (inner) ｠Rear wheelhouse (inner) (Independent rear suspension type) 2. Because the places where the floor panel and sidemember parts are joined have an important effect upon the rigidity of the entire body, welds in these places must be done with particular care.

3. After repairs have been completed, the wheel alignment, wheel base, tread, etc., must be

carefully checked to be sure that there is no deviation.

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.

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.

BASE OF BODY REPAIR

9-22

BODY REPAIR

｠At the outer and inner side of every welded place. ｠Within any semi-enclosed structure or component (aerosol-type rust inhibitors are effective for difficult-to-reach places). ｠At the outer and inner side of any place subjected to heat.

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

4. Use spot sealer if spot welds are made.

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

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

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

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.

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

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

THEFT PROTECTION M40900000070USA0000010000

Theft protection label For original parts

For replacement parts

ZB600239 0000

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.

BASE OF BODY REPAIR BODY REPAIR

9-23

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 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.

Knife

Masking film

ZB6002400000

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.

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9-24

BODY REPAIR

ATTACHMENT OF SILENCERS M40900000090USA0000010000

Dash panel interior side

: Thickness: 1.6 mm (0.06 in) : Thickness: 3.2 mm (0.13 in) (two 1.6 mm (0.06 in) silencers overlapped)

ZB6002410000

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

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

ZB600242 0000

BASE OF BODY REPAIR BODY REPAIR

9-25

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

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

ZB6002430000

POSITIONING DIMENSIONS FOR OPENINGS M40900000100USA0000010000

Porta power

ZB600244 0000

When replacing the panel of the opening of the front pillar, center pillar and other openings, make a point to securely bite the poltapower, etc. so the position of

the opening is not off-center. Upon assembling, adjust the opening dimensions to the standard specifications and then weld.

STANDARD PROCEDURES FOR SHEET METAL WORK M40900000120USA0000010000

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.

BASE OF BODY REPAIR

9-26

BODY REPAIR

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.

(1)

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.

(2)

(3)

ZB6002450000

ZB6002460000

｠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.

BASE OF BODY REPAIR BODY REPAIR

9-27

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 M40900000130USA0000010000

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.

3.Finally, determine what repair methods should be used. ｠To what extent will frame straightening and other overall repairs be necessary in order to restore the damaged areas to the way they were? ｠At what stage of the repairs should panels adjoining the components to be frame straightened, etc., be removed? ｠Decide upon the work steps and restoration methods to be followed after the rough, overall repairs are completed.

Select the frame straightener based upon the results of above, and use it to pull in the appropriate direction.

More than one direction may be appropriate, depending upon the damage.

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

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

FRAME STRAIGHTENING NOTES

｠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.

Wires for protection

ZB6002470000

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9-28

BODY REPAIR ｠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 M40900000140USA0000010000

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

Test hammer

Sidemember

ZB6002480000

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 (0.2 - 0.3 inch) holes (to prevent further cracking), by using a drill, at points 7 - 8 mm (0.3 inch) from the crack ends.

Crack-stop hole A A Crack

Ø6 – 8 mm (0.2 – 0.3 in) A : 7 – 8 mm (0.3 in)

ZB6002490000

BASE OF BODY REPAIR BODY REPAIR Ø10 – 12 mm (0.4 – 0.5 in)

9-29

3.Use a Φ 10 - 12 mm (0.4 - 0.5 inch) drill to bevel the hole openings.

Ø6 – 8 mm (0.2 – 0.3 in)

Ø10 – 12 mm (0.4 – 0.5 in)

ZB600250 0000

Crack-sto p hole

Crack

Appr ox.

1 mm (00.4 in)

Appr ox.

90°

A

Appr ox.

8 mm (0.3 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.

Appr ox.

1 mm (0.04 in)

If a chisel is used

If a gouge is used

A

A

ZB6002510000

｠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.

ZB600252 0000

｠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°

ZB600253 0000

10 mm (0.4 in)

Welded point ZB600254 0000

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 (0.4 inch) from its edges.

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9-30

BODY REPAIR

NOTE: If the crack is at the upper side of the frame, (1)

(2)

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.

ZB6002550000

NOTES REGARDING REPAIR WORK M40900000150USA0000010000

SAFETY MEASURES 1

2

3

4 5

6

8

7

9

10

11

ZB6002560000

PROTECTIVE GEAR 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

BASE OF BODY REPAIR BODY REPAIR

9-31

9. Foot and ankle protectors 10 Safety shoes .

11 Work gloves . clock spring). If there is a defect, replace the SUPPLEMENTAL RESTRAINT SYSTEM (SRS) defective part.

1.Items to review when servicing SRS (7)Whenever you finish servicing the SRS, check (1)Be sure to read Service Manual GROUP 52B, the SRS warning light operation to make sure Supplemental Restraint System (SRS). For safe that the system functions properly. operation, please follow the directions and heed (8) Be sure to deploy the air bag before disposing all warnings. of the air bag module or disposing of a vehicle (2)Wait at least 60 seconds after disconnecting the equipped with an air bag. battery cable before doing any further work. The 2.

Observe the following when carrying out operations SRS system is designed to retain enough on places where SRS components are installed, voltage to deploy the air bag even after the including operations not directly related to the SRS battery has been disconnected. Serious injury air bag. may result from unintended air bag deployment (1)When removing or installing parts, do not allow if work is done on the SRS system immediately any impact or shock to occur to the SRS after the battery cable is disconnected. components.

(3)Warning labels must be heeded when servicing (2)If heat damage may occur during paint work, or handling SRS components. remove the SRS-ECU, the air bag module, clock (4)Always use the designated special tools and test spring, the front impact sensor, the side impact equipment. sensor, and the seat belt pre-tensioner.

(5)Store components removed from the SRS in a ｠SRS-ECU, air bag module, clock spring, front clean and dry place. The air bag module should impact sensor, the side impact sensor: 93 °C be stored on a flat surface and placed so that the (200 °F) or more pad surface is facing upward. ｠Seat belt pre-tensioner: 90 °C (194 °F) or (6)Never attempt to disassemble or repair the SRS more components (SRS-ECU, air bag module and

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 Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING.

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9-32

BODY REPAIR

When the body is used as the ground during welding for body repairs, be absolutely sure to first disconnect the battery's positive (+) cable.

ZB6002570000

｠Be sure that both the ignition and lighting switches are "LOCK" (OFF) position before either disconnecting or reconnecting a battery cable. (If this is not done, equipment containing semiconductors could be damaged). ｠Note that the memory of electronic equipment having a memory function will be cleared when the battery cable is disconnected.

NOTE: Vehicles today include a great many electronic parts and components, and these are in general very susceptible to adverse effects caused by overcurrent, reverse current, electromagnetic waves, high temperature, high humidity, impacts, etc. In particular, such electronic components can be damaged if there is a large current flow during welding from the body side, etc.This is because, for electronic components that incorporate a back-up circuit (for memory retention) that functions (by a trickle current) even when the ignition switch is at OFF, an electronic circuit is formed even when the switch is at OFF.

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

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

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

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.

BASE OF BODY REPAIR

9-33

BODY REPAIR

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

ZB6002580000

ZB6002590000

HEAT-WITHSTAND TEMPERATURES OF RESIN-PLASTIC PARTS M40900000160USA0000010000

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

Material name Abbreviation Heat-deformation Where mainly used temperature °C (°F) 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)

-

acetate CAB

60 - 100 (140 - 212)

Door trim molding

Cellulose butylate Polyamide

PA

140 - 160 (284 - 320)

Harness connector, Wheel Cooling fan, Fuel strainer

cover,

Talc polyamide

filled 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 PE-HD (HDPE) polyethylene

70 - 90 (158 - 194)

Fuel tank, Splash shield

Phenole formaldehyde

170 - 190 (338 - 374)

Ashtray

PF

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BODY REPAIR

Material name

Abbreviation

Heat-deformation temperature °C (°F)

Where mainly used

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 PP-TD (PPF) polypropylene

100 (212)

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

Talc filled PP-TD10 (PPF) polypropylene (10%)

110 - 120 (230 - 248)

Center pillar trim

Talc filled PP-TD15 (PPF) polypropylene (15%)

110 - 120 (230 - 248)

Front pillar trim, Center pillar trim, Rear pillar trim

Talc filled PP-TD20 (PPF) polypropylene (20%)

120 - 130 (248 - 266)

Beltline trim, Front deck garnish, Front pillar trim

Talc filled PP-TD30 (PPF) polypropylene (30%)

130 - 140 (266 - 284)

Quarter trim, Rear side trim

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

fiber PUR-GF [RIM] RIM

100 - 120 (212 - 248)

Air dam panel

*1

-

Glass reinforced urethane

Polyvinyl alcohol

PVAL

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 reinforced unsaturated polyester

fiber UP-(GT + TD) 200 (392) [SMC], [BMC]

Rear air spoiler

Ethylene acetate

vinyl E/VAC (EVA)

Mud guard

Talc filled PP + polypropylene [HMPP]

60 (140)

E/P-TD 80 - 100 (176 - 212)

Bumper face, Side air dam, Side protector molding

BASE OF BODY REPAIR

9-35

BODY REPAIR

Material name

Abbreviation

Heat-deformation temperature °C (°F)

Where mainly used

Polyvinyl chloride, PVC, PUR-E Polyurethane

*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 PPE (PPO) + PA6 150 - 160 (302 - 320) ether + Polyamide 6

Wheel cover

Polyphenylene PPE (PPO) ether + Polyamide PA66 66

Wheel cover

+ 160 - 170 (320 - 338)

Polyphenylene PPE (PPO) + PS ether + Polystyrene

120 - 130 (248 - 266)

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

Wheel cover

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 light is used for drying, use a heatresistant cover, etc., to protect parts.

HOW TO DISTINGUISH TYPES OF PLASTICS M40900000170USA0000010000

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

Plastic name Abbrevi Flame color Combustion SelfOdor ation conditions extinguishi ng Polyvinyl chloride PVC

Yellow flame top Burns to black residue Blue flame bottom

Polyethylene

Yellow flame top Burns cleanly Blue flame bottom melting

PE

Yes

while No

Irritating odor

acid

Candle-like odor

BASE OF BODY REPAIR

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CORROSION PROTECTION

Plastic name

Abbrevi Flame color ation

Combustion conditions

SelfOdor extinguishi ng

Polypropylene

PP

Yellow flame top ｠Burns briskly and drips No ｠Slight white smoke Blue flame bottom

Petroleum-like odor

Polyurethane

PUR

Orange

Rubber odor

TRUR

Orange

Polycarbonate

PC

Yellow

Polyamide (nylon)

PA

Yellow flame top Melts and drips Blue flame bottom

Yes

Strong formic acid odor

Polyester resin

UP

Yellow

Ashes remain

No

Styrene odor

Glass-fiberFRP reinforced plastic

Yellow

Ashes with glass-fiber No remnants remain

Differs according to plastic type

Phenol resin

PF

Yellow

Ashes remain

Yes

Formalin odor

ABS resin

ABS

Orange

Burns accompanied by No foaming and black smoke

Rubber odor

Crackles as burns; drips No Cinders remain

To some Sweet odor extent

CORROSION PROTECTION ANTICORROSION TREATMENT AT THE FACTORY M40900000190USA0000010000

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

THE USE OF GALVANIZED STEEL PLATE

: locations where galvanized steel plate is used.

ZB6002600000

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

BASE OF BODY REPAIR

9-37

CORROSION PROTECTION

ZINC PHOSPHATE COATING 1 2 3 4 5 6

ZB6002610000

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

CATIONIC ELECTRODEPOSITION UNDERCOATING

Cationic coationg

Anionic coating

Counteragent

Counteragent

Anionic electrodeposition

Cationic electrodeposition

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

ZB6002620000

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

Alkali solution

Section A – A

ZB6002630000

BASE OF BODY REPAIR

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CORROSION PROTECTION

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.

ZB6002640000

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.

ZB6002650000

ANTICORROSION PRIMER

A

1 1

A 1. Rocker panel primer application

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

ZB600266 0000

BASE OF BODY REPAIR CORROSION PROTECTION

9-39

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

ZB6002670000

ANTICORROSION TREATMENT AT THE TIME OF BODY REPAIR WORK M40900000200USA0000010000

ZB6002680000

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

CORROSION PROTECTION FOR HOLLOW PARTS

ZB6002690000

｠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.

BASE OF BODY REPAIR

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CORROSION PROTECTION

SPOT SEALER

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

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

ZB6002700000

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.

ZB6002710000

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)

ZB6002720000

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.

BASE OF BODY REPAIR CORROSION PROTECTION

Clean away any excess

ZB6002730000

ZB6002740000

ZB6002750000

9-41

｠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. ｠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. ｠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.

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REPAIR OF SYNTHETIC-RESIN PARTS

UNDERCOATING

: Undercoating application locations ZB600276 0000

｠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.

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.

REPAIR OF SYNTHETIC-RESIN PARTS SYNTHETIC-RESIN PARTS REPAIR PROCEDURES M40900000202USA0000010000

Bumper is taken as a repair work example for explanation.

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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

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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.

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2. Reshaping of damaged area

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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

3. Fixing of glass cloth (Backing)

ZB6002800000

｠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

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.

ZB6002810000

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5. Base surface preparation (Surface grinding) Remove burrs on the surface, and grind with a sandpaper #120 to make the repair area surface lower than the surrounding area.

When using a sander #120, grind at a low speed 6000 r/min.

Background

Old paint layer ZB6002820000

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

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7. Filling (Putty application)

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

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

2.For scrape, apply putty to the repair area. ｠Putty: Epoxy resin putty Brand: 3M™ Automix EZ Sond Flexble Parts 5887 or equivalent ｠Putty: Epoxy resin putty Brand: 3M™ Resin Putty No.1, 8120 or equivalent

NOTE: ｠The amount to be applied at a time is approximately 1.5 mm (0.06 inches). Therefore, recoat it as needed. ｠For tear and scratch, apply putty after sanding the surface.

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8. Surface grinding After drying, grind with a sandpaper #120.

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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.

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10. Cleaning and degreasing Using SU Silicone Off, degrease and wipe off completely.

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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

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12. Primer-surfacer coating ｠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.

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13. Primer-surfacer grinding 1.Grind the base surface with a sandpaper #240 to #320.

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2.Apply the putty to cover pinholes, grind marks, and slight distortion. Do not apply an excessive amount at a time. Repeat application of small amount, taking a drying time.

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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

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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.

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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.

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