Page 1
2008
GROUP INDEX
MITSUBISHI
LANCER EVOLUTION
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 vehicleís 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.
following also available, and should be used in
The
conjunction with this manual.
TECHNICAL INFORMATION MANUAL
MSSP-260B-2008
SERVICE MANUAL MSSP-206B-2008
PARTS CATALOG BUM6Y108A_
BODY CONSTRUCTION . . . . . . . . .
BODY DIMENSIONS . . . . . . . . . . . . .
WELDED PANEL REPLACEMENT. .
CORROSION PROTECTION . . . . . .
SYNTHETIC-RESIN PARTS . . . . . . .
BODY COLOR . . . . . . . . . . . . . . . . . .
BASE OF BODY REPAIR . . . . . . . . .
1
2
3
4
5
6
9
Mitsubishi Motors Corporation reserves the right to make changes in
design or to make additions to or improvements in its products without
imposing any obligations upon itself to install them on its products
previously manufactured.
©2007 Mitsubishi Motors Corporation
All Rights, Reserved
Printed in USA
MSSP-460B-2008
Page 2
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 N U M BERS
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
Page 3
GROUP 1
BODY
CONSTRUCTION
CONTENTS
1-1
BODY COMPONENTS. . . . . . . . . . . . 1-2
BODY MAIN CROSS-SECTIONAL
VIEWS . . . . . . . . . . . . . . . . . . . . . . . . 1-4
MAINTENANCE, SERVICEABILITY . 1-6
BODY CONSTRUCTION
CHARACTERISTICS . . . . . . . . . . . . . 1-8
FRONT BODY. . . . . . . . . . . . . . . . . . . . . . . 1-8
SIDE BODY. . . . . . . . . . . . . . . . . . . . . . . . . 1-15
REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 1-17
ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 1-20
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
SILENCER APPLICATION
LOCATIONS . . . . . . . . . . . . . . . . . . . . 1-25
FOAMING MATERIAL USAGE
LOCATIONS . . . . . . . . . . . . . . . . . . . . 1-26
STIFFENER AND DAMP SHEET
APPLICATION LOCATIONS . . . . . . . 1-27
THEFT PROTECTION . . . . . . . . . . . . 1-28
Page 4
1-2
BODY CONSTRUCTION
BODY COMPONENTS
27
24
25
30
26
28
BODY COMPONENTS
37
36
29
35
32
31
79
80
33*
*
81
97*
34
99*
*
98
82
92
93
38
39
84
91
83
40
87
86
88
M4010001001309
85
89
90
11
13
12
23
10
9*
14
15
16
8
78
22
18
77
20
21
76
96
95*
94
74**
75**
47
43
70
48
19
*
17
60
73
72
59
71
50
56
54
4*
61*
57*
55
49
51
41
42
44
45
46
52*
58*
5
7
6
2
3
68
66
67
65
62
53
1
: Anti-corrosion steel panels
: High-tensile steel panels (*: Indicates 590MPa-high-tensile steel panels.)
69
(**: Indicates 980MPa-ultra-high-tensile steel panels.)
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64
*
63**
AB700971
AB
Page 5
BODY CONSTRUCTION
BODY COMPONENTS
1-3
1. Front bumper reinforcement
2. Headlight support panel upper
3. Front body frame to side sill brace
4. Front sidemember rear
5. Front inner sidemember
6. Headlight support panel
7. Front sidemember plate
8. Front outer sidemember
9. Front sidemember extension
10. Front fender gusset
11. Headlight support panel upper
12. Front fender shield
13. Fender shield frame upper outer
14. Fender shield frame upper inner
15. Spring house panel
16. Dash panel crossmember upper
17. Dash panel crossmember lower
18. Dash panel
19. Brake pedal support reinforcement
20. Cowl top panel
21. Brake pedal support bracket
22. Front deck crossmember
23. Hood panel inner
24. Hood panel outer
25. Front door side door beam
26. Front door panel inner
27. Front door panel outer
28. Rear door side door beam
29. Rear door panel inner
30. Rear door panel outer
31. Roof rail front lower
32. Roof rail front upper
33. Roof bow center lower <Vehicles without sunroof
(aluminum panel)>
34. Roof bow center upper <Vehicles without sunroof
(aluminum panel)>
35. Roof rail rear
36. Roof panel
37. Roof panel reinforcement <Vehicles with sunroof
(steel panel)>
38. Rear shelf panel
39. Trunk lid panel inner
40. Trunk lid panel outer
41. Fuel filler door panel (Left side)
42. Rear bumper reinforcement
43. Rear bumper reinforcement
44. Rear end panel outer
45. Rear end panel inner
46. Rear bumper side bracket
47. Rear seatback bracket lower
48. Rear floor
49. Rear floor rear end crossmember
50. Rear floor crossmember
51. Rear floor side panel
52. Rear floor sidemember extension
53. Rear floor sidemember lower
54. Rear seat under floor
55. Rear seat belt reinforcement (Left side)
56. Rear seat belt reinforcement (Right side)
57. Rear floor extension
58. Rear floor rear seat under crossmember
59. Front floor crossmember rear
60. Front floor backbone reinforcement
61. Front floor crossmember front
62. Front floor
63. Front floor side sill inner
64. Front floor sidemember
65. Front floor crossmember rear center
66. Front floor crossmember front
67. Front fender
68. Headlight support panel lower
69. Radiator bracket lower
70. Side outer panel
71. Front fender bracket
72. Upper frame to front pillar brace
73. Front deck frame upper outer
74. Side sill reinforcement outer front
75. Side sill reinforcement outer rear
76. Side sill inner support front
77. Front pillar lower reinforcement
78. Front pillar inner lower
79. Front pillar inner center
80. Front upper inner pillar
81. Roof side rail inner
82. Rear seatback brace
83. Rear wheel house panel inner
84. Rear wheel house panel front lower outer
85. Quarter panel lower inner (Left side)
86. Quarter panel inner
87. Quarter panel extension inner
88. Quarter panel extension lower outer
89. Quarter panel extension outer
90. Rear combination light housing panel
91. Rear pillar reinforcement
92. Roof side rail reinforcement rear
93. Rear pillar reinforcement lower
94. Center pillar reinforcement
95. Rear door hinge reinforcement
96. Rear door hinge reinforcement support
97. Roof side rail reinforcement
98. Center pillar inner lower
99. Center pillar inner upper
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Page 6
1-4
BODY CONSTRUCTION
BODY MAIN CROSS-SECTIONAL VIEWS
BODY MAIN CROSS-SECTIONAL VIEWS
M4010002001067
A
F
E
A
Roof panel
Roof side rail
D
reinforcement rear
B
D
C
AB700285
AB
B
Roof side
rail inner
Rear door hinge
C
reinforcement
support
Roof rail
front lower
Roof side rail
reinforcement
front
Roof side
rail support
Roof rail
front upper
AB601100
Side outer
panel
Center pillar
reinforcement
AB700969
Center pillar
inner upper
Side outer
panel
AC
AB
Roof side
rail inner
E
Front end
crossmember
upper
Front end
crossmember lower
Front door hinge
F
reinforcement lower
Side outer panel
AB700536
Front end
crossmember
bulkhead
AB601099
Front pillar
inner lower
AB
AC
Rear door hinge
reinforcement
Center pillar
reinforcement
AB601102
AC
TSB Revision
Front pillar
reinforcement lower
Side outer
panel
AB700537
AB
Page 7
BODY CONSTRUCTION
BODY MAIN CROSS-SECTIONAL VIEWS
H
G
1-5
G
Side outer
panel
H
Roof side rail
reinforcement
front
Roof rail rear
I
Roof panel
J
Front upper
inner pillar
AB602354
AB601108
AC
AB
K
L
J
Side sill
AB700286
Rear floor
side sill
inner
AB
reinforcement
outer rear
Front floor
side sill
Side outer panel
Rear pillar
K
reinforcement
lower
inner
AB700539
AB
Rear wheel
house panel
inner
Side outer
panel
Quarter
inner
panel
Quarter panel extension
lower outer
AB700540
AB
I
Side sill
reinforcement
outer front
Side outer
panel
Front pillar
inner lower
Side sill inner
support front
AB700538
AB
TSB Revision
L
Rear end
panel inner
Rear bumper
reinforcement
Rear end
panel outer
AB601110
AC
Page 8
1-6
BODY CONSTRUCTION
MAINTENANCE, SERVICEABILITY
MAINTENANCE, SERVICEABILITY
FENDER SHIELD
A positioning hole, lug, and notch have been added
on the front end upper bar side, front upper frame
inner, upper frame extension inner, front side mem
ber brace upper and dash panel to improve assembling workability during panel replacement.
-
M4010003000948
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AB700964
AB
Page 9
BODY CONSTRUCTION
MAINTENANCE, SERVICEABILITY
SIDE STRUCTURE
A panel positioning notch has been added on the
door opening to improve assembling workability
when replacing the panel.
1-7
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.
Panel positioning notch
AB201388
AB700289
AB
AB
Front outer pillar
Center outer pillar
Quarter panel outer
Front floor side sill outer
AB700613
AB
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Page 10
1-8
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION CHARACTERISTICS
FRONT BODY
HEADLIGHT SUPPORT
• The crush box structure, which has an octagonal
cross-section at the front end of the front side
member, has been adopted. This structure can
effectively absorb energy upon frontal impact and
reduces the vehicle repair cost caused by a light
collision.
9.0 ± 2.0 N·m
80 ± 17 in-lb
2
M4010010001200
• The bolt-on headlight support panel upper is
used to improve maintainability.
-
• An aluminum front bumper reinforcement has
been adopted to improve the body rigidity, han
-
dling stability, and riding comfort.
3
3
5
A
7
4
5
1
20 ± 5 N·m
15 ± 3 ft-lb
1. Front bumper reinforcement
2. Headlight support panel upper
3. Front end crossmember gusset
4. Front end crossmember upper
5. Radiator bracket lower A
6. Front end crossmember bulkhead
7. Radiator bracket lower B
8. Shipping hook front
9. Shipping reinforcement front
10. Front end crossmember lower
6
8
10
9
8
9
A
Crush box
The crush box structure has been changed to
straight type with an octagon cross-section so that
the structure can effectively absorb energy from the
impact at the time of collision.
7
AB701123
AB700911
AB
AB
TSB Revision
Page 11
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
FENDER SHIELD
The padding structure of the front fender bracket has
been adopted to efficiently absorb energy upon
impact by the crushable structure and improve the
pedestrian protection capability.
7
(Right side)
5
8
9
1-9
10
12
(Left side)
6
4
3
11
13
22
2
21
14
20
16
15
18
17
1
19
23
28
27
26
24
25
12
10
8
7
6
9
5
AB700410
AB
14
15
16
4
31
30
28
TSB Revision
32
29
20
33
34
23
13
26
27
3
2
1
AB700409
AB
Page 12
1-10
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
1. Upper side bar front
2. Front end upper bar side
3. Front fender bracket
4. Upper frame bulkhead front
5. Fender shield frame upper outer
6. Upper frame bulkhead center
7. Upper frame bulkhead rear
8. Front fender bracket
9. Front upper frame inner
10. Upper frame inner plate
11. Harness bracket
12. Spring house corner gusset
13. Spring house bracket reinforcement
14. Spring house bracket front
15. Spring house panel rear
16. Spring house reinforcement rear
17. Horn bracket
18. Spring house harness bracket
19. Suction hose bracket
20. Spring house panel
21. Power steering reservoir tank bracket
22. Engine mounting bracket upper
23. Front fender shield
24. Engine mounting gusset
25. Condense tank reinforcement
26. Fender gusset
27. Front fender bracket
28. Front sidemember
29. Engine control module bracket
30. Clutch tube bracket <M/T>
31. Harness bracket front
32. Harness bracket rear
33. Relay box bracket
34. Transaxle mounting gusset
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Page 13
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
1-11
FRONT SIDEMEMBER REINFORCEMENT
• The front sidemember structure has been
changed to a straight frame structure with an
octagon cross section that efficiently absorbs
energy from the impact at the time of collision.
• The front sidemember is supported in three directions by the dash crossmember center, dash
crossmember lower and front sidemember rear in
order to improve the frontal collision characteris
tics, and increase the vehicle body rigidity.
(Right side)
1*
3
2
16
17
22
21
15
20
19
18
• The 590-MPa class high tensile strength steel
panels have been adopted for the front sidemem
ber extension, front sidemember rear bulkhead
and front sidemember rear to improve the body
rigidity.
-
4
23
11
24
5
*
*
6
-
14
*: Indicates 590MPa-high-tensile steel panels.
13
21
16
15
1. Front sidemember extension
2. Front sidemember outer
3. Front brake hose bracket
4. Front sidemember reinforcement rear lower
5. Front sidemember rear bulkhead
6. Front sidemember rear
7. Height sensor bracket
8. Dash crossmember extension lower
9. I plate bracket
10. Front body frame to side sill brace
11. Tie down reinforcement front
12. Front suspension crossmember bracket front
22
A
B
12
13
12
10
9
17
23
4
10
11
13. Front sidemember inner
14. Front sidemember plate
15. Front sidemember bulkhead front
16. Engine mounting bulkhead
17. Front suspension crossmember bulkhead
18. Headlight bracket lower
19. Headlight support panel
20. Engine mounting reinforcement
21. Engine mounting bracket front
22. Engine mounting bracket rear
23. Front sidemember brace upper
24. Front sidemember reinforcement rear
5
7
8
AB700925
AB
6
AB700929
AC
TSB Revision
Page 14
1-12
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
A
(Left side)
20
16
2
B
23
2
21
7
13
AB602309
AD
17
12
9
13
AB602310
AD
8
20
6
*
4
5
*
13
3
14
16
15
17
19
18
22
21
10
*
2
*: Indicates 590MPa-high-tensile steel panels.
5
1. I plate bracket
2. Dash crossmember extension lower
3. Front body frame to side sill brace
4. Tie down reinforcement front
5. Front sidemember rear
6. Front sidemember rear bulkhead
7. Front sidemember reinforcement rear lower
8. Front sidemember outer
9. Front brake hose bracket
10. Front sidemember extension
11. Front sidemember plate
1
7
12
11
AB700920
AB
15
19
20
21
14
B
A
12
4
6
3
12. Front suspension crossmember bracket front
13. Front sidemember inner
14. Front sidemember brace upper
15. Transaxle mounting bracket
16. Connector bracket
17. Headlight support panel
18. Headlight bracket lower
19. Front suspension crossmember bulkhead
20. Transaxle mounting bulkhead rear
21. Transaxle mounting bulkhead front
22. Front sidemember reinforcement
22
13
AB700931
AC
TSB Revision
Page 15
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
1-13
A
13
15
8
22
20
AB700583
AC
FRONT DECK
• The impact absorbing opening on the cowl top
outer reinforcement upper has been added to effi
ciently absorb energy upon impact and improve
the pedestrian protection capability.
B
14
13
8
19
12
• Rigidity was heightened and driving stability was
improved by bonding the fender shield frame
-
upper outer and front pillar by the upper frame to
front pillar brace.
AB700584
6
AC
4
3
1. Cowl top panel lower
2. Wiper B bracket
3. Cowl top stay bracket rear
4. Cowl top outer reinforcement upper
5. Cowl top panel inner
6. Cowl top panel outer
7. Deck crossmember stay bracket
5
8
9
7
2
10
11
13
12
1
8. Brake pedal support bracket
9. Clutch pedal support bracket <M/T>
10. Upper frame extension inner
11. Brake pedal support reinforcement
12. Front fender bracket
13. Cowl top outer reinforcement lower
14. Upper frame to front pillar brace
14
AB602289
AC
TSB Revision
Page 16
1-14
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
DASH PANEL
The 590-MPa class high tensile strength steel panels
have been adopted for the dash crossmember cen
ter, dash crossmember extension, dash panel reinforcement and dash crossmember side to improve
the body rigidity.
-
3*
2
*: Indicates 590MPa-high-tensile steel panels.
1. Brake tube bracket
2. Harness bracket
3. Dash crossmember center
4. Dash crossmember extension
5. Canister bracket
6. Dash heat protector bracket
7. Dash panel
8. Backbone reinforcement front
7
9
12*
6
8
10
11
13
5
4*
1
15
14*
16
AB700934
9. Dash panel lower
10. Accelerator pedal bracket
11. Steering shaft bracket
12. Dash panel reinforcement
13. Clutch pedal reinforcement lower <M/T>
14. Dash crossmember side
15. Dash crossmember lower bulkhead
16. Dash crossmember lower
AB
TSB Revision
Page 17
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
1-15
SIDE BODY
SIDE STRUCTURE
• The 590-MPa class high tensile strength steel
panels or 980-MPa class ultra high tensile
strength steel panels have been adopted for the
front pillar, center pillar, side sill, and roof side rail
to improve the body rigidity.
• Rigidity was heightened and driving stability was
improved by bonding the roof bow and roof rail
and the roof side rail inner by the roof rail exten
sion.
15*
5
2
4
12
6*
8*
11
1
2
7
13
10
9
64*
-
25
14
• A rear shelf lower brace is used to connect the
spring house middle panel and rear shelf upper
brace, so that the body rigidity, handling stability,
and riding comfort are improved.
• The number of the spot welding points at the door
opening has been increased to heighten the body
rigidity and to improve handling stability.
16
23
21
22
17
19
18
20
24
28
27
29
35
36
38
34
26
30
31
32
37
33
40
M4010011001087
39
3
63*
1
62
66
61
58
67*
60
59
57
56**
54
*: Indicates 590MPa-high-tensile steel panels.
**: Indicates 980MPa-ultra-high-tensile steel panels.
65*
53
52
52
51
55**
50
69
68
70
49
72
73
71
48
41
47
45
46
42
43
44
AB700954
AB
TSB Revision
Page 18
1-16
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
1. Front pillar inner lower
2. Front pillar inner center
3. Hood opener bracket (Left side)
4. Cowl side trim bracket (Right side)
5. Deck crossmember bracket (Right side)
6. Front upper inner pillar
7. Center pillar inner lower
8. Center pillar inner upper
9. Center pillar seat belt reinforcement lower
10. Center pillar seat belt reinforcement upper
11. Roof rail front extension
12. Roof rail center extension <Vehicles without sunroof
(aluminum panel)>
13. Bracket C <Vehicles with sunroof (steel panel)>
14. Roof rail rear extension
15. Roof side rail inner
16. Harness bracket (Right side)
17. Rear shelf upper brace
18. Rear seat belt reinforcement
19. Nut plate <Vehicles with subwoofer>
20. Subwoofer upper bracket <Vehicles with subwoofer>
21. Rear seat hook A
22. Rear seatback brace rear
23. Rear seatback plate reinforcement
24. Rear seatback brace bulkhead
25. Rear seatback brace front
26. Rear spring house reinforcement upper front
27. Rear shelf lower brace
28. Rear spring house reinforcement upper rear
29. Rear spring house bracket
30. Trunk trim bracket
31. Washer tank center bracket (Left side)
32. Spring house middle front panel (Left side)
33. Filler pipe mounting bracket (Left side)
34. Spring house middle panel
35. Harness bracket (Left side)
36. Rear wheel house panel inner
37. Rear wheel house panel front lower outer
38. Curtain air bag bracket
39. Quarter panel lower inner (Left side)
40. Quarter inner panel
41. Quarter panel extension inner
42. Quarter panel extension lower outer
43. Rear combination light housing
44. Quarter corner panel
45. Quarter outer upper extension
46. Quarter outer upper side extension
47. Fuel filler neck bracket (Left side)
48. Side outer panel
49. Fender bracket
50. Fender bracket lower
51. Front fender bracket
52. Cowl side trim bracket
53. Front upper outer frame rear
54. Upper frame outer reinforcement
55. Side sill reinforcement outer rear
56. Side sill reinforcement outer front
57. Side sill inner support front
58. Front pillar reinforcement lower
59. Front door hinge reinforcement lower
60. Front pillar reinforcement center bulkhead
61. Front door hinge reinforcement upper
62. Deck support pipe (Left side)
63. Front pillar support
64. Roof side rail support
65. Roof side rail reinforcement front
66. Rear door hinge reinforcement support
67. Rear door hinge reinforcement
68. Center pillar reinforcement
69. Roof side rail reinforcement rear
70. Rear pillar reinforcement
71. Flap gate striker reinforcement
72. Nut plate
73. Rear pillar reinforcement lower
TSB Revision
Page 19
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
SIDE STRUCTURE REINFORCEMENT
The ring structure of the side structure reinforcement
has been adopted to improve the collision characteristics and the rigidity of the whole vehicle.
Roof side rail reinforcement rear
Roof side rail reinforcement front
1-17
Rear pillar reinforcement
Rear pillar reinforcement lower
Front pillar
reinforcement lower
REAR BODY
REAR DECK
Side sill reinforcement outer rear
Center pillar reinforcement
Side sill reinforcement outer front
AB700608
M4010012000764
AB
3
4
2
1
18 ± 7 N·m
13 ± 5 ft-lb
1. Washer tank bracket upper
2. Rear seat hook A
3. Rear shelf panel
4. Rear shelf reinforcement
TSB Revision
6
7
5. Seat belt reinforcement center
6. Rear shelf extension
7. Rear seatback reinforcement
5
AB700406
AB
Page 20
1-18
REAR END PANEL
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
5.0 ± 1.0 N·m
44 ± 9 in-lb
3
2
1
1. Rear bumper side bracket
2. Rear end panel inner
3. Trunk lid striker reinforcement
ROOF
• An aluminum roof panel has been adopted to
improve lightweightness for greater handling sta
bility. <Vehicles without sunroof (aluminum
panel)>
• The closed section structure has been adopted
for the roof rail front and the roof bow center to
heighten body rigidity, improve handling stability
and riding comfort, and to reduce vibration and
noise.
4
4. Rear end panel outer
5. Rear bumper reinforcement
5
• The 590-MPa class high tensile strength steel
-
panel has been adopted for the roof bow center
lower to improve the body rigidity. <Vehicles with
out sunroof (aluminum panel)>
AB700570
M4010013001306
AB
-
TSB Revision
Page 21
BODY CONSTRUCTION CHARACTERISTICS
<Vehicles without sunroof (aluminum panel)>
5
1
BODY CONSTRUCTION
8*
4
3
1-19
6
7
9
*: Indicates 590MPa-high-tensile steel panels.
<Vehicles with sunroof (steel panel)>
5
1. Sunvisor bracket
2. Reading light bracket
3. Roof rail front lower
4. Roof rail front upper
5. Roof panel
6. Roof rail rear
7. Roof bow center upper
2
1
AB700936
AB
6
10
4
11
13
12
AB700863
AE
3
1
2
1
8. Roof bow center lower
9. Dome light bracket
10. Roof panel reinforcement
11. Set rear bracket
12. Bracket A
13. Bracket B
14. Set front bracket
14
TSB Revision
Page 22
1-20
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
UNDER BODY
FRONT FLOOR
The 590-MPa class high tensile strength steel panels
have been adopted for the front floor crossmember
front and front floor sidemember, and the 980-MPa
class ultra high tensile strength steel panels for the
front floor side sill inner, to improve the body rigidity.
5
4
3
*
2
6
7
M4010014001202
8
9
1
16
*: Indicates 590MPa-high-tensile steel panels.
**: Indicates 980MPa-ultra-high-tensile steel panels.
1. Front floor
2. Front floor crossmember front reinforcement
3. Front floor crossmember front
4. Parking brake lever reinforcement
5. Backbone reinforcement
6. Parking brake cable reinforcement
7. Seat center bracket rear
8. Front floor crossmember rear
15
10
14
12
**
11
13
*
9. Seat side bracket rear
10. Seat belt reinforcement
11. Front floor side sill inner center reinforcement
12. Front floor side sill inner
13. Front floor sidemember
14. Front floor crossmember rear center
15. Front floor crossmember front
16. Front floor reinforcement lower (Right side)
AB700937
AB
TSB Revision
Page 23
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
1-21
REAR FLOOR
• The 590-MPa class high tensile strength steel
panels have been adopted for the rear floor
extension and rear seat crossmember to improve
the body rigidity.
7
5
6
4
2
1*
• The rear floor rear end crossmember has been
straightened to heighten body rigidity, improve
handling stability and riding comfort, and to
reduce vibration and noise.
8
3
9
16
*: Indicates 590MPa-high-tensile steel panels.
1. Rear floor extension
2. Rear seat under floor
3. Rear floor pan rear
4. Rear seatback bracket lower
5. Rear floor crossmember upper
6. Battery bracket rear floor front
7. Battery bracket rear floor
8. Spare tire bracket
9. Rear floor rear end crossmember
15*
14
13
11
10
11
12
17
16
10. Rear floor crossmember front
11. Fuel tank rear bracket
12. Rear seat belt reinforcement (Left side)
13. Rear seat belt reinforcement (Right side)
14. Rear seat crossmember bulkhead inner
15. Rear seat crossmember
16. Sidemember front floor extension
17. Rear floor sidemember
AB700404
AB
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Page 24
1-22
BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION
REAR FLOOR SIDEMEMBER
REINFORCEMENT
The 590-MPa class high tensile strength steel panels
have been adopted for the rear floor sidemember
reinforcement, rear floor sidemember extension, rear
floor side sill inner and rear floor sidemember bulk
head to improve the body rigidity.
-
33
2
32
29
6*
30
31
10
5
4
7
28
9
11
12*
13
16
27
8
15
14
26
3
1
23
25
24*
22
17
*: Indicates 590MPa-high-tensile steel panels.
A
23
18
20
24
22
6
25
19
21
15
28
27
19
20
18*
AB700942
AB
10
30
29
31
B
12
11
AB700587
AB700953
AC
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Page 25
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
1-23
1. Rear floor side panel
2. Rear bumper beam reinforcement
3. Rear floor crossmember extension rear
4. Rear suspension bracket center
5. Rear suspension center reinforcement
6. Rear floor sidemember reinforcement
7. Rear floor crossmember extension rear upper
8. Rear floor crossmember extension rear
9. Muffler hanger rear
10. Shipping pipe
11. Shipping bracket reinforcement
12. Rear floor sidemember extension
13. Rear bumper support
14. Canister bracket (Left side)
15. Rear spring house panel lower
16. ABS sensor bracket
17. Brake hose bracket
A
1
6
18. Rear floor side sill inner
19. Rear suspension bracket front
20. Trailing arm bracket lower
21. Rear floor sidemember lower
22. Rear floor sidemember extension front
23. Rear tie down plate
24. Rear floor sidemember bulkhead
25. Trailing arm bracket
26. Trailing arm bulkhead
27. Rear floor sidemember rear reinforcement
28. Rear suspension center bulkhead
29. Rear floor sidemember bulkhead rear
30. Rear suspension bracket rear
31. Pipe nut
32. Hydraulic unit bracket front (Right side)
33. Hydraulic unit bracket rear (Right side)
B
1
21
25
20
18
AB700589
AC
21
29
15
AB700588
AB
TSB Revision
Page 26
1-24
BODY CONSTRUCTION
BODY CONSTRUCTION CHARACTERISTICS
DOOR
An uneven thickness steel sheet* has been used for
the front and rear door panel inners to make the forward part of the vehicle thicker for reduction in vehicle weight and higher rigidity.
(Front door)
2
5
1
(Rear door)
3
4
M4010015000893
NOTE: *: A steel sheet of varying thickness that is
welded into one steel sheet.
6
7
8
9
11
10
12
13
14
AB602334
AB
19
12
23
16
15
1. Front door panel outer
2. Front door beltline outer reinforcement
3. Front door outer stiffener
4. Front door side door beam
5. Front door window front sash
6. Front door window upper sash
7. Front door window rear sash
8. Front door latch reinforcement
9. Front door beltline inner reinforcement
10. Front door mirror reinforcement
11. Front door inside handle bracket
12. Nut plate
13. Front door checker reinforcement
14. Front door panel inner
17
18
21
24
22
20
25
12
27
15. Rear door panel outer
16. Rear door beltline outer reinforcement
17. Rear door side door beam
18. Rear door window front sash
19. Rear door window upper sash
20. Rear door beltline inner reinforcement
21. Rear door beltline bracket
22. Rear door sash reinforcement
23. Rear door stat corner bracket
24. Rear door latch reinforcement
25. Rear door window sash lower bracket
26. Rear door inside handle bracket
27. Rear door panel inner
26
AB700413
AB
TSB Revision
Page 27
BODY CONSTRUCTION
SILENCER APPLICATION LOCATIONS
1-25
SILENCER APPLICATION LOCATIONS
A silencer (MD-12, RSS and melting sheet) has been
affixed on the upper surface of the floor for vibration
damping.
NOTE: .
•
MD-12 is a high performance sheet composed of
asphalt applied with mica and thermosetting resin
for improving anti-vibration performance.
<GSR>
M4010005001271
•
RSS (Rubber Special Sheet) is a product name
of Nihon Tokushu Toryo Co., Ltd. The product
features the same performance as a steel sheet
sandwich type and refers to a heat cured resin
sheet that is molded into a sheet with a uniform
thickness. It contains degenerating resin and filler
with asphalt and rubber as the main contents.
<MR>
: 1.6 mm (
: 1.6 mm (
: 3.2 mm (
: 1.6 mm (
[
Place three 1.6 mm (
0.063 in)
0.063 in)
0.126 in)
0.063 in)
thick melting sheet
thick MD-12 [Place a 1.6 mm (
thick MD-12 [Place two 1.6 mm (
thick melting sheet and 2.0 mm (
0.063 in)
melting sheet one on top of the next.
0.063 in)
0.063 in)
0.079 in)
NOTE: [ ] indicates the number of melting sheets that
are used for repair.
melting sheet.
melting sheet one on top of another.
thick RSS
]
]
AB700568
AB700568
]
AB700569
AB
AB
TSB Revision
Page 28
1-26
BODY CONSTRUCTION
FOAMING MATERIAL USAGE LOCATIONS
FOAMING MATERIAL USAGE LOCATIONS
The sound dampening foam material have been
adopted to the upper and lower sections of the front
pillar, center pillar lower section, rear pillar and wheel
house arch inside to shield from external noise.
M4010006000163
CAUTION
The sound dampening foam material may burn
when heated. Always observe the following
instructions:
• Never use a gas burner to burn the areas
where sound dampening foam material is
used.
• When cutting the parts which are provided
with sound dampening foam material, ensure
to use tools (air saw, etc.) that do not gener
ate fire.
• If there are residual sound dampening foam
material remaining on the cut section (body
side), remove the sound dampening foam
material from periphery of the welding area
before welding work.
-
TSB Revision
Sound dampening foam material
Sound dampening foam material
AB700801
AB
Page 29
BODY CONSTRUCTION
STIFFENER AND DAMP SHEET APPLICATION LOCATIONS
1-27
STIFFENER AND DAMP SHEET APPLICATION LOCATIONS
M4010001400263
A damp sheet (roof insulator) <Vehicles without sunroof (aluminum panel)> on the inner side of the roof
panel and a stiffener on the inner side of the rear
door panel outer have been adopted for higher sur
face rigidity.
-
NOTE: .
•
The main contents of a stiffener are epoxy resin.
It comes in a sheet form and contains a mixture
of glass fiber and filler, and cures (stiffens) when
heated.
•
No spare part of the stiffener for repair is available in the field. If the stiffener is damaged,
replace it together with the panel.
Damp sheet (roof insulator)
AB700461
(Rear door)
Stiffener
AB700893
AB700892
AB
AB
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Page 30
1-28
BODY CONSTRUCTION
THEFT PROTECTION
Theft protection plate and label
For original parts
For replacement parts
THEFT PROTECTION
CAUTION
When replacing a part that has the theft protection plate,
label or stamp on it, be sure that the part has either A or B
shown in the figure. It is illegal if both A and B are
attached, or neither A nor B is attached.
In order to protect against theft, a Vehicle Identification Number
(VIN) is attached as a plate or label to the following major parts
of the engine, transaxle and main outer panels: Engine cylinder
block, Transaxle housing, Front fender, Hood, Trunk lid,
Bumpers, Side outer panel, Doors. In addition, a theft-protec
tion label is attached to replacement parts for main outer panels. The same data is stamped into replacement parts for the
engine and the transaxle.
CAUTION
Cautions regarding panel repairs:
• When repainting original parts, do so after first masking
the theft-protection label. After painting, be sure to peel
off the masking tape.
• The theft-protection label for replacement parts is covered by masking tape, so such parts can be painted as
is. The masking tape should be removed after painting
is finished.
• The theft-protection label should not be removed from
original parts or replacement parts.
M4010017000145
-
AC704152
.
AB
TSB Revision
Page 31
LOCATIONS
BODY CONSTRUCTION
THEFT PROTECTION
1-29
D
D'
A
B
F
F'
E
E'
C
AC710510
AC
TSB Revision
Page 32
1-30
BODY CONSTRUCTION
THEFT PROTECTION
Label area (x: for original equipment parts, y: for replacement parts)
Engine
x
y
Manual transaxle (M/T)
x
y
View A (Front fender)
a
AC609841
AB
AC612304
AB
Twin clutch sportronic shift transmission (TC-SST)
AC708134
y
AB
x
AC707965
AB
View B (Hood)
Section a - a
x
b
a
b
The illustration indicates left outer side.
Right side is symmetrically opposite.
Section b - b
y
AC608723
AB
TSB Revision
x
y
AC708344
AC708456
AB
Page 33
BODY CONSTRUCTION
THEFT PROTECTION
Label area (x: for original equipment parts, y: for replacement parts)
View C (Trunk lid)
x
y
1-31
View D (Front bumper)
x
AC612302
AC710511
AB
AB
View D'
y
AC710513
TSB Revision
Page 34
1-32
BODY CONSTRUCTION
THEFT PROTECTION
Label area (x: for original equipment parts, y: for replacement parts)
View E (Rear bumper)
View F (Side outer panel)
x
View E'
x
AC608729
AB
y
AC608730
AB
View F'
y
The illustration indicates left outer side.
Right side is symmetrically opposite.
Front door (both side)
G
c
c
The illustration indicates left outer side.
Right side is symmetrically opposite.
AC608733
View G
x
Section c - c
y
AC608731
AB
AC
The illustration indicates left outer side.
Right side is symmetrically opposite.
Rear door (both side)
H
d
d
The illustration indicates left outer side.
Right side is symmetrically opposite.
AC611136
View H
x
Section d - d
y
AC608734
AB
AC
TSB Revision
Page 35
GROUP 2
BODY DIMENSIONS
CONTENTS
2-1
BODY DIMENSIONS AND
MEASUREMENT METHODS. . . . . . . 2-2
TYPE A
(PROJECTED DIMENSIONS) . . . . . . 2-4
UNDER BODY . . . . . . . . . . . . . . . . . . . . . . 2-4
SUSPENSION INSTALLATION
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . 2-8
TYPE B (ACTUAL-MEASUREMENT
DIMENSIONS). . . . . . . . . . . . . . . . . . . 2-10
UNDER BODY. . . . . . . . . . . . . . . . . . . . . . . 2-10
SUSPENSION INSTALLATION
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . 2-12
FRONT BODY . . . . . . . . . . . . . . . . . . . . . . . 2-14
SIDE BODY . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
REAR BODY . . . . . . . . . . . . . . . . . . . . . . . . 2-20
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Page 36
2-2
BODY DIMENSIONS
BODY DIMENSIONS AND MEASUREMENT METHODS
BODY DIMENSIONS AND MEASUREMENT METHODS
• Type A (projected dimensions) is the dimension when a
measurement location is projected onto the plane.
NOTE: The height indicates a distance from the assumed
standard line established 100 mm (3.9in) below the lowest
measurement point.
• Type B (actual-measurement dimensions) is the actual distance between the measurement points.Measure using a
tracking gauge or a measuring tape, etc.
NOTE: .
•
Make the lengths of the tracking gauge probes the same
(A=Aí).
•
Do not bend or twist the measuring tape.
Probe
Projected dimension
Height
Actual-measured
dimension
A
A'
AB302138
AB302139
AE
AE
M4020001000448
Center of hole
AB302140
AB302141
AF
AD
• 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.
• The body center points are shown for the purpose of checking the position of the left and right symmetry location.
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Page 37
NOTES
BODY DIMENSIONS
BODY DIMENSIONS AND MEASUREMENT METHODS
2-3
TSB Revision
Page 38
2-4
(
)
BODY DIMENSIONS
TYPE A (PROJECTED DIMENSIONS)
TYPE A (PROJECTED DIMENSIONS)
UNDER BODY
76
(3.0)
2
967
(38.1)
1
76
(3.0)
960
(37.8)
3
616
(24.3)
540
(21.3)
616
24.3
910
(35.8)
510
(20.1)
4
1,050
(41.3)
875
(34.4)
5
462
(18.2)
624
(24.6)
197
(7.8)
564
(22.2)
375
(14.8)
M4020005002156
mm (in)
833
(32.8)
667
(26.3)
894
7
(35.2)
894
8
350
(13.8)
(35.2)
9
344
(13.5)
6
1,262
(49.7)
10
718
(28.3)
440
(17.3)
1,022
(40.2)
11
393
(15.5)
929
(36.6)
877
(34.5)
990
(39.0)
545
(21.5)
12
Center line of the vehicle
13
AB700574
AB
1,138
969
(38.1)
1,124
(44.3)
964
(38.0)
1,120
(44.1)
3
1,079
(42.5)
1,394
(54.9)
1,028
(40.5)
4
5
2
1
763
(30.0)
(44.8)
7
686
(27.0)
6
641
(25.2)
544
(21.4)
1,254
(49.4)
960
(37.8)
8
1,117
(44.0)
9
1,195
(47.0)
1,218
(48.0)
11
1,342
(52.8)
1,025
(40.4)
12
1,369
(53.9)
1,080
(42.5)
13
10
Center line of the vehicle
AB700575
AB
No. Standard measurement point Hole shape Size mm (in)
1 Center of front end crossmember lower water draining hole (left side) Round 8 (0.31)
2 Center of front end crossmember lower water draining hole (right side) Round 8 (0.31)
3* Center of front sidemember inner positioning hole Round 25 (0.98)
4* Center of front axle crossmember mounting hole (front) Round 15.5 (0.61)
5* Center of front sidemember rear water draining hole Round 16 (0.63)
6 Center of propeller shaft mounting hole (left side) Round 11 ( 0.43)
7 Center of propeller shaft mounting hole (right side) Round 11 ( 0.43)
8* Center of front floor sidemember positioning hole (front) Round 16 (0.63)
TSB Revision
Page 39
BODY DIMENSIONS
TYPE A (PROJECTED DIMENSIONS)
2-5
No. Standard measurement point Hole shape Size mm (in)
9* Center of front floor sidemember positioning hole (rear) Round 16 (0.63)
10* Center of rear floor sidemember lower positioning hole (front) Oblong 33.9×18
(1.335
×0.71)
11* Center of rear suspension bracket front water draining hole Round 16 (0.63)
12* Center of rear floor sidemember lower positioning hole (rear) Round 25 (0.98)
13* Center of rear floor sidemember extension water draining hole (left
Round 14 (0.55)
side), Center of rear shipping bracket mounting hole (right side)
NOTE: The * mark indicates the mounting position for the frame centering gauge.
mm (in)
230
(9.1)
8
350
(13.8)
291
(11.5)
11
10
9
286
(11.3)
1,644
(64.7)
105
(4.1)
154
(6.1)
715
(28.1)
1,101
(43.3)
12
354
(13.9)
13
357
(14.1)
AB700418
1
2
280
(11.0)
Standard line
3
347
(13.7)
294
(11.6)
1,125
(44.3)
4
1,049
(41.3)
100
(3.9)
510
(20.1)
486
(19.1)
7
157
(6.2)
6
105
(4.1)
5
259
(10.2)
716
(28.2)
NOTE: The assumed standard line is established 100 mm (3.9in) below the measurement point No.5.
1, 3
2
4
AB
1
5
3
AB700470
AB
6, 7
AB700471
6
AB
8, 9
AB700472
AB
8
7
AB700473
AB
AB600999
AB
9
AB601000
AB
TSB Revision
Page 40
2-6
BODY DIMENSIONS
TYPE A (PROJECTED DIMENSIONS)
10
AB700474
AB
11, 12
11
AB700475
12
AB
13
AB700973
AB
TSB Revision
Page 41
NOTES
BODY DIMENSIONS
TYPE A (PROJECTED DIMENSIONS)
2-7
TSB Revision
Page 42
2-8
BODY DIMENSIONS
TYPE A (PROJECTED DIMENSIONS)
SUSPENSION INSTALLATION DIMENSIONS
510
(20.1)
1,298
(51.1)
1,132
(44.6)
910
(35.8)
4
14
293
(11.5)
875
(34.4)
886
(34.9)
5
15
217
(8.5)
Center line of the vehicle
529
(20.8)
894
(35.2)
9
787
(31.0)
480
(18.9)
84
(3.3)
1,138
(44.8)
17
16
331
(13.0)
328
(12.9)
1,000
(39.4)
18
768
(30.2)
441
(17.4)
760
(29.9)
19
903
(35.6)
20
1,004
(39.5)
M4020013001783
mm (in)
AB700578
AB
1,116
(43.9)
1,230
(48.4)
1,187
(46.7)
1,272
(50.1)
1,323
(52.1)
1,048
(41.3)
945
(37.2)
1,028
(40.5)
907
(35.7)
1,200
(47.2)
1,117
(44.0)
4
9
17
18
19
20
16
AB700579
14
5
15
Center line of the vehicle
No. Standard measurement point Hole shape Size mm (in)
4 Center of front axle crossmember mounting hole (front) Round 15.5 (0.61)
5 Center of front sidemember rear water draining hole Round 16 (0.63)
9 Center of front floor sidemember positioning hole (rear) Round 16 (0.63)
14 Center of front shock absorber mounting hole Round 80 (3.15)
15 Center of front axle crossmember mounting hole (rear) Round 15.5 (0.61)
16 Center of trailing arm mounting hole (outer side) Round 15.5 (0.61)
17 Center of trailing arm mounting hole (inner side) Round 15.5 (0.61)
AB
18 Center of rear suspension crossmember mounting hole (front) Round 15 (0.59)
19 Center of rear shock absorber mounting hole Round 70.8 (2.79)
20 Center of rear suspension crossmember mounting hole (rear) Round 15 (0.59)
TSB Revision
Page 43
BODY DIMENSIONS
TYPE A (PROJECTED DIMENSIONS)
2-9
187
(7.4)
15˚34´
18
Vehicle center
0˚
19
20
284
(11.2)
354
(13.9)
683
(26.9)
mm (in)
B
A
A
Vehicle center
3˚06´
14
6˚54´
540
(21.3)
B
464
(18.3)
1,087
(42.8)
4
767
(30.2)
294
(11.6)
162
(6.4)
15
5
100
(3.9)
105
(4.1)
9
187
(7.4)
17
16
Standard line
510
(20.1)
217
(8.5)
1,066
(42.0)
489
(19.3)
785
(30.9)
1,223
(48.1)
AB700848
NOTE: The assumed standard line is established 100 mm (3.9in) below the measurement point No.5.
4
5, 15
9
15
5
14
AB700472
AB
AB700479
16, 17
AB
AB601180
18, 20
AB
AB
AB700478
AB
TSB Revision
17
16
AB700480
AB
18
20
AB700481
AB
Page 44
2-10
19
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
UNDER BODY
102
(4.0)
616
(24.3)
960
(37.8)
3
542
(21.3)
616
(24.3)
2
967
(38.1)
1
101
(4.0)
AB700482
910
(35.8)
4
1,079
(42.5)
546
(21.5)
AB
875
(34.4)
5
644
(25.4)
222
(8.7)
567
(22.3)
7
487
(19.2)
378
(14.9)
6
894
(35.2)
8
669
(26.3)
350
(13.8)
894
(35.2)
9
348
(13.7)
1,262
(49.7)
10
740
(29.1)
460
(18.1)
856
(33.7)
1,022
(40.2)
11
399
(15.7)
877
(34.5)
12
932
(36.7)
545
(21.5)
M4020005002167
990
(39.0)
13
mm (in)
AB700576
AB
971
(38.2)
1,124
(44.3)
966
(38.0)
1,081
(42.6)
2
1,120
(44.1)
1,415
(55.7)
1
3
1,046
(41.2)
4
5
765
(30.1)
704
(27.7)
1,138
(44.8)
7
6
643
(25.3)
566
(22.3)
1,255
(49.4)
1,118
(44.0)
960
(37.8)
8
9
1,209
(47.6)
1,225
(48.2)
11
1,357
(53.4)
1,027
(40.4)
12
1,371
(54.0)
1,080
(42.5)
13
10
AB700577
AB
TSB Revision
Page 45
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
2-11
No. Standard measurement point Hole shape Size mm (in)
1 Center of front end crossmember lower water draining hole (left side) Round 8 (0.31)
2 Center of front end crossmember lower water draining hole (right side) Round 8 (0.31)
3 Center of front sidemember inner positioning hole Round 25 (0.98)
4 Center of front axle crossmember mounting hole (front) Round 15.5 (0.61)
5 Center of front sidemember rear water draining hole Round 16 (0.63)
6 Center of propeller shaft mounting hole (left side) Round 11 ( 0.43)
7 Center of propeller shaft mounting hole (right side) Round 11 ( 0.43)
8 Center of front floor sidemember positioning hole (front) Round 16 (0.63)
9 Center of front floor sidemember positioning hole (rear) Round 16 (0.63)
10 Center of rear floor sidemember lower positioning hole (front) Oblong 33.9×18
(1.335×0.71)
11 Center of rear suspension bracket front water draining hole Round 16 (0.63)
12 Center of rear floor sidemember lower positioning hole (rear) Round 25 (0.98)
13 Center of rear floor sidemember extension water draining hole (left
Round 14 (0.55)
side), Center of rear shipping bracket mounting hole (right side)
1, 3
5
2
1
3
AB700470
AB
AB700471
AB
6, 7
6
4
8, 9
AB700472
AB
8
7
AB700473
AB
AB600999
AB
9
AB601000
AB
10
AB700474
11, 12
AB
TSB Revision
11
AB700475
12
AB
13
AB700973
AB
Page 46
2-12
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
SUSPENSION INSTALLATION DIMENSIONS
546
(21.5)
886
(34.9)
910
(35.8)
4
322
(12.7)
15
875
(34.4)
226
(8.9)
5
1,298
(51.1)
535
(21.1)
894
(35.2)
9
807
(31.8)
487
(19.2)
84
(3.3)
1,138
(44.8)
17
16
345
(13.6)
342
(13.5)
1,000
(39.4)
18
786
(30.9)
446
(17.6)
778
(30.6)
903
(35.6)
20
M4020013001794
mm (in)
AB700580
AB
1,120
(44.1)
1,243
(48.9)
1,191
(46.9)
17
18
1,283
(50.5)
1,333
(52.5)
20
1,050
(41.3)
954
(37.6)
1,046
(41.2)
4
15
909
(35.8)
5
1,203
(47.4)
9
1,120
(44.1)
16
AB700581
No. Standard measurement point Hole shape Size mm (in)
4 Center of front axle crossmember mounting hole (front) Round 15.5 (0.61)
5 Center of front sidemember rear water draining hole Round 16 (0.63)
9 Center of front floor sidemember positioning hole (rear) Round 16 (0.63)
15 Center of front axle crossmember mounting hole (rear) Round 15.5 (0.61)
16 Center of trailing arm mounting hole (outer side) Round 15.5 (0.61)
17 Center of trailing arm mounting hole (inner side) Round 15.5 (0.61)
18 Center of rear suspension crossmember mounting hole (front) Round 15 (0.59)
AB
20 Center of rear suspension crossmember mounting hole (rear) Round 15 (0.59)
TSB Revision
Page 47
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
2-13
4
16, 17
AB700472
17
AB700480
16
AB
AB
5, 15
18, 20
18
15
AB700479
20
AB700481
9
5
AB
AB
AB601180
AB
TSB Revision
Page 48
2-14
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
FRONT BODY
509
(20.0)
394
(15.5)
33
32
29
327
(12.9)
26
1
*
: <Vehicles without sunroof (aluminum panel)>
2
*
: <Vehicles with sunroof (steel panel)>
27
391
(15.4)
1,438
(56.6)
995 *
(39.2)
2
994 *
(39.1)
901
(35.5)
913
(35.9)
891
(35.1)
336
23
(13.2)
21
Body center point
1
1,508
(59.4)
1,494
(58.8)
901
(35.5)
1,060
(41.7)
22
1,174
(46.2)
37
1,486
(58.5)
25
392
(15.4)
30
1
1,094*
(43.1)
39
Body center point
1,625 *
(64.0)
1,072
(42.2)
1,485
(58.5)
877
(34.5)
31
28
329
(13.0)
24
1,106*
(43.5)
401
(15.8)
2
1
1,630 *
(64.2)
36
2
425
(16.7)
34
35
40
38
M4020006001101
41
mm (in)
AB700431
AC
855
(33.7)
822
(32.4)
33
32
29
27
26
Body center point
896
(35.3)
1,032
(40.6)
713
(28.1)
23
21
TSB Revision
781
(30.7)
1,042
(41.0)
22
1,458
(57.4)
714
(28.1)
37
864
(34.0)
1,449
(57.0)
25
810
(31.9)
31
30
732
(28.8)
1,558
(61.3)
28
24
819
(32.2)
36
34
35
38
AB700602
AB
Page 49
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
2-15
mm (in)
AB700603
857
(33.7)
33
32
29
26
Body center point
27
549
(21.6)
873
(34.4)
782
(30.8)
23
953
(37.5)
1,026
(40.4)
601
(23.7)
21
980
(38.6)
774
(30.5)
22
37
937
(36.9)
30
1,556
(61.3)
25
31
24
555
(21.9)
831
(32.7)
860
(33.9)
28
544
(21.4)
36
341
(13.4)
38
35
34
No. Standard measurement point Hole shape Size mm (in)
21 Center of front end crossmember positioning notch (Body center
− −
point)
22 Center of front end crossmember dynamic damper mounting hole
Round 9 (0.35)
(left side)
23 Center of front end crossmember dynamic damper mounting hole
Round 9 (0.35)
(right side)
24 Center of front bumper reinforcement mounting hole (left lower) Round 9 (0.35)
AB
25 Center of front bumper reinforcement mounting hole (left upper) Round 9 (0.35)
26 Center of front bumper reinforcement mounting hole (right lower) Round 9 (0.35)
27 Center of front bumper reinforcement mounting hole (right upper) Round 9 (0.35)
28 Center of front sidemember inner positioning notch (left side)
29 Center of front sidemember inner positioning notch (right side)
− −
− −
30 Center of headlight support panel upper mounting hole (left front) Round 6.6 (0.26)
31 Center of headlight support panel upper mounting hole (left rear) Round 6.6 (0.26)
32 Center of headlight support panel upper mounting hole (right front) Round 6.6 (0.26)
33 Center of headlight support panel upper mounting hole (right rear) Round 6.6 (0.26)
34 Center of front end upper bar side positioning hole Round 6 (0.24)
35 Center of front fender mounting hole Round 6.6 (0.26)
36 Center of front strut mounting hole Round 11.5 (0.45)
37 Center of cowl top panel mounting hole Round 6.6 (0.26)
38 Center of hood hinge mounting hole Round 9 (0.35)
39 Center of roof panel positioning notch (Body center point)
40 Corner of roof panel <Vehicles without sunroof (aluminum panel)>
41 Corner of roof panel <Vehicles with sunroof (steel panel)>
− −
− −
− −
TSB Revision
Page 50
2-16
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
21, 22
21
26, 27
26
22
AB700488
27
AB700435
AB
AB
23
28
AB700489
AB700436
AB
AB
24, 25
29
25
AB700437
24
AB700434
AB
AB
30, 31
36
30
31
AB601016
AB700439
AB
AB
32, 33
37
32
33
AB700438
AB601022
AB
AB
34, 35
38
34
35
AB601020
AB700440
AB
AB
TSB Revision
Page 51
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
2-17
39
AB601235
AB
40
AB700849
AB
41
AB601024
AD
TSB Revision
Page 52
2-18
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
SIDE BODY
52
364
(14.3)
53
43
42
657
(25.9)
822
(32.4)
1,106
(43.5)
762
(30.0)
863
(34.0)
1,076
(42.4)
45
1,049
(41.3)
1,096
(43.1)
1,072
(42.2)
1,159
(45.6)
44
1,176
(46.3)
44
47
46
635
(25.0)
54
355
(14.0)
55
867
(34.1)
1,290
(50.8)
49
1,044
(41.1)
775
(30.5)
781
(30.7)
835
(32.9)
48
970
(38.2)
51
48
640
(25.2)
713
(28.1)
56
50
M4020007001018
mm (in)
AB700854
AB
AB700855
No. Standard measurement point Hole shape Size mm (in)
42 Front pillar positioning notch (upper)
43 Front pillar positioning notch (lower)
44 Roof side rail positioning notch (front)
45 Side sill positioning notch (front)
46 Center pillar positioning notch (upper)
47 Center pillar positioning notch (lower)
48 Roof side rail positioning notch (rear)
49 Side sill positioning notch (rear)
50 Quarter panel positioning notch (upper)
51 Quarter panel positioning notch (lower)
− −
− −
− −
− −
− −
− −
− −
− −
− −
− −
52 Center of front door upper hinge mounting hole Round 11 (0 .43)
53 Center of front door lower hinge mounting hole Round 11 ( 0 .43)
AB
TSB Revision
Page 53
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
2-19
No. Standard measurement point Hole shape Size mm (in)
54 Center of rear door upper hinge mounting hole Round 11 . 5 (0.4 5 )
55 Center of rear door lower hinge mounting hole Round 11 (0 .43)
56 Center of rear door switch mounting hole Round 5 (0.20)
42
45
AB601025
AB601028
AC
AC
43, 53
47, 55
47
53
55
43
AB700484
AB601030
AB
AC
44, 46
48
44
46
AB601027
AB601031
AC
AC
49
52
AB700485
AB700487
AB
AB
50
54
AB601033
AB601029
AC
AC
51, 56
51
56
AB700486
AB
TSB Revision
Page 54
2-20
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
REAR BODY
63
57
60
58
Body center point
61
62
655
(25.8)
66
1,045*
(41.1)
1,361 *
(53.6)
1
1,056*
(41.6)
1,190
(46.9)
1,268
(49.9)
1
1,365 *
(53.7)
2
59
1,252
(49.3)
64
1,100
(43.3)
M4020008001055
mm (in)
1
743 *
2
(29.3)
1,244
(49.0)
742 *
(29.2)
2
198
(7.8)
65
117
990
(39.0)
(4.6)
*1 : <Vehicles without sunroof (aluminum panel)>
2
*
: <Vehicles with sunroof (steel panel)>
Body center point
60
61
63
62
66
1,232
(48.5)
67
67
761
(30.0)
1,346
(53.0)
649
(25.6)
1,189
(46.8)
507
(20.0)
59
64
1,458
(57.4)
505
(19.9)
778
(30.6)
65
1,050
(41.3)
295
(11.6)
606
(23.9)
AB700990
AB700991
AB
AB
No. Standard measurement point Hole shape Size mm (in)
57 Corner of roof panel <Vehicles without sunroof (aluminum panel)>
58 Corner of roof panel <Vehicles with sunroof (steel panel)>
59 Body center point of rear shelf panel
− −
− −
− −
TSB Revision
Page 55
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
2-21
No. Standard measurement point Hole shape Size mm (in)
60 Center of trunk lid hinge mounting hole (front) Round 9 (0.35)
61 Center of trunk lid hinge mounting hole (rear) Round 9 (0.35)
62 Corner of side outer panel
− −
63 Center of rear combination light mounting hole Round 8 (0.31)
64 Center of trunk lid latch striker mounting hole (left side) Round 6.6 (0.26)
65 Center of trunk lid latch striker mounting hole (right side) Round 6.6 (0.26)
66 Center of rear bumper reinforcement mounting hole (upper) Round (left
side), Oblong
(right side)
15 (0.59) (left
side), 15
×0.67)
(0.59
(right side)
67 Center of rear bumper reinforcement mounting hole (lower) Round 15 (0.59)
57
60, 61
61
60
AB700850
AB
58
62, 63
63
AB601054
62
AC
59
AB601056
64, 65
65
64
×17
AC
66, 67
66
67
AB601055
AB700992
AC
AB
TSB Revision
AB700446
AB
AB700447
AB
Page 56
2-22
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
INTERIOR
1,430
(56.3)
Body center point
68
1,357
(53.4)
43
1,430
(56.3)
1,430
(56.3)
42
1,179
(46.4)
42
45
1,190
(46.9)
1,375
(54.1)
44
1,135
(44.7)
44
47
1,059
(41.7)
1,171
(46.1)
1,430
(56.3)
1,430
(56.3)
46
46
49
1,330
(52.4)
1,130
(44.5)
1,190
(46.9)
48
48
50
51
50
Body center point
M4020009001230
mm (in)
AB700461
AB
69
Body center point
69
70
43
1,004
(39.5)
1,073
(42.2)
834
(32.8)
59
1,067
(42.0)
71
735
(28.9)
47
45
Body center point
593
(23.3)
1,076
(42.4)
720
(28.3)
720
(28.3)
783
(30.8)
49
659
(25.9)
51
AB700600
AB
TSB Revision
AB700462
AB
Page 57
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
2-23
No. Standard measurement point Hole shape Size mm (in)
42 Front pillar positioning notch (upper)
43 Front pillar positioning notch (lower)
− −
− −
44 Roof side rail positioning notch (front)
45 Side sill positioning notch (front)
46 Center pillar positioning notch (upper)
47 Center pillar positioning notch (lower)
48 Roof side rail positioning notch (rear)
49 Side sill positioning notch (rear)
50 Quarter panel positioning notch (upper)
51 Quarter panel positioning notch (lower)
59 Body center point of rear shelf panel
− −
− −
− −
− −
− −
− −
− −
− −
− −
68 Center of parking brake lever mounting hole (Body center point) Round 11 (0.4 3 )
69 Body center point of rear floor extension
− −
70 Center of rear shock absorber mounting hole Round 14 (0.55)
71 Center of rear end trim mounting hole Round 8.5 (0.335)
42
43
44, 46
45
AB601025
AB601028
AC
AC
47
AB700598
AB601030
AB
AC
48
44
46
AB601027
AB601031
AC
AC
TSB Revision
Page 58
2-24
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
49
59
AB700485
AB601056
AB
AC
50
68
AB601033
AB601063
AC
AC
51
69
AB700858
AB700463
AB
AB
70
AB700464
AB
71
AB700465
AB
TSB Revision
Page 59
72
73
140
(5.5)
BODY DIMENSIONS
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS)
1,401
(55.2)
1,392
(54.8)
1,392
(54.8)
1,397
(55.0)
130
(5.1)
2-25
mm (in)
74
75
AB600984
AE
No. Standard measurement point Hole shape Size mm (in)
72 Center of deck crossmember mounting hole (left-upper) Round 13 (0.51)
73 Center of deck crossmember mounting hole (left-lower) Round 13 (0.51)
74 Center of deck crossmember mounting hole (right-upper) Round 9 (0.35)
75 Center of deck crossmember mounting hole (right-lower) Round 9 (0.35)
72, 73
72
74, 75
74
73
75
AB601067
AC
AB601066
AC
TSB Revision
Page 60
NOTES
Page 61
GROUP 9
BASE OF BODY
REPAIR
CONTENTS
9-1
GENERAL . . . . . . . . . . . . . . . . . . . . . 9-2
WELDING. . . . . . . . . . . . . . . . . . . . . . 9-2
WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
ELECTRIC RESISTANCE SPOT
WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
GAS SHIELD ARC WELDING . . . . . . . . . . 9-8
OTHER TYPES OF WELDING . . . . . . . . . . 9-12
BODY REPAIR. . . . . . . . . . . . . . . . . . 9-14
STANDARD BODY REPAIR
PROCEDURES. . . . . . . . . . . . . . . . . . . . . . 9-14
THEFT PROTECTION . . . . . . . . . . . . . . . . 9-23
ATTACHMENT OF SILENCERS . . . . . . . . 9-24
POSITIONING DIMENSIONS FOR
OPENINGS . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
STANDARD PROCEDURES FOR
SHEET METAL WORK . . . . . . . . . . . . . . . . 9-26
USING A FRAME STRAIGHTENER . . . . . . 9-27
FRAME REPAIR PROCEDURES . . . . . . . . 9-28
NOTES REGARDING REPAIR WORK . . . . 9-31
HEAT-WITHSTAND TEMPERATURES
OF RESIN-PLASTIC PARTS . . . . . . . . . . . 9-34
HOW TO DISTINGUISH TYPES OF
PLASTICS . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
CORROSION PROTECTION . . . . . . . 9-37
ANTICORROSION TREATMENT AT
THE FACTORY . . . . . . . . . . . . . . . . . . . . . . 9-37
ANTICORROSION TREATMENT AT
THE TIME OF BODY REPAIR WORK . . . . 9-40
REPAIR OF SYNTHETIC-RESIN
PARTS . . . . . . . . . . . . . . . . . . . . . . . . 9-43
SYNTHETIC-RESIN PARTS REPAIR
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 9-43
Page 62
9-2
BASE OF BODY REPAIR
GENERAL
GENERAL
Group 9 is applicable for all models.
WELDING
WELDING
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 fol
lowing methods.
Fusion methods Shielded arc welding
Temperature: 1,130 – 1,550˚C
(2,066 – 2,822˚F)
Welding methods
Pressure methods
[Temperature approximatery 1,500˚C (2,732˚F) or higher at weld area]
Brazing methods Brazing
M4090000100018
M4090001000058
-
CO
2
gas arc welding
Gas welding
Electric resistance spot welding
–
Temperature: 620
(1,148 – 1,742˚F)
950˚C
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.
Soldering
–
Temperature: 183
310˚C
(361 – 590˚F)
AB301447
AB
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.
TSB Revision
Page 63
BASE OF BODY REPAIR
WELDING
9-3
ELECTRIC RESISTANCE SPOT WELDING
Electric resistance spot welding is a method for fusing metal parts together. Two or three metal sheets
are positioned between two copper-alloy electrode
tips, and pressure and a large current are then
applied, thus causing the contacting surfaces to heat
up and fuse together because of the electric contact
resistance.
.
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.
M4090002000040
ADVANTAGES OF ELECTRIC
RESISTANCE SPOT WELDING
• Because the time required for welding at each
point is brief, the work can be done quickly and at
reduced cost.
• Because both metals are fused and pressure
applied to make the weld, the strength and reli
ability 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.
-
AB200026
AB200027
AB200028
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.
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.
.
TSB Revision
Page 64
9-4
NUGGET FORMATION
BASE OF BODY REPAIR
WELDING
Cooling water
More than
1.6 mm
(0.063 in)
B'
B
A'
Weak ← Shear strength per point → Strong
A
Small ← Welding current → Large
1.6 mm (0.063 in)
or less
C Is The Scatter Point
C
C'
D'
Elect-
D
rode
Steel
panel
Nugget
Electrode
Cooling water
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 rap
idly (between points A and B).
Melting point
Water
temperature
Max. Heating temperature
540
(1,000)
1,095
(2,000)
1,650˚C
(3,000)˚F
AB301468
As the current level increases further, the weld
strength for thick panels [more than 1.6 mm (0.063
inch)] continues to increase proportionately (between
points B and C); however, for thin panels [1.6 mm
(0.063 inch) or less], the weld strength reaches a
peak very quickly and will increase only slightly, even
if the current level increases (between points B' and
C').
Then, for both thick panels and thin panels, the molten metal will scatter if the current level increases
past a certain point.
AD
.
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Page 65
NOTES REGARDING WELDING
D
Dt::Diameter of the electrode tip
Thickness of the panel
BASE OF BODY REPAIR
WELDING
t
9-5
90 – 120˚
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 alwa ys k eep the end of t ip i n t he c or re ct
shape, use a tip cutter, file or similar tool to
shape it if it becomes worn.
2. Alignment of the electrode tips
• Adjust the arms so that the upper and lower
electrode tips are in a straight line.
3. Alignment and length of the arms
• Adjust the electrode tips so that the upper and
lower arms are parallel.
• Select an appropriate arm length. Note, however, that the arm length should not be more
than 350 mm (13.8 inches) in order to ensure
nugget strength.
4. The weld points
• The overall strength will increase as the pitch
decreases; however, if the pitch decreases
too much, the current will be short-circuit
diverted to the previous weld point and the
strength of the individual nuggets will be insuf
ficient.
AB301455
• Make the spot welds at the center of the
flanges to provide sufficient adhesion. When
welding at an edge, make the spot welds at
least 5 mm (0.2 inch) from the edge of the
flange.
• The number of spot weld points should be the
same as, or slightly more than the number of
original repair welds.
• When spot welding three or more panels
together, if painted surfaces cause a loss of
conductivity, make the welds at the same
places as the factory welds. If this is done,
extra welds will not be necessary, but if extra
welds are necessary, switch to plug welding.
.
WELDING REQUIREMENTS
Standard steel plate (SPCC, etc.)
CAUTION
If the total thickness of the plates at the weld
places is 3 mm (0.12 inch) or more, use plug
welding, because spot welding will not provide
sufficient welded strength.
Example
• Center pillar (outer): plate thickness 1.4 mm
(0.055 inch), material SPCC
• Center pillar (inner): plate thickness 1.5 mm
(0.059 inch), material SPCC
AE
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Page 66
9-6
BASE OF BODY REPAIR
The number of weld points are as below when the
outer and inner center pillars are repaired by weld
ing.
WELDING
-
Factory welds (F)
8 Points 8 Points
As shown by the Welding Requirements table, the number of repair welds is as follows.
8 (points) × 130 (%) = 10.4 (points)
The number of weld points should, therefore, be ten or eleven.
If, however, a pitch of 26 mm (1.02 inch) or more cannot be maintained, the plug
welding method (eight weld points) should be used.
11 Points 11 Points
Repair welds (R)
AB200031
AE
Panel
Number of repair weld (percentage of factory weld)
thickness*
[mm (in)]
Safety
equipment
area
1.0 (0.04) or
less
1.2 (0.047) 150% Maintain pitch of at least 22 mm (0.87 inch); if not possible, plug weld.
1.4 (0.055) or
100% Same number as factory welds
100% Same number as factory welds; plug welding
more
Other
area
1.2 (0.047) or
less
100% Same number as factory welds
1.4 (0.055) 130% Maintain pitch of at least 26 mm (1.02 inch); if not possible, plug weld.
1.6 (0.063) or
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.
.
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Page 67
BASE OF BODY REPAIR
GALVANIZED STEEL PLATE (SECC)
CAUTION
If the total thickness of the plates at the weld
places is 3 mm (0.12 inch) or more, use plug
welding, because spot welding will not provide
sufficient welded strength.
WELDING
9-7
Panel
Number of repair weld (percentage of factory weld)
thickness*
[mm (in)]
Safety
equipment
area
0.9 (0.035 or
less
1.0 (0.04) 200% Maintain pitch of at least 18 mm (0.71 inch); if not possible, plug weld.
1.2 (0.047) or
100% Same number as factory welds
100% Same number as factory welds; plug welding
more
Other area
0.9 (0.035) or
100% Same number as factory welds
less
1.0 (0.04) 140% Maintain pitch of at least 18 mm (0.71 inch); if not possible, plug weld.
1.2 (0.047) or
100% Same number as factory welds; plug welding
more
NOTE: *: For welding steel plates of different thicknesses, conform to the welding conditions for the thinner
plate.
.
USING A TEST PIECE TO CHECK NUGGET
FORMATION
Weld 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
WELD POINT
1
2
3
AB200032
AB
diameter.
Using the weld point as an axis, apply force in the direction indicated by the arrows in the illustration, and determine the
strength of the weld.
1. Good (The welded part remains at one side).
2. and 3.
The weld conditions are unsatisfactory; adjust the welding
current, the current application time, and/or the applied
pressure.
.
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Page 68
9-8
3 mm (0.12 in)
AB200033
AB200033
AC
BASE OF BODY REPAIR
WELDING
CHECKING NUGGET STRENGTH FOLLOWING
SPOT WELDING
CAUTION
• Stop wedging the tip or the chisel or flat-tipped screwdriver as soon as the size of the nuggets can be determined; do not wedge it in more than 30 mm (1.18
inches).
• After checking the nugget diameter, correct the place
where the checking was done.
Wedge the tip of a chisel or flat-tipped (-) screwdriver into the
space between two weld points.
• The nuggets should not break apart.
• The nugget diameter should be 3 mm (0.12 inch) or more.
GAS SHIELD ARC WELDING
Shield gas
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
M4090003000043
Wire
Nozzle
Contact tip
Metal vapor
AB301456
AB301456
AD
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 (CO
) gas shielded
2
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.
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Page 69
MIG SPOT WELDING
BASE OF BODY REPAIR
WELDING
Wire
9-9
Gas cup
Gas outlet
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 par
tial melting is done to obtain a spot weld.
.
Procedure
CAUTION
• Make sure that the area to be welded is perfectly clean; remove oxidation film, scales,
rust, dirt, etc.
• The two panels to be welded must be in perfect contact with each other.
1. Position the tip of the nozzle at a right angle to the
surface to be welded.
2. Being sure that the two prongs are not leaning to
either side, set them in direct contact with the
panel to the welded.
3. Welding will begin when the torch trigger is
squeezed, and will stop automatically when the
weld is complete.
.
FEATURES OF MIG SPOT WELDING
In comparison to resistance spot welding, MIG spot
welding has the following advantages and disadvan
tages.
• The number and pitch of the weld points
should be approximately the same as for the
factory welds.
Item Mig spot welding Electric resistance spot welding
Working
characteristics
• Light weight
• Welding possible at various
positions (no limit upon welding
positions)
• Although the torch with separate
transformer is lightweight, the torch
combined with transformer type is heavy.
• The arm must be exchanged to conform
to the weld location.
Weld time/point Slow (0.5 second or more) Fast (0.5 second or less)
AB200036
AE
-
Treatment after
welding
Necessary (grinding by grinder,
etc.)
Power High voltage, low current
(15 − 30 V, 50 − 200 A)
Flux material • CO2 (carbonic acid gas)
• Weld wire
Weld points/10
minutes
(rate of use)
Distortion caused by
• 25 points or less
• Arc instability and contact tip
burn if rate of use is exceeded.
Occurs easily Rare
welding
TSB Revision
Unnecessary
Low voltage, high current
(2 − 4 V, 4 − 10 kA)
Unnecessary
• 50 − 60 points
• Welding rod deformation and transformer
overheating if rate of use is exceeded.
Page 70
9-10
BASE OF BODY REPAIR
WELDING
Item Mig spot welding Electric resistance spot welding
Welding strength Depends on strength of welding
wire itself.
• Same as base material
• Little oxidation
• Uniform welding quality
Weld traces Button head (slightly convex) Slight concave
(Almost no indentation if swivel tip
used.)
Swivel tip
Re-repairability
(cutting away welded
area)
Torch
Perfect
contact
Difficult
(Much welding trace High hardness
of weld points)
.
The MIG welding done around the doors, wheelhouse arches,
etc., to prevent the flanges from coming undone after hemming
work is also called MIG spot welding.
AB200038
AB
PLUG WELDING
CAUTION
In order to prevent the formation of blowholes, fill in each
5 – 6 mm
(0.2 – 0.24 in)
Diameter
hole
hole completely in one pass.Be sure that the two panels
are in perfect contact.Be sure that the penetration goes all
the way to the bottom panel.
Plug welding is done by making holes 5 − 6 mm (0.2−0.24 inch)
in diameter in one of the panels to be welded together, position
ing the torch at a right angle to the holes and then filling in the
holes one at a time.
AB200037
Easy
(Can be separated by spot cutter.)
AD
-
AB301460
AD
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Page 71
15 – 30˚ 15 – 30˚
AB200041
BASE OF BODY REPAIR
WELDING
CONTINUOUS WELDING
There are several types of continuous welding: fillet (lap joint)
welding, butt welding, T joint welding, gap welding, etc.; these
are called short-circuit arc welding, and provide a stable arc at
a relatively low current.
.
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.
The angle of the torch should be 15 − 30 degree angle for
either technique, and the tip should be maintained at a distance
of 6
− 10 mm (0.24 − 0.39 inch) from the surface being welded.
9-11
Forehand
technique
Anti-Warp Welding Techniques
54321
1.
Backhand technique
4321
2.
Symmetrical technique
3.
"Stepping stone" technique
Backhand
technique
AB301457
54321
AB200043
AD
AD
.
Preventing warping
1. Backhand technique
Because the direction for each weld pass and that for the
fusion progression are opposite, the residual stress is
evenly distributed.
2. Symmetrical technique
Because the welds are made in symmetrical positions in
relation to the center of the joint, the residual stress is also
symmetrical.
3. "Stepping stone" technique
Because the welds are made at random positions, the
residual stress is the most evenly distributed; however, the
possibility of flaws at the starting and stopping points is rela
tively high.
-
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Page 72
9-12
BASE OF BODY REPAIR
WELDING
NOTES REGARDING MIG WELDING
Note the following notes regarding MIG welding.
1. The surface to be welded must be perfectly
clean; be sure to remove any non-conductive
paint.
2. If the end of the wire forms into a ball, it will
adversely affect the formation of the arc; cut the
end off with a pair of wire snips or a similar tool.
OTHER TYPES OF WELDING
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 mol
ten 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 dif
ferent 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 fol
lowing materials (filler metals) are usually used for
brazing.
-
3. Select a welding current to match the thickness of
the panels being welded.
4. For continuous welding, maintain a constant weld
speed and keep both the height and the width of
the bead constant.
In addition, the tack welding pitch and the welding
bead should be shorter as the thickness of the
panels being welded decreases.
M4090004000046
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
1,922
°F), and it is the most commonly used braz-
-
ing filler metal used for body repair.
− 1,050°C (1,562 −
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 alumi
num, magnesium, and others with low melting
points.
-
Notes with regard to brazing work
Examples of brazed joints
• Use a wire brush, sandpaper, file etc., to remove
any oxide film grease, dirt, etc., from the surfaces
of the panels to be brazed.
AB200044
AF
• When doing brass brazing, if the panels and the
filler metal are heated excessively, a weak
iron-copper alloy will form, which could crack
easily. Be careful not to apply excessive heat.
• The joint of the panels must overlap as indicated
in the illustration.
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Page 73
Welding
rod
Oxy-acetylene
flame
Deposite
BASE OF BODY REPAIR
WELDING
GAS WELDING
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 tempera
ture 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.
9-13
-
Base metal
.
AB200049
AD
The flame in gas welding can be classified according
to the ratio of acetylene and oxygen.
1. Carburizing flame
Acetylene cone
Flame core
Outer flame
2. Standard flame
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 rela
tively 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 black
ish-purplish color. The combustion is unstable,
and the flame flickers continuously.
3. Peroxide flame
.
Flame core
Outer flame
Outer flame
Flame core
AB200050
AE
Notes with regard to gas welding
1. Handle the oxygen and acetylene tanks carefully.
2. Adjust the flame in accordance with the type of
metal being welded.
3. Select a nozzle to match the work to be done.
Avoid overheating and adhesion of foreign matter
(dirt, etc.)
4. The following points are particularly important
when welding mild steel plate.
• Melt a sufficient amount of welding rod, but be
careful not to melt the base metal. Use the
same amount of welding rod on both sides.
• Use the correct amount of welding rod in
accordance with the melting point of the base
metal.
• Avoid welding over places which have been
welded before.
• In order to avoid warping, do only the amount
of tack welding that is absolutely required.
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Page 74
9-14
BASE OF BODY REPAIR
BODY REPAIR
BODY REPAIR
STANDARD BODY REPAIR PROCEDURES
The following is an explanation of the standard repair
procedures for the monocoque body and the
frame-type body. Furthermore, please refer to the
replacement of welded panels for the applicable
model for information concerning the procedures for
replacement of panels (as classified by position) for
the various models.
NOTE: That reference should be made to page
P.9-27 concerning repair procedures for the frame of
frame-type vehicles.
.
CAUTION
• Select an appropriate location for the cutting operation,
and perform the work carefully, so as not to cut into the
reinforcements located inside the pillars, panels which
are not be replaced, or any other such parts.
• There are harnesses, hoses, and other such parts
routed inside the front pillar, the rear pillar, the fender
shield, the side sill, etc.; perform the repair work only
after any such material has been removed.
• For overlap cutting, allow an overlap of approximately
AB200051
30
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.
M4090006000075
STANDARD PROCEDURES FOR
REPLACEMENT OF WELDED PANELS
In order to maintain the proper levels of strength,
rigidity, and precision when making welded panel
replacements, it is essential to first gain a thorough
understanding of the body structure, and then to per
form all repair operations carefully and correctly. In
addition, when performing the operations, be sure to
use the proper protective equipment for each opera
tion.
− 50 mm (1.18 − 1.97 inches) when performing the
-
-
AB200052
AB200053
TSB Revision
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.
Page 75
AB200054
BASE OF BODY REPAIR
BODY REPAIR
NOTE: If a replacement panel is to be mounted by doing
plug welding from the side of the panel remaining on the
body, either a hole can be made in the panel on the body, or
a hole can be made right through both the panel which is to
remain on the body and the panel to be replaced.
CAUTION
When performing this operation, warping of the surrounding panels may occur if an excessive amount of heat is
applied; therefore, be careful to avoid doing this.
4. Breaking of brazing and arc welds
Heat only the brazed or arc welded portion (such as the
upper portion of pillars, etc.), and then separate by using a
screwdriver while melting occurs.
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).
9-15
AB200055
AB200056
AB200057
6. Making of holes in new parts for MIG plug welding
Make holes approximately 5 − 6 mm (0.2 − 0.24 inch) in
diameter at points where plug welding is to be performed
because spot welding is not possible.
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Page 76
9-16
BASE OF BODY REPAIR
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.
AB200058
CAUTION
Do not use a flame for paint coat removal because doing
so might damage the paint coat of panels which are not to
be replaced, thus causing corrosion.
8. Removal of the paint coat from new parts and from the
vehicle body
In order to provide for the proper flow of electric current
during spot welding operations, remove the paint coat from
both sides of the new part and the body by using a polisher
wheel or similar tool.
AB200059
Edge of the
new part
Edge of the
panel on the body
AB200060
AB200061
AD
9. Rough cutting of new parts
Cut off the unnecessary portions of new parts. Allow an
overlap of approximately 30
− 50 mm (1.18 − 1.97 inches)
when performing overlap cutting of the pillars, side sills, or
other locations.
CAUTION
Carefully select the location for cutting, taking care not to
cut a reinforcement at the inner side of a pillar, etc. or a
panel that is not to be replaced.
10.Overlap cutting of new parts
For locations in which butt welding is to be done, first
temporarily attach the new parts to the body, and then cut
the two panels simultaneously.
NOTE: If a reinforcement or a panel which is not to be
replaced is cut accidentally, first repair the mistake by weld
ing before proceeding with the rest of the work.
-
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Page 77
Twolayer construction
Inner panel
Approx. 50 mm
Outer panel
(1.97in)
BASE OF BODY REPAIR
BODY REPAIR
CAUTION
Perform the operations carefully so that the cut ends fit
together properly.
11.Cutting of new parts by using a measurement marking
If overlap cutting is not possible in a place where butt
welding is to be done, make a measurement marking on the
new part at the exact same measurement which was used
for the cutting of the body panel, and then cut the new part
by using this measurement marking.
• Two-layer construction
When cutting a front pillar or center pillar which has a
two-layer construction but no reinforcement, make the cut
ting of the inner panel and that of the outer panel approximately 50 mm (1.97 inches) apart in order to obtain
maximum strength.
9-17
-
Three-layer construction
Inner panel
cut line
Outer panel
and reinforcement cut line
Inner panel cut line
AB200062
Inner panel
AB200063
AB200064
AD
AD
• Three-layer construction
When cutting a front pillar or center pillar which has a
three-layer (including a reinforcement) construction (dou
ble-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 replace
ment 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.
-
-
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Page 78
9-18
AB200065
BASE OF BODY REPAIR
BODY REPAIR
CAUTION
During temporary mounting, it is extremely important to
obtain accurate measurements for each component. The
mounting positions for the front and rear suspensions are
especially crucial with regard to safety; therefore, it is nec
essary that all work concerning these areas be done carefully and correctly.
13.Temp orary moun ting of new pa rts
(1) In order to bring the new parts into the proper mounting
position, measure each part carefully and make any
corrections necessary in order to obtain agreement with
the measurements.
(2) In addition, make temporary welds, and then check to
confirm that the closing and fit of the doors, fenders, etc.,
are correct.
For parts which should be symmetrical to the body
center, measure the distances from the body center point
to both the left part and the right part, and confirm that the
distances are the same.
-
AB200066
AB200067
CAUTION
Weld completely so that there are no pinholes.
14.Butt welding
For burr welding, make a 10 − 15 mm (0.39 − 0.59 inch) MIG
spot weld, and then, in order to prevent warping which might
be caused by the welding heat, complete the welding by
making welds of the specified width at alternate positions.
AB200068
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Page 79
AB200070
AB200070
BASE OF BODY REPAIR
BODY REPAIR
15.Spot welding
When doing spot welding, it is not only important to correctly
position the electrode tips, but also to hold the two panels
securely together with vise-grip pliers or some other type of
clamps, being sure that they are in perfect contact with each
other.
• Be sure that the force applied by the arm is sufficient.
• Use a test piece to check the secondary current and the
current application time of the spot welder, and adjust the
values as appropriate.
16.Plug welding
If spot welds cannot be made, make holes for plug welding
in the new parts, and then MIG weld. Because the quality of
the fusion varies according to the size of the holes, they
should be about 5
− 6 mm (0.2 − 0.24 inch) in diameter. In
addition, be sure the two surfaces are in complete contact
with each other by using vise-grip pliers to securely hold
them.
NOTE: Depending on the working conditions, it might also
be necessary to make holes in the panel remaining on the
body
9-19
AB401282
AB401282
Hemming tool
17.Hemming (Adhesion type)
(1) Apply an adhesive to the area to be hemmed of the door
outer panel.
Section
A – A
A
A
AB500010
AB500010
AD
(2) For the area to be hemmed of the door outer panel, apply
an adhesive and smooth the panel with a hammer and a
dolly. Then, hem the panel with a hemming tool.
AB200072
AD
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9-20
Hemming tool
BASE OF BODY REPAIR
BODY REPAIR
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.
AB200072
AB200073
AD
(2) After completing the hemming work, make MIG spot
welds at 50
− 60 mm (1.97 − 2.36 inches) intervals on the
inside.
CAUTION
Be sure not to grind the panel down too much. Before
welding the outer panel, be sure to apply an anticorrosion
agent.
19.Finishing work for butt welding and plug welding
Do the finishing work to smooth the protruding weld traces.
However, the butt joints of reinforcements and other internal
parts will be stronger if the weld traces are not finished.
AB200074
AB200076
TSB Revision
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.
Page 81
AB200077
BASE OF BODY REPAIR
BODY REPAIR
CAUTION
Wipe off any anticorrosion agent which oozes out onto
surfaces to be painted later; the presence of such anticor
rosion 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.
9-21
-
AB200078
AB200079
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).
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9-22
BASE OF BODY REPAIR
BODY REPAIR
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 neces
sary 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 danger
ous 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 care
fully 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.
-
• 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.
.
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BASE OF BODY REPAIR
BODY REPAIR
9-23
Theft protection label
For original parts
For replacement parts
AC211646
AD
THEFT PROTECTION
M4090007000067
In order to prevent theft, following Vehicle Identification Number
(VIN) has been engraved and attached, in the form of a label to
the engine, transaxle, and main of the outer body:
Engine cylinder block, Transaxle housing, Fender,
Doors, Quarter panel, Hood, Liftgate, Trunk lid,
Bumpers
Furthermore, supplementary parts for the main portions of the
outer body have theft protection labels attached and the sup
plementary parts for the engine and the transaxle are engraved
with the same details.
PANEL REPAIR CAUTION
Knife
Masking film
1. Take care when respraying the original part to cover the theft
protection label with masking tape prior to respraying. In
addition, remember to peel off the masking tape after
completion of the respray.
2. Because theft protection labels on the supplementary parts
are covered with masking tape already, they can be
resprayed just as they are.
3. Take care not to peel off the theft protection labels from
either the original or the supplementary parts.
HOW TO PEEL OFF THE SURFACE MASKING
FILM FROM THE THEFT-PROTECTION LABEL
CAUTION
Be careful not to damage the paint surface or the label
itself.
1. Using a sharp knife at the corner of the label surface, lift up
the masking film only.
2. Grasp the masking film and peel it all off.
NOTE: If the masking film tears, repeat from step 1. Use the
knife, however, to lift the opposite corner of the label, rather
than trying to continue peeling from the place where it tore.
AB200080
AD
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9-24
BASE OF BODY REPAIR
BODY REPAIR
ATTACHME N T OF SILENCERS
M4090009000052
Dash panel interior side
:
Thickness: 1.6 mm (0.063 in)
:
Thickness: 3.2 mm (0.126 in) (two 1.6 mm (0.063 in) silencers overlapped)
Silencers (petroleum-asphalt sheets) are attached to
the upper surface of the floor and at the interior side
of the dash panel in order to absorb vibrations and
shut out exhaust gas heat. If these silencers are
peeled off in the course of replacement or repair of a
1. Heat the "silencer layer" (petroleum-asphalt sheet) with a
blow drier to soften it.
AB200098
AB200097
AD
welded panel, cut and attach replacement material
(in the shape shown in the figure). For detailed infor
mation concerning the locations where silencers are
to be attached for individual models, refer to the
manual for that model.
-
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Page 85
AB200099
BASE OF BODY REPAIR
BODY REPAIR
2. Align the silencer layer in the position where it is to be
installed, and then press it down with a roller or a block of
wood so that it adheres well.
NOTE: An infrared light can also be used to heat both the
silencer layer and the body panels (be sure to wear gloves).
9-25
POSITIONING DIMENSIONS FOR OPENINGS
Porta power
M4090010000045
AB200100
AD
When replacing the panel of the opening of the front
pillar, center pillar and other openings, make a point
to securely bite the poltapower, etc. so the position of
the opening is not off-center. Upon assembling,
adjust the opening dimensions to the standard speci
fications and then weld.
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-
Page 86
9-26
BASE OF BODY REPAIR
BODY REPAIR
STANDARD PROCEDURES FOR SHEET METAL WORK
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)
.
1. Check whether or not there is foreign material (mud, etc.) on
the panel surface. If so, clean it away.
CAUTION
The surface of the hammer and dolly must be free of scars,
etc.
2. Select the appropriate hammer and dolly to be used
according to the panel shape.
CAUTION
Care should be taken, as far as possible, not to permit the
panel plates to become elongated.
3. Use the hammer and dolly to repair the dents and other
uneven surfaces of the panel.
(1) First repair the larger areas of damage so that they are as
close as possible to the original condition before the
damage occurred.
(2) Next repair the areas of moderate damage.
(3) Finally, smooth the surface out.
M4090012000030
(2)
(3)
AB200101
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AB200102
BASE OF BODY REPAIR
BODY REPAIR
CAUTION
• Be careful not to file too much; this will reduce the
strength and rigidity of the panel.
• Do not use the file in one direction only; alternate use
in two directions diagonally opposite each other.
4. Next, file the area so that convex and concave parts are no
longer clearly visible, and at the same time remove small
projections.
5. After once again smoothing the clearly visible dents and
projections by using the hammer and dolly, follow step 4
above.
Alternately repeat hammering and filing until there are file
traces over the entire repair area.
6. Make a solder build-up at the repair.
7. Finally, finish up the solder build-up using a body file.
9-27
USING A FRAME STRAIGHTENER
For serious and extensive damage, when for example the damage extends to the frame of members, it
is necessary to first use a frame straightener to make
a rough, overall repair of the body, and then to pro
ceed 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 compo
nents 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.
M4090013000044
3. Finally, determine what repair methods should be
used.
• To wh at ext ent wi ll fra me str ai gh t eni ng and ot her
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 direc
tion. More than one direction may be appropriate,
depending upon the damage.
If the damage is of a moderate degree or less, it may
be possible to do all that is necessary in one pull.
If, however, the damage is major, that is to say if
repairs must be made to components of the passenger compartment such as the dash panel, etc., it may
be necessary, after completing the first pull, to set up
the frame straightener at a different position and use
it again at that position.
-
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9-28
Wires for
protection
AB200103
AD
BASE OF BODY REPAIR
BODY REPAIR
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 rub
ber pieces are used at the installation part in order to
improve vibration prevention, and these mounting rubber
pieces might be deformed if there is a deviation of the
installation position.
• If the part to be pulled is made of high-tensile steel (which
has a higher tensional strength and yield point than ordinary
steel), the pulling must be done with care in order to avoid
"over pull" and "spring back". It is particularly important for
the pulling of sidemembers and other reinforcement compo
nents made of high-tensile steel that the pulling not be all
done at one time; pull gradually while using a hammer to
repair distorted areas as the pulling is done.
-
-
FRAME REPAIR PROCEDURES
The frame is subjected to the following types of
loads.
• Vertical loads: Vertical loads may occur either
while stopped or during travel.
• Lateral (horizontal) loads: This type of loads
occurs during turning, start-off and braking.
• Tor sion al l oads : Tor sion al l oads occ ur w hil e tr av eling on roads with poor surface conditions.
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.
Sidemember
Test hammer
AB200127
AD
M4090014000047
These various types of loads are compounded under
various conditions, and are applied to the frame.
As a result, it is important, before attempting to repair
the frame, to carefully observe the shape of the dam
aged part and to in that way fully understand the
cause of the damage.
-
REPAIRING CRACKS
If the check reveals a crack(s) in the frame, repair as described
bellow.
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BASE OF BODY REPAIR
BODY REPAIR
9-29
Crack-stop hole
A
Crack
Ø6 – 8 mm
(0.24 – 0.31 in)
A : 7 – 8 mm (0.28 – 0.31 in)
Ø10 – 12 mm
(0.39 – 0.47 in)
Crack
A
AB301469
Ø10 – 12 mm
(0.39
Ø6
– 8 mm
– 0.31 in)
(0.24
AB301470
AB301470
Crack-stop
hole
AD
– 0.47 in)
AB
AC
1. Remove the components near the crack.
2. Make φ 6 − 8 mm (0.24 − 0.31 inch) holes (to prevent further
cracking), by using a drill, at points 7
− 8 mm (0.28 − 0.31
inch) from the crack ends.
3. Use a φ 10 − 12 mm (0.39 − 0.47 inch) drill to bevel the hole
openings.
4. Use a chisel or gouging tool to open up the crack and holes,
and then fill the crack and holes by MIG welding.
Approx.
1 mm
(0.04 in)
A
A
Approx.
90˚
If a chisel
is used
A
Approx.
8 mm
(0.31 in)
If a gouge
is used
AA
Approx.
1 mm
(0.04 in)
AB301471
AB200131
AD
AB
CAUTION
• Gas welding should be avoided because it causes thermal distortion of the frame.
• When using a grinder for finishing, be careful not to
grind the frame excessively.
5. Using a grinder for finishing after welding.
CAUTION
• The reinforcement plate should completely cover the
cracked part.
• The reinforcement plate should be the same thickness
and material as the frame.
6. To avoid a concentration of stress, prepare a reinforcement
plate that has been cut to 30
− 45 degree angle at both
ends.
A : 30 – 45˚
AB301461
AB
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9-30
10 mm (0.39 in)
(2)
Welded point
AB200133
AB200133
(1)
BASE OF BODY REPAIR
BODY REPAIR
CAUTION
Be sure that the edges of the reinforcement plate are not
near any place where a concentration of stress of the
crossmember or spring hanger installation part, etc. could
easily occur.
7. Attach the reinforcement plate to the repaired crack area by
MIG welding. In order to avoid a concentration of stress at
the time, weld the reinforcement plate at points about 10 mm
(0.39 inch) from its edges.
AD
AB200134AB200134
AB
NOTE: If the crack is at the upper side of the frame, attach
the reinforcement plate facing downward, as shown in (1).
If the crack is at the lower side, attach the reinforcement
plate to face upward, as shown in (2).
8. Finally, apply a coating of chassis black to the repaired area
and to any places where the coating has flaked off.
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BASE OF BODY REPAIR
BODY REPAIR
9-31
NOTES REGARDING REPAIR WORK
M4090015000039
SAFETY MEASURES
.
1
4
7
9
23
5
10
6
8
11
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
9. Foot and ankle protectors
10. Safety shoes
11. Work glo v es
AB200104
.
SUPPLEMENTAL RESTRAINT SYSTEM
(SRS)
1. Items to review when servicing SRS
(1) Be sure to read Service Manual GROUP 52B,
Supplemental Restraint System (SRS). For
safe operation, please follow the directions
and heed all warnings.
(2) Wait at least 60 seconds after disconnecting
the battery cable before doing any further
work. The SRS system is designed to retain
enough voltage to deploy the air bag even
after the battery has been disconnected.
Serious injury may result from unintended air
bag deployment if work is done on the SRS
system immediately after the battery cable is
disconnected.
(3) Warning labels must be heeded when
servicing or handling SRS components.
(4) Always use the designated special tools and
test equipment.
(5) Store components removed from the SRS in a
clean and dry place. The air bag module
should be stored on a flat surface and placed
so that the pad surface is facing upward.
(6) Never attempt to disassemble or repair the
SRS components (SRS-ECU, air bag module
and clock spring). If there is a defect, replace
the defective part.
(7) Whenever you finish servicing the SRS, check
the SRS warning light operation to make sure
that the system functions properly.
(8) Be sure to deploy the air bag before disposing
of the air bag module or disposing of a vehicle
equipped with an air bag.
2. Observe the following when carrying out
operations on places where SRS components are
installed, including operations not directly related
to the SRS air bag.
(1) When removing or installing parts, do not allow
any impact or shock to occur to the SRS
components.
(2) If heat damage may occur during paint work,
remove the SRS-ECU, the air bag module,
clock spring, the front impact sensor, the side
impact sensor, and the seat belt pre-tensioner.
• SRS-ECU, air bag module, clock spring, front
impact sensor, the side impact sensor: 93
°F) or more
(200
°C
• Seat belt pre-tensioner: 90 °C (194 °F) or more
.
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9-32
AB200105
BASE OF BODY REPAIR
BODY REPAIR
SECURING THE VEHICLE
If the vehicle is raised on a jack, be sure to always support it
with jack stands positioned at the specified points.
.
CLEARING THE AREA OF FLAMMABLE
MATERIALS
Because of the presence of many various kinds of flammable
materials, organic solvents, etc., in the work area, there is
always the possibility of a fire or explosion. It is, therefore,
important to keep the work area as clear as possible of such
dangerous materials.
.
HANDLING ELECTRONIC PARTS AND
SEMICONDUCTORS
WARNING
Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER
HANDLING.
When the body is used as the ground during welding for body
repairs, be absolutely sure to first disconnect the battery's posi
tive (+) cable.
CAUTION
• Be sure that both the ignition and lighting switches are
"LOCK" (OFF) position before either disconnecting or
reconnecting a battery cable. (If this is not done, equip
ment 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, elec
tromagnetic 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 elec
tronic circuit is formed even when the switch is at OFF.
.
HANDLING COMBUSTIBLE MATERIALS
If welding work is to be done in the area of the fuel tank, the fuel
tank must be removed to prevent the generation of flammable
gases. Also be sure to cap the inlet port and the pipes of the
fuel tank after removal to prevent the escape of any fuel or
flammable gases.
Wipe up any fuel, oil, etc., spilled in the work area as soon as
possible.
Only the amounts of paint to be used for the day's work should
be in the work area; do not keep excessive amounts of paint, or
paint which is not going to be used, in the work area.
-
-
-
-
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BASE OF BODY REPAIR
BODY REPAIR
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 adhe-
sives, organic solvents, etc.
If an unavoidable exposure occurs, the exposed area
should be immediately washed with clean water.
VEHICLE PROTECTION
• Vehicle covers (fender covers, seat covers, etc.) and tape (if
there is the possibility of damage by tools, equipment, etc.)
should be used to protect painted surfaces, interior/exterior
parts and components, etc., from staining and damage.
9-33
AB200106
AB200107
• For welding operations, a heat-resistant protective cover
should be used to protect glass, seats, instrument panel,
carpeting, etc.
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9-34
BASE OF BODY REPAIR
BODY REPAIR
HEAT-WITHSTAND TEMPERATURES OF RESIN-PLASTIC PARTS
Because resin-plastic parts are deformed by heat,
they should be removed if the heat to be applied is
high enough to cause deformation, as shown by the
table below.
Material name Abbreviation Heat-deformation
temperature °C (°F)
Acrylonitrile
styrene acrylate
Acrylonitrile
butadiene styrene
Cellulose acetate CA 50 − 90 (122 − 194) -
Cellulose acetate
butylate
Polyamide PA 140 − 160 (284 − 320) Harness connector, Wheel cover,
Tal c f il le d
polyamide
Polybutylene
terephthalate
ASA 80 (176) Door mirror, Pillar garnish, License
ABS 80 (176) Air spoiler, Console box, Radiator grille,
CAB 60 − 100 (140 − 212) Door trim molding
PA-T D 190 − 200 (374 − 392) Hood garnish, Door outside handle
PBT 120 (248) Dome light lens, Headlight lens
Where mainly used
garnish, Radiator grille
Rear garnish, Headlight bezel
Cooling fan, Fuel strainer
M4090016000054
Polyethylene PE 100 (212) Heater duct, Fender liner, Washer tank
High density
polyethylene
Phenole
formaldehyde
Polymethyl
methacrylate
Polyacetal POM 120 (248) Door regulator handle, Ball joint seat
Polypropylene PP 80 (176) Glove compartment, Bumper face,
Polyphenylene
ether
Tal c f il le d
polypropylene
Tal c f il le d
polypropylene
(10%)
Tal c f il le d
polypropylene
(15%)
PE-HD (HDPE) 70 − 90 (158 − 194) Fuel tank, Splash shield
PF 170 − 190 (338 − 374) Ashtray
PMMA 80 − 100 (176 − 212) Light lens
Pillar trim, Steering wheel, Heater unit,
Cooling fan
PPE (PPO) 130 − 140 (266 − 284) Accelerator pedal pad, Wheel cover,
Speaker garnish
PP-TD (PPF) 100 (212) Front deck garnish, Stone guard, Floor
console, Instrument panel
PP-TD10 (PPF) 110 − 120 (230 − 248) Center pillar trim
PP-TD15 (PPF) 110 − 120 (230 − 248) Front pillar trim, Center pillar trim, Rear
pillar trim
Tal c f il le d
polypropylene
(20%)
Tal c f il le d
polypropylene
(30%)
PP-TD20 (PPF) 120 − 130 (248 − 266) Beltline trim, Front deck garnish, Front
pillar trim
PP-TD30 (PPF) 130 − 140 (266 − 284) Quarter trim, Rear side trim
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9-35
Material name Abbreviation Heat-deformation
temperature °C (°F)
Polyurethane PUR 80 − 100 (176 − 212) Bumper, Steering wheel
Polyurethane
(formed)
Glass fiber
reinforced RIM
urethane
Polyvinyl alcohol PVAL *1 -
Polyvinyl butyral PVB -
Polyvinyl chloride PVC 80 (176) Steering wheel, Side protector molding,
Thermoplastic
elastomer (olefine)
Urea formaldehyde UF 120 − 145 (248 − 293) -
Glass fiber
reinforced
unsaturated
polyester
Ethylene vinyl
acetate
Tal c f il le d
polypropylene
Polyvinyl chloride,
Polyurethane
Thermoplastic
elastomer
(styrene), Talc filled
polypropylene
PUR-E 80 − 100 (176 − 212) Seat cushion, Arm rest, Door trim,
PUR-GF [RIM] 100 − 120 (212 − 248) Air dam panel
TPO (TEO) 80 (176) Mud guard, Side air dam
UP-(GT + TD)
[SMC], [BMC]
E/VAC (EVA) 60 (140) Mud guard
PP + E/P-TD
[HMPP]
PVC, PUR-E *2 Instrument panel pad
TES, PP-TD 100 − 120 (212 − 248) Side splash
200 (392) Rear air spoiler
80 − 100 (176 − 212) Bumper face, Side air dam, Side
Where mainly used
Instrument panel
Shift lever cover, Window molding
protector molding
Polycarbonate +
Acrylonitrile
butadiene
Polycarbonate +
Polyethylene
terephthalate
Polycarbonate +
Polybutylene
terephthalate
Polyphenylene
ether + Polyamide
6
Polyphenylene
ether + Polyamide
66
Polyphenylene
ether + Polystyrene
PC + ABS 120 − 125 (248 − 257) Door outside handle
PC + PET 120 (248) Door outside handle
PC + PBT 130 − 140 (266 − 284) Door outside handle
PPE (PPO) + PA6 150 − 160 (302 − 320) Wheel cover
PPE (PPO) +
PA66
PPE (PPO) + PS 120 − 130 (248 − 266) Wheel cover
160 − 170 (320 − 338) Wheel cover
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9-36
NOTE: .
•
A slash (/) in the abbreviation indicates that two different materials make two-layer construction.
A plus sign (+) indicates that the two different materials mix each other.
•
If the new material symbols designated by the ISO differ form the old symbols, both are given, with the old
symbol being enclosed in brackets. ISO: International Organization for Standardization
•
*1: Temperature differs depending on the ratio of the materials included.
•
*2: Impossible to fix the temperature due to the multi-layer and foam material structure.
•
If an infra-red lamp is used for drying, use a heat-resistant cover, etc., to protect parts.
BASE OF BODY REPAIR
BODY REPAIR
HOW TO DISTINGUISH TYPES OF PLASTICS
There are various methods that can be employed to
determine types of plastics, among them (1) using a
chemical solvent, etc., to check it chemically, (2)
scratching the material to determine its make-up, (3)
cutting of a small piece (where the scar can't be
seen) and burning it to judge by the way it burns, etc.
The following is an outline of the burning method,
which is a relatively simple method.
Plastic name
Polyvinyl chloride PVC Yel lo w f l a m e t o p
Polyethylene PE Yel lo w f l a m e t o p
Polypropylene PP Yellow flame top
Polyurethane PUR Orange Crackles as burns;
Abbreviation
TRUR Orange
Flame color Combustion
Conditions
Burns to black residue Yes Irritating acid
Blue flame bottom
Burns cleanly while
Blue flame bottom
Blue flame bottom
melting
• Burns briskly and
drips
• Slight white smoke
drips
M4090017000035
Selfextinguishing
No Candle-like
No Petroleum-like
No Rubber odor
Odor
odor
odor
odor
Polycarbonate PC Yellow Cinders remain To so me
extent
Polyamide
(nylon)
Polyester resin UP Yel l o w Ashes remain No Styrene odor
Glass-fiber-reinfo
rced plastic
Phenol resin PF Yellow Ashes remain Ye s Formalin odor
ABS resin ABS Orange Burns accompanied by
PA Yellow flame top
Blue flame bottom
FRP Yellow Ashes with glass-fiber
Melts and drips Yes Strong formic
remnants remain
foaming and black
smoke
No Differs
No Rubber odor
Sweet odor
acid odor
according to
plastic type
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Page 97
BASE OF BODY REPAIR
CORROSION PROTECTION
CORROSION PROTECTION
9-37
ANTICORROSION TREATMENT AT THE FACTORY
Anticorrosion treatment at the time of production
includes the following measures.
THE USE OF GALVANIZED STEEL PLATE
: locations where galvanized steel
plate is used.
M4090019000064
AB200136
AB
Because galvanized steel plate has excellent corrosion resistance, it is used in areas which have a high
possibility of painting deficiency.
ZINC PHOSPHATE COATING
In order to improve the adhesive properties of the paint coat on
1
2
3
4
5
6
AB200109
the steel plate, and also to improve the finish of the paint coat,
the entire body is coated with a film of zinc phosphate prior to
undergoing the electrodeposition undercoating process.
1. Final coat
2. Intermediate coat
3. Anticorrosion primer
4. Undercoat
5. Zinc phosphate film
6. Steel plate
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9-38
BASE OF BODY REPAIR
CORROSION PROTECTION
CATIONIC ELECTRODEPOSITION UNDERCOATING
Anionic
coating
Counteragent
Anionic 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 chemically formed phosphate crystals. This
method, therefore, maximizes the corrosion resis
tance 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
A
A
SECTION A – A
order to provide resistance to water, dust, and corrosion.
Cationic
coating
Counteragent
Cationic electrodeposition
Alkali
solution
AB200110
AB200110
AD
AB301462
AB200112
AB
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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.
Page 99
AB200113
ANTICORROSION PRIMER
BASE OF BODY REPAIR
CORROSION PROTECTION
WAX INJECTION
Wax injection is used at the lower part of the frame, side sill and
hollow panels, etc., in order to obtain a better anticorrosion
effect.
9-39
A
1
1. Rocker panel primer application
Anticorrosion primer is used at the side sill outer panels in order to prevent corrosion and to suppress
vibration.
SEALING TAPE
Sealing tape is attached at unused holes, at the inner side of
the panel, for waterproofing and anticorrosion protection.
: Locations for
attachment of sealing tape
AB301463
AB301463
AF
1
A
AB701034
AB701034
AB
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9-40
AB200116
AB200117
BASE OF BODY REPAIR
CORROSION PROTECTION
ANTICORROSION TREATMENT AT THE TIME OF
BODY REPAIR WORK
The following procedures should be followed for anticorrosion
protection when making repairs.
M4090020000046
CORROSION PROTECTION FOR HOLLOW
PARTS
CAUTION
• Wipe away any excess anticorrosion agent on the
coated surface, because it can adversely affect the
coating.
• When spraying the anticorrosion agent, use holes in
different areas to ensure that all weld surfaces of the
hollow structure are well coated.
The insides of hollow parts (such as the side sill, pillars, etc.)
which have been welded are more susceptible to corrosion.
Spray an aerosol-type anticorrosion agent into these parts by
using the trim mounting holes and other openings.
AB200118
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 dam
aged by the heat of welding.
SPOT SEALER
In order to prevent corrosion from occurring at the contact surfaces of panels which are spot welded, apply an electroconductive spot sealer.
.
SPOT SEALER APPLICATION STEPS
1. Remove all paint, etc., from the areas to be spot welded by
using sandpaper or a pneumatic belt sander.
-
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