Toyota Scion 2006 User Manual

IN-18
INTRODUCTION
ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this manual.
ABS Antilock Brake System A/C Air Conditioner assy assembly ECT Electronic Controlled Transmission ECU Electronic Control Unit e.g. Exempli Gratia (for Example) Ex. Except FWD Front Wheel Drive Vehicles 4WD Four Wheel Drive Vehicles in. inch LH Left-hand LHD Left-hand Drive MIG Metal Inert Gas M/Y Model Year PPS Progressive Power Steering RH Right-hand RHD Right-hand Drive SRS Supplemental Restraint System SSM Special Service Materials w/ with w/o without
FOREWORD
This repair manual has been prepared to provide essential in­formation on body panel repair methods (including cutting and welding operations, but excluding painting) for the SCION xA.
Applicable models: NCP61 series
This manual consists of body repair methods, exploded dia­grams and illustrations of the body components and other in­formation relating to body panel replacement such as handling precautions, etc. However, it should be noted that the front fend­ers of the SCION model is bolted on and require no welding.
When repairing, don’t cut and join areas that are not shown in this manual. Only work on the specified contents to maintain body strength.
Body construction will sometimes differ depending on specifica­tions and country of destination. Therefore, please keep in mind that the information contained herein is based on vehicles for general destinations.
For the repair procedures and specifications other than collision­damaged body components of the SCION xA refer to the repair manuals.
If you require the above manuals, please contact your SCION Dealer.
All information contained in this manual is the most up-to-date at the time of publication. However, specifications and procedures are subject to change without prior notice.
Glass Cover
INTRODUCTION
GENERAL REPAIR INSTRUCTIONS
1. WORK PRECAUTIONS
(a) VEHICLE PROTECTION
(1) When welding, protect the painted surfaces, windows,
seats and carpet with heat resistant, fire-proof covers.
IN-1
WRONG
Seat Cover
F10001A
(b) SAFETY
(1) Never stand in direct line with the chain when using a
puller on the body or frame, and be sure to attach a safety cable.
F10002A
(2) Before performing repair work, check for fuel leaks.
If a leak is found, be sure to close the opening totally.
(3) If it is necessary to use a flame in the area of the fuel
tank, first remove the tank and plug the fuel line.
WRONG
F10003A
F10004
(c) SAFETY WORK CLOTHES
(1) In addition to the usual mechanic’s wear, cap and
safety shoes, the appropriate gloves, head protector, glasses, ear plugs, face protector, dust-prevention mask, etc. should be worn as the situation demands.
Code Name
A Dust-Prevention Mask B Face Protector C Eye Protector D Safety Shoes E Welder’s Glasses F Ear Plugs G Head Protector H Welder’s Gloves
IN-2
INTRODUCTION
2. HANDLING PRECAUTIONS OF PLASTIC BODY PARTS
(1) The repair procedure for plastic body parts must conform with the type of plastic material. (2) Plastic body parts are identified by the codes in the following table. (3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, paint-
ing etc.), consideration must be given to the property of the plastic.
*
Heat
Code
Material
name
resistant temperature limit C (F)
Resistance to
alcohol or gasoline
Notes
AAS
ABS
AES
ASA
CAB
EPDM
FRP
Acrylonitrile Acrylic Styrene
Acrylonitrile Butadiene Styrene
Acrylonitrile Ethylene Styrene
Acrylonitrile Styrene Acrylate
Cellulose Acetate
Ethylene Propylene
Fiber Reinforced Plastics
80
(176)
80
(176)
80
(176)
80
(176)
80
(176)
100
(212)
180
(356)
Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts.
Alcohol and gasoline are harmless. Avoid alkali.
Avoid gasoline and organic or aromatic solvents.
Avoid gasoline and organic or aromatic solvents.
Avoid gasoline and organic or aromatic solvents.
Avoid gasoline and organic or aromatic solvents.
Avoid gasoline and organic or aromatic solvents.
Most solvents are harmless but avoid dipping in gasoline, solvents, etc.
EVA
PA
PBT
PC Polycarbonate
*Temperatures higher than those listed here may result in material deformation during repair.
Ethylene Acetate
Polyamide (Nylon)
Polybutylene Terephthalate
70
(158)
80
(176)
160
(320)
120
(248)
Alcohol is harmless if applid only for short time in small amounts (e.g., quick wiping to remove grease).
Alcohol and gasoline are harmless. Avoid battery acid.
Alcohol and gasoline are harmless. Most solvents are harmless.
Alcohol is harmless.
Avoid gasoline and organic or aromatic solvents.
Avoid gasoline brake fluid, wax, wax removers and organic solvents. Avoid alkali.
Code
Material
name
*
Heat
resistant
temperature
limit C (F)
INTRODUCTION
Resistance to
alcohol or gasoline
IN-3
Notes
PE Polyethylene
PET
PMMA
POM
PP Polypropylene
PPO
PS Polystyrene
PUR Polyurethane
Polyethylene Terephthalate
Polymethyl Methacrylate
Polyoxymethylene (Polyacetal)
Modified Polyphenylene Oxide
80
(176)
75
(167)
80
(176)
100
(212)
80
(176)
100
(212)
60
(140)
80
(176)
Alcohol and gasoline are harmless. Most solvents are harmless.
Alcohol and gasoline are harmless. Avoid dipping in water.
Alcohol is harmless if applied only for short time in small amounts.
Alcohol and gasoline are harmless. Most solvents are harmless.
Alcohol and gasoline are harmless. Most solvents are harmless.
Alcohol is harmless.
Alcohol and gasoline are harmless if applied only for short time in small amounts.
Alcohol is harmless if applied only for very short time in small amounts (e.g., quick wiping to remove grease).
Avoid dipping or immersing in alcohol, gasoline, solvents, etc.
Gasoline is harmless if applied only for quick wiping to remove grease.
Avoid dipping or immersing in alcohol, gasoline, solvents, etc.
Avoid dipping or immersing in alcohol, gasoline, solvents, etc.
Alcohol and gasoline are harmless if
PVC
SAN
TPO
TPU
TSOP
UP
*Temperatures higher than those listed here may result in material deformation during repair.
Polyvinylchloride (Vinyl)
Styrene Acrylonitrile
Thermoplastic Olefine
Thermoplastic Polyurethane
TOYOTA Super Olefine Polymer
Unsaturated Polyester
80
(176)
80
(176)
80
(176)
80
(176)
80
(176)
110
(233)
applied only for short time in small amounts (e.g., quick wiping to remove grease).
Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts.
Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
Alcohol and gasoline are harmless. Most solvents are harmless.
Alcohol and gasoline are harmless. Avoid alkali.
Avoid dipping or immersing in alcohol, gasoline, solvents, etc.
Avoid dipping or immersing in alcohol, gasoline, solvents etc.
Most solvents are harmless but avoid dipping in gasoline, solvents, etc.
Avoid dipping or immersing in alcohol, gasoline, solvents, etc.
IN-4
INTRODUCTION
3. LOCATION OF PLASTIC BODY PARTS
Parts Name Code Radiator Grille TSOP Front Bumper Cover TSOP Front Bumper Hole Cover TSOP Headlight PP/PC Fog light TSOP Side Turn Signal Light PMMA/ABS Fender Panel Mudguard TSOP Front Fender Mudguard PP/EPDM Cowl Top Ventilator Louver TSOP Outer Rear View Mirror ABS/PA Front Pillar Upper Cover AES Side Mudguard TSOP Front Door Outside Handle PC/PA Rear Door Outside Handle PC/PA Quarter Panel Rear Mudguard TSOP Rear Wheel House Plate PP/EPDM Back Door Outside Garnish ABS Back Door Outside Handle PA High Mount Stop Light PMMA/ABS Rear Bumper Cover TSOP Rear Combination Light PMMA/AAS License Plate Light PMMA/ABS Rear Fog Light PC/ABS Rear Spoiler ABS
Resin material differs with model.
/ Made up of 2 or more kinds of materials.
INTRODUCTION
HANDLING PRECAUTIONS ON RELATED COMPONENTS
1. BRAKE SYSTEM
The brake system is one of the most important safety components. Always follow the directions and notes given in brake (32) section of the repair manual for the relevant model when handling brake system parts.
NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC sys­tem.
2. DRIVE TRAIN AND CHASSIS
The drive train and chassis are components that can have great effects on the running performance and vibration resistance of the vehicle. After installing components in the sections listed in the table below, perform alignments to ensure correct mounting angles and dimensions. Particularly accurate repair of the body must also be done to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Always follow the directions giv­en in the repair manual for the relevant model during alignment and section DI of this section.
IN-15
Component to be aligned
Front Wheels Front Suspension (26) section
Rear Wheels Rear Suspension (27) section
Section of repair manual
for relevant model
3. COMPONENTS ADJACENT TO THE BODY PANELS
Various types of component parts are mounted directly on or adjacently to the body panels. Strictly ob­serve the following precautions to prevent damaging these components and the body panels during han­dling.
Before repairing the body panels, remove their components or apply protective covers over the com-
ponents.
Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components and the body paint.
Before removing components from the outer surface of the body, attach protective tape to the body to
ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.
Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.
4. ECU (ELECTRONIC CONTROL UNIT)
Many ECUs are mounted in this vehicle. Take the following precautions during body repair to prevent damage to the ECUs.
Before starting electric welding operations, disconnect the negative (-) terminal cable from the bat-
tery. When the negative (-) terminal cable is disconnected from the battery , memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by each memory system. Then when work is finished, reset the clock and audio systems as before. When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are all equipped with memory function, it is not possible to make a record of the memory contents. So when the operation is finished, it will be necessary to explain this fact to the customer, and request the customer to adjust the features and reset the memory.
Do not expose the ECUs to ambient temperatures above 80C (176F).
NOTICE: If it is possible the ambient temperature may reach 80C (176F) or more, remove the ECUs from the vehicle before starting work.
Be careful not to drop the ECUs and not to apply physical shocks to them.
INTRODUCTION
HOW TO USE THIS MANUAL
1. BODY PANEL REPLACEMENT THIS MANUAL
IN-5
BP-34
QUARTER PANEL (CUT)
REPLACEMENT
REMOVAL
BODY PANEL REPLACEMENT
POINT
1 Remove the [A] at the same time.
PART NAME
[A] Fuel Filler Opening Lid
:
REPLACEMENT PART AND METHOD
A
QUARTER PANEL (CUT)
Replacement method (ASSY) ... Assembly replacement (CUT) ... Major cutting (less than 1/2 of part used) (CUT-H) ... Half cutting (about 1/2 of part used) (CUT-P) ... Partial cutting (most of part used)
:
REMOVAL CONDTIONS
B
:
PART LOCATION
C
:
REMOVAL DIAGRAM
D
Describes in detail removal of the damaged part involving repair by cutting.
:
REMOVAL GUIDE
E
Provides additional information to more efficiently help you perform the removal.
Replacement part
F13890A
IN-6
INTRODUCTION
BODY PANEL REPLACEMENT BP-35
INSTALLATION
Temporaily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fiting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.After welding, apply body sealer and under-coating to the corresponding parts.After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
I
F
J
G
I
5mm
POINT
1 Before temporarily installing the new parts, apply body sealer to the wheel arch.
HINT:
1) Apply body sealer about 5mm (0.20in.) front the flange, avoiding any oozing.
2) Apply sealer evenly, about 3 - 4mm (0.12 - 0.16in.) in diameter.
3) For other sealing points, refer to section PC.
PART NAME
[A] Fuel Filler Opening Lid [B] Waterproof Rivet
H
:
INSTALLATION CONDITIONS
F
:
INSTALLATION DIAGRAM
G
Describes in detail installation to the new part involving repair by welding and/or cutting, but excluding painting.
:
INSTALLATIOLN GUIDE
H
Provides additional information to more efficiently help you perform the installation.
:
SYMBOLS
I
(See page IN-7)
:
ILLUSTRATION OF WELD POINTS
J
Weld method and panel position symbols (See page IN-9)
:
PART NAME
K
F13891A
INTRODUCTION
IN-7
2. SYMBOLS
The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas and the types of weld required.
SYMBOLS MEANING ILLUSTRATION
CUT AND JOIN LOCATION
(SAW CUT)
CUT AND JOIN LOCATION
(Cut Location for
Supply Parts)
CUT LOCATION
CUT WITH DISC
SANDER, ETC.
BRAZE
(Removal)
BRAZE
(Installation)
WELD POINTS
SPOT WELD OR
MIG PLUG WELD
(See Page IN-9)
CONTINUOUS
MIG WELD
(BUTT WELD)
CONTINUOUS
MIG WELD
(TACK WELD)
BODY SEALER
F13893A
IN-8
INTRODUCTION
SYMBOLS MEANING ILLUSTRATION
Assembly Mark
BODY SEALER
(Flat Finishing)
BODY SEALER
(No flat Finishing)
F13894A
INTRODUCTION
3. ILLUSTRATION OF WELD POINT SYMBOLS EXAMPLE:
REMOVAL INSTALLATION
IN-9
Weld points
Remove weld point and panel position
SYMBOLS
MEANING ILLUSTRATION SYMBOLS MEANING ILLUSTRATION
Remove Weld Points
(Outside)
(Middle)
Weld points
Weld method and panel position
Spot Weld
MIG Plug Weld
(Inside)
HINT: Panel position symbols are as seen from the working posture.
Spot MIG Weld
F13892A
IN-16
INTRODUCTION
PRECAUTIONS FOR REPAIRING BODY STRUCTURE PANELS
1. HEAT REPAIR FOR BODY STRUCTURE PANELS
Toyota prohibits the use of the heat repair method on body structure panels when repairing a vehicle damaged in a col­lision. Panels that have high strength and rigidity, as well as a long life span for the automobile body are being sought after. At Toyota, in order to fulfill these requirement, we use high tensile strength steel sheets and rust preventive steel sheets on the body. High tensile steel sheets are made with alloy additives and a special heat treatment in order to improve the strength. To prevent the occurrence of rust for a long period of time, the surface of the steel is coated with a zinc alloy. If a body structure parts are heat repaired with an acetylene torch or ot h e r heating source, the crystalline organization of the steel sheet will change and the strength of the steel sheet will be reduced. The ability of the body to resist rust is significantly lowered as well since the rust resistant zinc coating is destroyed by heat and the steel sheet surface is oxidized.
2. STRUCTURE PANEL KINKS
A sharp deformation angle on the panel that cannot be re­turned to its original shape by pulling or hammering is called a kink. Since structure parts were designed to exhibit a 100% per­formance when they were in their original shape, if they are deformed in an accident, or if the deformed parts are re­paired and reused, they become unable to exhibit the same performance as intended in the design. It is necessary to replace the part where the kink has oc­curred.
INTRODUCTION
3. IMPACT BEAM REPAIR
The impact beam and bracket are necessary and important parts in maintaining a survival space for passengers in a side collision. For impact beam, we use special high tensile strength steel. The high tensile strength steel maintains its special crystal­line organization by heat treatment or alloy additives. Since these parts were designed to exhibit a 100% perfor­mance when they were in their original shape, if they are deformed in an accident, or if the deformed parts are re­paired and reused, they become unable to exhibit the same performance as intended in the design. It is necessary to replace the door assembly when impact beam or bracket is damaged.
IN-17
IN-10
Cutting Okay
Reinforcement
INTRODUCTION
PROPER AND EFFICIENT WORK PROCEDURES
1. REMOVAL
(a) PRE-REMOVAL MEASURING
(1) Before removal or cutting operations, take measure-
ments in accordance with the dimension diagram. Al­ways use a puller to straighten a damaged body or frame.
F10007
(b) CUTTING AREA
(1) Always cut in a straight line and avoid reinforced area.
WRONG
Corners
F10008A
(c) PRECAUTIONS FOR DRILLING OR CUTTING
(1) Check behind any area to be drilled or cut to insure
that there are no hoses, wires, etc., that may be dam­aged.
HINT: See “Handling Precautions on Related Compo­nents” on page IN-15.
F10009A
(d) REMOVAL OF ADJACENT COMPONENTS
(1) When removing adjacent components, apply protec-
tive tape to the surrounding body and your tools to pre­vent damage.
HINT: See “Handling Precautions on Related Compo­nents” on page IN-15.
F10010
Less than 3mm
F10011A
F10012
INTRODUCTION
2. PREPARATION FOR INST ALLATION
(a) SPOT WELD POINTS
(1) When welding panels with a combined thickness of
over 3mm (0.12in.), use a MIG (Metal Inert Gas) weld­er for plug welding.
HINT: Spot welding will not provide sufficient durability for panels over 3mm (0.12in.) thick.
(b) APPLICATION OF WELD-THROUGH PRIMER
(SPOT SEALER) (1) Remove the paint from the portion of the new parts
and body to be welded, and apply weld-through prim­er.
IN-11
Air Saw
Puncher
20  30mm
F10013A
F10014
Overlap
(c) MAKING HOLES FOR PLUG WELDING
(1) For areas where a spot welder cannot be used, use a
puncher or drill to make holes for plug welding.
REFERENCE: mm (in.)
Thickness of welded portion Size of plug hole
1.0 (0.04) under 5 (0.20) ø over
1.0 (0.04) - 1.5 (0.06) 6.4 (0.26) ø over
1.5 (0.06) over 8 (0.31) ø over
(d) SAFETY PRECAUTIONS FOR ELECTRICAL COM-
PONENTS (1) When welding, there is a danger that electrical compo-
nents will be damaged by the electrical current flowing through the body.
(2) Before starting work, disconnect the negative terminal
of the battery and ground the welder near the welding location of the body.
(e) ROUGH CUTTING OF JOINTS
(1) For joint areas, rough cut the new parts, leaving 20 -
30mm (0.79 - 1.18in.) overlap.
F10015A
IN-12
Body Measurement Diagrams
INTRODUCTION
3. INSTALLATION
(a) PRE-WELDING MEASUREMENTS
(1) Always take measurements before installing under-
body or engine components to insure correct assem­bly. After installation, confirm proper fit.
F10016A
(b) WELDING PRECAUTIONS
(1) The number of welding spots should be as follows.
Spot weld: 1.3 X No. of manufacturer’s spots. Plug weld: More than No. of manufacturer’s plugs.
(2) Plug welding should be done with a MIG (Metal Inert
Gas) welder. Do not gas weld or braze panels at areas other than specified.
WRONG
CORRECT WRONG
Tip Cutter
F10017A
(c) POST-WELDING REFINISHING
(1) Always check the welded spots to insure they are se-
cure.
(2) When smoothing out the weld spots with a disc grind-
er, be careful not to grind off too much as this would weaken the weld.
F10018A
(d) SPOT WELD LOCATIONS
(1) Try to avoid welding over previous spots.
F10019A
Old Spot Locations
New Spot Locations
F10020A
(e) SPOT WELDING PRECAUTIONS
(1) The shape of the welding tip point has an effect on the
strength of the weld.
(2) Always insure that the seams and welding tip are free
of paint.
INTRODUCTION
IN-13
Sealer Gun
4. ANTI-RUST TREATMENT
(a) BODY SEALER APPLICATION
(1) For water-proofing and anti-corrosion measures, al-
ways apply the body sealer to the body panel seams and hems of the doors, hoods, etc.
F10021A
(b) UNDERCOAT APPLICATION
(1) To prevent corrosion and protect the body from dam-
age by flying stones, always apply sufficient under­coat to the bottom surface of the under body and in­side of the wheel housings.
F10022
5. ANTI-RUST TREATMENT AFTER PAINTING PROCESS
(a) ANTI-RUST AGENT (WAX) APPLICATION
(1) To preserve impossible to paint areas from corrosion,
always apply sufficient anti-rust agent (wax) to the in­side of the hemming areas of the doors and hoods, and around the hinges, or the welded surfaces inside the boxed cross-section structure of the side member, body pillar, etc.
F10023
IN-14
INTRODUCTION
6. ANTI-RUST TREATMENT BY PAINTING
REFERENCE:
Painting prevents corrosion and protect the sheet metal from damage. In this section, anti-chipping paint only for anti-corrosion purpose is described.
(a) ANTI-CHIPPING PAINT
(1) To prevent corrosion and protect the body from dam-
age by flying stones, etc., apply anti-chipping paint to the rocker panel, wheel arch areas, balance panel, etc.
HINT: Depending on the model or the application area, there are cases where the application of anti-chipping paint is necessary before the second coat or after the top coat.
Apply the anti-chipping paint after
the top coat.
Anti-Chipping Paint Top Coat
Second Coat Under Coat (ED Primer) Steel Metal
Apply the anti-chipping paint before
the second coat.
Top Coat Second Coat
Anti-Chipping Paint Under Coat (ED Primer)
Steel Metal
F10024A
VIEWS OF THIS TEXT
Scope of the repair work explanation
This text explains the welding panel replacement instructions from the vehicle’ s white body condi-
tion. W e have abbreviated the explanations of the removal and reinstallation of the equipment parts up to the white body condition and of the installation, inspection, adjustment and final inspection of equipment parts after replacing the weld panel.
Section categories
Each section has been divided as shown below.
Section Title Contents Examples
INTRODUCTION
BODY PANEL REPLACEMENT
BODY DIMENSIONS Body aligning measurements. Dimension diagrams.
PAINT COATING
Explanation of general body repair. Views of weld panel replacement instructions.
Instructions for replacing the weld panels from the white body condition, from which bolted parts have been removed, with individual supply parts.
Scope and type of anti-rust treatment, etc. together with weld panel replacement.
Abbreviation of contents in this text.
The following essential procedures have been abbreviated. When actually working, conduct this
work properly. (1) Jack and lift operations. (2) Clean and wash removed parts, if necessary. (3) Visual inspection.
Cautionary items. Views of weld panel replacement instructions.
Front side member replacement. Quarter panel replacement.
Under coat. Body sealer.
BP-40
BODY PANEL REPLACEMENT
BACK DOOR OPENING TROUGH (ASSY)
REPLACEMENT
With the body lower back panel removed.
REMOVAL
F15540A
POINT
1 Remove the [A] at the same time.
PART NAME
[A] Back door Opening Lower Reinforcement
F15540
BODY PANEL REPLACEMENT
BP-41
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.After welding, apply body sealer and under-coating to the corresponding parts.After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
F15541
POINT
1 Inspect the fitting of the back door and rear combination light, etc., before welding, since this affects the ap-
pearance of the finish.
PART NAME
[A] Back Door Opening Lower Reinforcement
[B] Rear Bumper Upper Side Retainer
BP-38
BODY PANEL REPLACEMENT
BODY LOWER BACK PANEL (ASSY)
REPLACEMENT
REMOVAL
F15538A
F15538
BODY PANEL REPLACEMENT
BP-39
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.After welding, apply body sealer and under-coating to the corresponding parts.After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
F15539
POINT
1 Inspect the fitting of the back door and rear combination light, etc., before welding, since this affects the ap-
pearance of the finish.
BODY PANEL REPLACEMENT
CENTER BODY PILLAR (CUT)
REPLACEMENT
REMOVAL
BP-27
F15527A
40mm (1.57in.) 50mm (1.97in.) 70mm (2.76in.)
F15527
BP-28
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.After welding, apply body sealer and under-coating to the corresponding parts.After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
POINT
1 Before temporarily installing the new parts, weld the [A], [B] and [C] with standard points.
PART NAME
[A] Rocker Outer Reinforcement
[B] Center Body Pillar Lower Reinforcement
[C] Center Body Inner Pillar 10mm (0.39in.) 62mm (2.44in.) 240mm (9.45in.)
F15528
BODY PANEL REPLACEMENT
BP-29
F15529
POINT
1 Inspect the fitting of the front door and rear door, etc., before welding, since this affects the appearance of the
finish.
2 After welding the reinforcement to the vehicle side, install the outer panel. 10mm (0.39in.) 20mm (0.79in.)
BODY PANEL REPLACEMENT
COWL TOP SIDE PANEL (ASSY)
REPLACEMENT
REMOVAL
BP-21
F15521A
F15521
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