INTRODUCTION
IN-18
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.
F10004
F10001A
F10002A
F10003A
Glass Cover
Seat Cover
WRONG
WRONG
INTRODUCTION
IN-1
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.
(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.
(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.
(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
INTRODUCTION
IN-2
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.
Code
Material
name
Heat
*
resistant
temperature
limit C (F)
Resistance to
alcohol or gasoline
Notes
AAS
Acrylonitrile
Acrylic Styrene
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
ABS
Acrylonitrile
Butadiene Styrene
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
AES
Acrylonitrile
Ethylene Styrene
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
ASA
Acrylonitrile
Styrene
Acrylate
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
CAB
Cellulose
Acetate
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
EPDM
Ethylene
Propylene
100
(212)
Alcohol is harmless.
Gasoline is harmless if applied only for
short time in small amounts.
Most solvents are harmless
but avoid dipping in gasoline,
solvents, etc.
FRP
Fiber
Reinforced
Plastics
180
(356)
Alcohol and gasoline are harmless. Avoid alkali.
EVA
Ethylene
Acetate
70
(158)
Alcohol is harmless if applid only for short
time in small amounts (e.g., quick wiping
to remove grease).
Avoid gasoline and organic
or aromatic solvents.
PA
Polyamide
(Nylon)
80
(176)
Alcohol and gasoline are harmless. Avoid battery acid.
PBT
Polybutylene
Terephthalate
160
(320)
Alcohol and gasoline are harmless. Most solvents are harmless.
PC Polycarbonate
120
(248)
Alcohol is harmless.
Avoid gasoline brake fluid,
wax, wax removers and
organic solvents. Avoid alkali.
*Temperatures higher than those listed here may result in material deformation during repair.
INTRODUCTION
IN-3
Code
Material
name
Heat
*
resistant
temperature
limit C (F)
Resistance to
alcohol or gasoline
Notes
PE Polyethylene
80
(176)
Alcohol and gasoline are harmless. Most solvents are harmless.
PET
Polyethylene
Terephthalate
75
(167)
Alcohol and gasoline are harmless. Avoid dipping in water.
PMMA
Polymethyl
Methacrylate
80
(176)
Alcohol is harmless if applied only for
short time in small amounts.
Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
POM
Polyoxymethylene
(Polyacetal)
100
(212)
Alcohol and gasoline are harmless. Most solvents are harmless.
PP Polypropylene
80
(176)
Alcohol and gasoline are harmless. Most solvents are harmless.
PPO
Modified
Polyphenylene
Oxide
100
(212)
Alcohol is harmless.
Gasoline is harmless if
applied only for quick wiping
to remove grease.
PS Polystyrene
60
(140)
Alcohol and gasoline are harmless if
applied only for short time in small
amounts.
Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
PUR Polyurethane
80
(176)
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.
PVC
Polyvinylchloride
(Vinyl)
80
(176)
Alcohol and gasoline are harmless if
applied only for short time in small
amounts (e.g., quick wiping to remove
grease).
Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
SAN
Styrene
Acrylonitrile
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid dipping or immersing
in alcohol, gasoline, solvents
etc.
TPO
Thermoplastic
Olefine
80
(176)
Alcohol is harmless.
Gasoline is harmless if applied only for
short time in small amounts.
Most solvents are harmless
but avoid dipping in gasoline,
solvents, etc.
TPU
Thermoplastic
Polyurethane
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
TSOP
TOYOTA
Super
Olefine Polymer
80
(176)
Alcohol and gasoline are harmless. Most solvents are harmless.
UP
Unsaturated
Polyester
110
(233)
Alcohol and gasoline are harmless. Avoid alkali.
*Temperatures higher than those listed here may result in material deformation during repair.
INTRODUCTION
IN-4
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
IN-15
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.
Component to be aligned
Section of repair manual
for relevant model
Front Wheels Front Suspension (26) section
Rear Wheels Rear Suspension (27) section
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 80C (176F) 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
F13890A
REPLACEMENT PART AND METHOD
QUARTER PANEL (CUT)
BODY PANEL REPLACEMENT
REPLACEMENT
BP-34
QUARTER PANEL (CUT)
POINT
1 Remove the [A] at the same time.
PART NAME
[A] Fuel Filler Opening Lid
A
:
Replacement part
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
Describes in detail removal of the damaged part involving repair by cutting.
D
:
REMOVAL GUIDE
Provides additional information to more efficiently help you perform the removal.
E
:
REMOVAL
IN-5
HOW TO USE THIS MANUAL
1. BODY PANEL REPLACEMENT THIS MANUAL
INTRODUCTION
F13891A
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
INSTALLATION CONDITIONS
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
INSTALLATION DIAGRAM
Describes in detail installation to the new part involving repair by welding and/or
cutting, but excluding painting.
INSTALLATIOLN GUIDE
Provides additional information to more efficiently help you perform the installation.
SYMBOLS
(See page IN-7)
ILLUSTRATION OF WELD POINTS
Weld method and panel position symbols (See page IN-9)
PART NAME
J
I
F
G
H
5mm
F
:
G
:
H
:
I
:
J
:
K
:
IN-6
F13893A
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)
SPOT WELD OR
MIG PLUG WELD
(See Page IN-9)
BODY SEALER
WELD POINTS
CONTINUOUS
MIG WELD
(BUTT WELD)
CONTINUOUS
MIG WELD
(TACK WELD)
—
—
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.
INTRODUCTION
F13894A
SYMBOLS MEANING ILLUSTRATION
Assembly Mark
BODY SEALER
(Flat Finishing)
BODY SEALER
(No flat Finishing)
—
—
—
IN-8
F13892A
REMOVAL INSTALLATION
SYMBOLS
Remove
Weld
Points
(Outside)
HINT: Panel position symbols are as seen from
the working posture.
Spot Weld
MIG Plug
Weld
Spot MIG
Weld
Weld points
Remove weld point and panel position
Weld method and panel position
Weld points
MEANING ILLUSTRATION SYMBOLS MEANING ILLUSTRATION
(Middle)
(Inside)
INTRODUCTION
IN-9
3. ILLUSTRATION OF WELD POINT SYMBOLS
EXAMPLE:
INTRODUCTION
IN-16
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
IN-17
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.
F10007
F10008A
F10009A
F10010
Cutting Okay
Reinforcement
Corners
WRONG
INTRODUCTION
IN-10
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.
(b) CUTTING AREA
(1) Always cut in a straight line and avoid reinforced area.
(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.
(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.
F10011A
F10012
F10013A
F10014
F10015A
Less than
3mm
Puncher
Air Saw
Overlap
20 30mm
INTRODUCTION
IN-11
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.
(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.
F10016A
F10017A
F10018A
F10019A
F10020A
Body
Measurement
Diagrams
WRONG
CORRECT WRONG
Tip Cutter
Old
Spot
Locations
New Spot
Locations
INTRODUCTION
IN-12
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.
(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.
(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.
(d) SPOT WELD LOCATIONS
(1) Try to avoid welding over previous spots.
(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.
F10021A
F10022
F10023
Sealer Gun
INTRODUCTION
IN-13
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.
(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.
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.
F10024A
Apply the anti-chipping paint after
the top coat.
Apply the anti-chipping paint before
the second coat.
Anti-Chipping Paint
Top Coat
Second Coat
Under Coat (ED Primer)
Steel Metal
Top Coat
Second Coat
Anti-Chipping Paint
Under Coat (ED Primer)
Steel Metal
INTRODUCTION
IN-14
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.
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
Explanation of general body repair.
Views of weld panel replacement instructions.
Cautionary items.
Views of weld panel replacement instructions.
BODY PANEL REPLACEMENT
Instructions for replacing the weld panels
from the white body condition, from which
bolted parts have been removed, with
individual supply parts.
Front side member replacement.
Quarter panel replacement.
BODY DIMENSIONS Body aligning measurements. Dimension diagrams.
PAINT COATING
Scope and type of anti-rust treatment, etc.
together with weld panel replacement.
Under coat.
Body sealer.
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.
BODY PANEL REPLACEMENT
F15540
POINT
1 Remove the [A] at the same time.
PART NAME
[A] Back door Opening Lower Reinforcement
F15540A
REMOVAL
BP-40
BACK DOOR OPENING TROUGH (ASSY)
REPLACEMENT
With the body lower back panel removed.
BODY PANEL REPLACEMENT
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-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.
BODY PANEL REPLACEMENT
F15538
F15538A
REMOVAL
BP-38
BODY LOWER BACK PANEL (ASSY)
REPLACEMENT
BODY PANEL REPLACEMENT
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.
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.
BODY PANEL REPLACEMENT
F15527
40mm (1.57in.) 50mm (1.97in.) 70mm (2.76in.)
F15527A
REMOVAL
BP-27
CENTER BODY PILLAR (CUT)
REPLACEMENT
BODY PANEL REPLACEMENT
F15528
10mm (0.39in.) 62mm (2.44in.) 240mm (9.45in.)
POINT
1 Before temporarily installing the new parts, weld the [A], [B] and [C] with standard points.
PART NAME
[A] Rocker Outer Reinforcement
[C] Center Body Inner Pillar
[B] Center Body Pillar Lower Reinforcement
BP-28
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.
BODY PANEL REPLACEMENT
F15529
10mm (0.39in.) 20mm (0.79in.)
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.
BP-29
BODY PANEL REPLACEMENT
F15521
F15521A
REMOVAL
BP-21
COWL TOP SIDE PANEL (ASSY)
REPLACEMENT
Loading...