Toyota Yaris 2007 User Manual

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 TOYOTA YARIS.

Applicable models: KSP90 series

NCP90, 91 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, this TOYOTA model are 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 TOYOTA YARIS refer to the repair manuals.

If you require the above manuals, please contact your TOYOTA 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.

VIEWS OF THIS TEXT

Scope of the repair work explanation

This text explains the welding panel replacement instructions from the vehicle's white body condition. We 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

This manual has been divided as shown below.

	Section Title	Contents	Examples
	INTRODUCTION	Explanation of general body repair.	Cautionary items.
		Views of weld panel replacement instructions.	Views of weld panel replacement instructions.
		Instructions for replacing the weld panels	Front side member replacement.
	BODY PANEL REPLACEMENT	from the white body condition, from which	Quarter panel replacement.
		bolted parts have been removed, with
		individual supply parts.
	BODY DIMENSIONS	Body aligning measurements.	Dimension diagrams.
	PAINT COATING	Scope and type of anti-rust treatment, etc.	Under coating.
		together with weld panel replacement.	Body sealer.

Contents omitted in this manual.

Make sure to perform the following essential procedures, although they are omitted in this manual.

(1)Jack and lift operations.

(2)Clean and wash removed parts, if necessary.

(3)Visual inspection.

INTRODUCTION

IN-1

Glass Cover

Seat Cover

F10001A

GENERAL REPAIR INSTRUCTIONS

1.WORK PRECAUTIONS

(a)VEHICLE PROTECTION

(1)When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fireproof covers.

(b)SAFETY

(1)Never stand in a direct line with the chain when using a puller on the body or frame, and be sure to attach a safety cable.

WRONG

F10002A

(2)Before performing repair work, check for fuel leaks. If a leak is found, be sure to close the opening completely.

(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

(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
F10004A		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, painting etc.), consideration must be given to the properties of the plastic.

			Heat*
	Code	Material	resistant	Resistance to	Notes
		name	temperature	alcohol or gasoline
			limit C ( F)
		Acrylonitrile	80	Alcohol is harmless if applied only for	Avoid gasoline and organic
	AAS			short time in small amounts (e.g., quick
		Acrylic Styrene	(176)		or aromatic solvents.
				wiping to remove grease).
		Acrylonitrile	80	Alcohol is harmless if applied only for	Avoid gasoline and organic
	ABS			short time in small amounts (e.g., quick
		Butadiene Styrene	(176)		or aromatic solvents.
				wiping to remove grease).
		Acrylonitrile	80	Alcohol is harmless if applied only for	Avoid gasoline and organic
	AES			short time in small amounts (e.g., quick
		Ethylene Styrene	(176)		or aromatic solvents.
				wiping to remove grease).
		Acrylonitrile	80	Alcohol is harmless if applied only for	Avoid gasoline and organic
	ASA	Styrene		short time in small amounts (e.g., quick
			(176)		or aromatic solvents.
		Acrylate		wiping to remove grease).
		Cellulose	80	Alcohol is harmless if applied only for	Avoid gasoline and organic
	CAB			short time in small amounts (e.g., quick
		Acetate	(176)		or aromatic solvents.
				wiping to remove grease).
		Ethylene	100	Alcohol is harmless.	Most solvents are harmless
	EPDM			Gasoline is harmless if applied only for	but avoid dipping in gasoline,
		Propylene	(212)
				short time in small amounts.	solvents, etc.
		Fiber	180
	FRP	Reinforced		Alcohol and gasoline are harmless.	Avoid alkali.
			(356)
		Plastics
		Ethylene	70	Alcohol is harmless if applied only for	Avoid gasoline and organic
	EVA			short time in small amounts (e.g., quick
		Acetate	(158)		or aromatic solvents.
				wiping to remove grease).
		Ethylene/
		Vinyl	70	Alcohol is harmless if applied only for	Avoid gasoline and organic
	E/VAC	Acetate		short time in small amounts (e.g., quick
			(158)		or aromatic solvents.
		Copolymer		wiping to remove grease).
		Resin
	PA	Polyamide	80	Alcohol and gasoline are harmless.	Avoid battery acid.
		(Nylon)	(176)
	PBT	Polybutylene	160	Alcohol and gasoline are harmless.	Most solvents are harmless.
		Terephthalate	(320)
			120		Avoid gasoline, brake fluid,
	PC	Polycarbonate		Alcohol is harmless.	wax, wax removers and
			(248)
					organic solvents. Avoid alkali.

*Temperatures higher than those listed here may result in material deformation during repair.

				INTRODUCTION	IN-3
			Heat*
	Code	Material	resistant	Resistance to	Notes
		name	temperature	alcohol or gasoline
			limit C ( F)
	PE	Polyethylene	80	Alcohol and gasoline are harmless.	Most solvents are harmless.
			(176)
	PET	Polyethylene	75	Alcohol and gasoline are harmless.	Avoid dipping in water.
		Terephthalate	(167)
		Polymethyl	80	Alcohol is harmless if applied only for	Avoid dipping or immersing
	PMMA				in alcohol, gasoline,
		Methacrylate	(176)	short time in small amounts.
					solvents, etc.
	POM	Polyoxymethylene	100	Alcohol and gasoline are harmless.	Most solvents are harmless.
		(Polyacetal)	(212)
	PP	Polypropylene	80	Alcohol and gasoline are harmless.	Most solvents are harmless.
			(176)
		Composite	80
	PPF	Reinforced		Alcohol and gasoline are harmless.	Most solvents are harmless.
			(176)
		Polypropylene
		Modified	100		Gasoline is harmless if
	PPO	Polyphenylene		Alcohol is harmless.	applied only for quick wiping
			(212)
		Oxide			to remove grease.
			60	Alcohol and gasoline are harmless if	Avoid dipping or immersing
	PS	Polystyrene		applied only for short time in small	in alcohol, gasoline,
			(140)
				amounts.	solvents, etc.
			80	Alcohol is harmless if applied only for very	Avoid dipping or immersing
	PUR	Polyurethane		short time in small amounts (e.g., quick	in alcohol, gasoline,
			(176)
				wiping to remove grease).	solvents, etc.
				Alcohol and gasoline are harmless if	Avoid dipping or immersing
		Polyvinylchloride	80	applied only for short time in small
	PVC				in alcohol, gasoline,
		(Vinyl)	(176)	amounts (e.g., quick wiping to remove
					solvents, etc.
				grease).
		Styrene	80	Alcohol is harmless if applied only for	Avoid dipping or immersing
	SAN			short time in small amounts (e.g., quick	in alcohol, gasoline,
		Acrylonitrile	(176)
				wiping to remove grease).	solvents, etc.
		Thermoplastic	80	Alcohol is harmless.	Most solvents are harmless
	TPO			Gasoline is harmless if applied only for	but avoid dipping in gasoline,
		Olefine	(176)
				short time in small amounts.	solvents, etc.
		Thermoplastic	80	Alcohol is harmless if applied only for	Avoid dipping or immersing
	TPU			short time in small amounts (e.g., quick	in alcohol, gasoline,
		Polyurethane	(176)
				wiping to remove grease).	solvents, etc.
		TOYOTA	80
	TSOP	Super		Alcohol and gasoline are harmless.	Most solvents are harmless.
			(176)
		Olefine Polymer
	UP	Unsaturated	110	Alcohol and gasoline are harmless.	Avoid alkali.
		Polyester	(233)

*Temperatures higher than those listed here may result in material deformation during repair.

IN-4	INTRODUCTION

3.LOCATION OF PLASTIC BODY PARTS

Parts Name	Code
Front Bumper Cover	TSOP
Radiator Grille	TSOP
Headlight	PC/PP
Fog Light	TSOP
Front Pillar Upper Cover	AES
Side Turn Signal Light	PMMA/PC/ABS
Cowl Top Ventilator Louver	TSOP/PP/PE
Rear Body Mudguard	PP
Door Outside Handle	PA/PC/PBT
Outer Rear View Mirror	PP/PA/ABS ASA
Front Door Window Frame Front Moulding	ASA
Front Spoiler Cover	TSOP
Front Fender Mudguard	PP
Back Door Outside Handle	PA
License Plate Light	PC
Rear Combination Light	PMMA/ASA
Rear Bumper Cover	TSOP
	HINT:
	Resin material differs depending on mod-
	el.
	/ Made up of 2 or more kinds of materials.

INTRODUCTION

IN-5

HOW TO USE THIS MANUAL

1.BODY PANEL REPLACEMENT IN THIS MANUAL

BODY PANEL REPLACEMENT

QUARTER PANEL (CUT)

REPLACEMENT

REMOVAL

POINT

1. Remove the [A] at the same time.

PART NAME

[A] Fuel filler opening lid 200 mm (7.87 in.)

REPLACEMENT PART AND METHOD

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)

Replacement part

REMOVAL CONDITIONS

PART LOCATION

REMOVAL DIAGRAM

Describes in detail the removal of the damaged part involving repair by cutting.

REMOVAL GUIDE

Provides additional information to more efficiently help you perform the removal.

F13890A

IN-6	INTRODUCTION

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, apply sealer to the wheel arch.

HINT

1)Apply body sealer about 5 mm (0.20 in.) front the flange, avoiding any oozing.

2)Apply sealer evenly, about 3−4 mm (0.12−0.16 in.) in diameter

3)For other sealing points, refer to section PC.

INSTALLATION CONDITIONS

INSTALLATION DIAGRAM

Describes in detail the installation of the new parts involving repair by welding and/or cutting, but excluding painting.

INSTALLATION GUIDE

Provides additional information to more efficiently help you perform the installation.

SYMBOLS

(See page IN-7)

INSTALLATION OF WELD POINTS

Weld method and panel position symbols (See page IN-9)

PART NAME

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

Ð

Assembly Mark

Ð

	Ð	BODY SEALER
		(Flat Finishing)
	Ð	BODY SEALER
		(No Flat Finishing)

F13894A

INTRODUCTION

IN-9

3. ILLUSTRATION OF WELD POINT SYMBOLS EXAMPLE:

REMOVAL

Weld points

Remove weld point and panel position

SYMBOLS MEANING

ILLUSTRATION

Remove

Weld

Points

(Outside)

(Middle)

(Inside)

HINT: Panel position symbols are as seen from the working posture.

INSTALLATION

Weld points

Weld method and panel position

SYMBOLS MEANING

ILLUSTRATION

Spot Weld

MIG Plug

Weld

Spot MIG

Weld

F13892A

IN-10

INTRODUCTION

PROPER AND EFFICIENT WORK

PROCEDURES

1.REMOVAL

(a)PRE-REMOVAL MEASURING

(1)Before removal or cutting operations, take measurements in accordance with the dimensions diagram. Always use a puller to straighten a damaged body or frame.

F10007A

Cutting Okay

Reinforcement

Corners

F10008A

WRONG	F10009A

(b)CUTTING AREA

(1)Always cut in a straight line and avoid reinforced areas.

(c)PRECAUTIONS FOR DRILLING OR CUTTING

(1)Check behind any area to be drilled or cut to ensure that there are no hoses, wires, etc., that may be damaged.

HINT: See ªHandling Precautions on Related Componentsº on page IN-15.

(d)REMOVAL OF ADJACENT COMPONENTS

(1)When removing adjacent components, apply protective tape to the surrounding body and your tools to prevent damage.

HINT: See ªHandling Precautions on Related Componentsº on page IN-15.

F10010A

INTRODUCTION

IN-11

Less than 3 mm

2.PREPARATION FOR INSTALLATION

(a)SPOT WELD POINTS

(1)When welding panels with a combined thickness of over 3 mm (0.12 in.), use a MIG (Metal Inert Gas) welder for plug welding.

HINT: Spot welding does not provide sufficient durability for panels with a combined thickness of over 3 mm (0.12 in.).

F10011A

(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.

F10012A

(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) ù over
Puncher
			1.0 (0.04) − 1.6 (0.06)	6.5 (0.26) ù over
	F10013A		1.7 (0.07) − 2.3 (0.09)	8 (0.31) ù over
			2.4 (0.09) over	10 (0.39) ù over

F10014A

	20 − 30 mm
Air Saw	Overlap

F10015A

(d)SAFETY PRECAUTIONS FOR ELECTRICAL COMPONENTS

(1)When welding, there is a danger that electrical components 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 − 30 mm (0.79 − 1.18 in.) of overlap.

IN-12

INTRODUCTION

Body Measurement Diagrams

F10016A

3.INSTALLATION

(a)PRE-WELDING MEASUREMENTS

(1)Always take measurements before installing underbody or engine components to ensure 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.

WRONG	F10017A

(c)POST-WELDING REFINISHING

(1)Always check the welded spots to ensure they are secure.

(2)When smoothing out the weld spots with a disc grinder, be careful not to grind off too much as this will weaken the weld.

CORRECT WRONG

F10018A

New Spot

Old Locations

Spot

Locations

(d)SPOT WELD LOCATIONS

(1)Avoid welding over previously welded areas.

F10020A

		(e) SPOT WELDING PRECAUTIONS
		(1)	The shape of the tip point of the spot welder signifi-
			cantly affects the strength of the weld. Therefore,
			maintain the tip point in the proper shape, and allow it
			to cool after every five or six spots.
		(2)	Completely remove the paint from the areas to be spot
			welded, including the seams and the surfaces that
			come in contact with the welding tip.
Tip Cutter		(3)	Use a sander to remove any burrs that are created
	F10019A		during spot welding.

INTRODUCTION

IN-13

Sealer Gun

F10021A

4.ANTI-RUST TREATMENT AFTER INSTALLATION (BEFORE PAINTING PROCESS)

(a)BODY SEALER APPLICATION

(1)For water-proofing and anti-corrosion measures, always apply the body sealer to the body panel seams and hems of the doors, hood, etc.

(b)UNDERCOAT APPLICATION

(1)To prevent corrosion and protect the body from damage by flying stones, always apply sufficient undercoating to the bottom surface of the under body and inside of the wheel housings.

F10022A

5.ANTI-RUST TREATMENT AFTER INSTALLATION (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 hood, and around the hinges, or the welded surfaces inside the box-shapedcross sections of the side members, body pillar, etc.

F10023A

IN-14

INTRODUCTION

6.ANTI-RUST TREATMENT BY PAINTING

REFERENCE:

Painting prevents corrosion and protects 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 damage 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		Apply the anti-chipping paint before
the top coat.		the second coat.
	Anti-Chipping Paint	Top Coat
		Second Coat
	Top Coat	Anti-Chipping Paint
	Second Coat
	Under Coat (ED Primer)	Under Coat (ED Primer)
	Steel Metal	Steel Metal
		F10024A

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 the 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. Body repair must be particularly accurate 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 components.

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 battery.

When the negative (−) terminal cable is disconnected from the battery, memory of the clock and audio systems will be canceled. 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 seats and outside rear view mirrors, which are all equipped with a 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 80 C (176 F).

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.

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 in high demand.

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 body structure parts are heat repaired with an acetylene torch or other 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 a panel that cannot be returned to its original shape by pulling or hammering is called a kink.

Structural parts are designed to perform in their original shape. If parts are deformed in an accident, or if the deformed parts are repaired and reused, the parts may be unable to perform as intended.

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 that help reduce the probability of injury to passengers in side collisions.

For impact beams, we use special high tensile strength steel.

The high tensile strength steel maintains its special crystalline organization by heat treatment or alloy additives. Structural parts are designed to perform in their original shape. If parts are deformed in an accident, or if the deformed parts are repaired and reused, the parts may be unable to perform as intended.

If the impact beam or bracket is damaged, replace the door assembly with the damaged beam.

Also, the bumper reinforcement is a necessary and important part that helps reduce the probability of injury to passengers in front collisions, and for the same reasons explained above, should be replaced if damaged.

Antilock Brake System Air Conditioner assembly

Electronic Controlled Transmission Electronic Control Unit

Exempli Gratia (for Example) Except

Front Wheel Drive Vehicles

Two Wheel Drive Vehicles

Four Wheel Drive Vehicles inch

Left-hand Left-hand Drive Metal Inert Gas Model Year

Progressive Power Steering Right-hand

Right-hand Drive Supplemental Restraint System Special Service Materials

with without

IN-18

INTRODUCTION

ABBREVIATIONS USED IN THIS MANUAL

For convenience, the following abbreviations are used in this manual.

ABS A/C assy ECT ECU e.g. Ex.

FWD 2WD 4WD in.

LH

LHD MIG M/Y PPS RH RHD SRS SSM w/ w/o

BODY PANEL REPLACEMENT

BP-1

RADIATOR SUPPORT (ASSY)

REPLACEMENT

F22816A

REMOVAL

F22816

POINT

1 *1: Bolt

BP-2	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 polyurethane foam to the corresponding parts.

After welding, apply body sealer and undercoating to the corresponding parts.

After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points.

F22817

POINT

1Inspect the fitting of the headlight, front fender, hood and other related parts, before welding as this affects the appearance of the finish.

2*1: Bolt

BODY PANEL REPLACEMENT

BP-3

1,324 mm

530 mm

944 mm

742 mm

F22818

POINT

1Measure the dimensions before installing the headlight.

2These values are reference values.

530 mm (20.87 in.)

742 mm (29.21 in.)

944 mm (37.17 in.)

1,324 mm (52.13 in.)

BP-4	BODY PANEL REPLACEMENT

FRONT FENDER MOUNTING BRACKET (ASSY)

REPLACEMENT

F22819A

REMOVAL

F22819

BODY PANEL REPLACEMENT

BP-5

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 polyurethane foam to the corresponding parts.

After welding, apply body sealer and undercoating to the corresponding parts.

After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld points.

F22820

POINT

1Inspect the fitting of the front fender and other related parts before welding as this affects the appearance of the finish.

BP-110

BODY PANEL REPLACEMENT

QUARTER PANEL UPPER EXTENSION

(CUT): Hatchback

REPLACEMENT

With the back door opening trough removed.

F22867A

REMOVAL

130 mm

F22867

130 mm (5.12 in.)

BODY PANEL REPLACEMENT

BP-111

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.

F22868

BP-112

BODY PANEL REPLACEMENT

FLOOR SIDE RAIL FRONT PANEL (ASSY):

Hatchback

REPLACEMENT

With the body lower back panel removed.

F22869A

REMOVAL

F23327

BODY PANEL REPLACEMENT

BP-113

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.

(10 mm 2)

F23328

10 mm ( 0.39 in.)