Mitsubishi MOTORS Lancer Evolution 2008 Body Repair Manual
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Mitsubishi MOTORS Lancer Evolution 2008 Body Repair Manual

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2008
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
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.
The following also available, and should be used in
conjunction with this manual.
TECHNICAL INFORMATION MANUAL
SERVICE MANUAL
PARTS CATALOG
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
GROUP INDEX
BODY CONSTRUCTION . . . . . . . . .
BODY DIMENSIONS . . . . . . . . . . . . .
WELDED PANEL REPLACEMENT. .
CORROSION PROTECTION . . . . . .
SYNTHETIC-RESIN PARTS . . . . . . .
panel
replacement
BODY COLOR . . . . . . . . . . . . . . . . . .
BASE OF BODY REPAIR . . . . . . . . .
MSSP-260B-2008
MSSP-206B-2008
BUM6Y108A_
1
2
3
4
5
6
9

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Summary of Contents for Mitsubishi MOTORS Lancer Evolution 2008

  • Page 1 SERVICE MANUAL MSSP-206B-2008 PARTS CATALOG BUM6Y108A_ 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.
  • 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.

  • Page 3: Table Of Contents

    GROUP 1 BODY CONSTRUCTION CONTENTS BODY COMPONENTS... . UNDER BODY..... . . 1-20 DOOR .

  • Page 4: Body Components

    BODY CONSTRUCTION BODY COMPONENTS BODY COMPONENTS M4010001001309 75** 74** 63** : Anti-corrosion steel panels : High-tensile steel panels (*: Indicates 590MPa-high-tensile steel panels.) (**: Indicates 980MPa-ultra-high-tensile steel panels.) AB700971AB TSB Revision...
  • Page 5 BODY CONSTRUCTION BODY COMPONENTS 49. Rear floor rear end crossmember Front bumper reinforcement 50. Rear floor crossmember Headlight support panel upper 51. Rear floor side panel Front body frame to side sill brace 52. Rear floor sidemember extension Front sidemember rear 53.

  • Page 6: Body Main Cross-Sectional Views

    BODY CONSTRUCTION BODY MAIN CROSS-SECTIONAL VIEWS BODY MAIN CROSS-SECTIONAL VIEWS M4010002001067 AB700285AB Roof side rail Roof panel reinforcement rear Roof side rail inner Roof rail front upper Roof rail Side outer panel front lower AB601100AC AB700536 Front end Roof side rail Side outer crossmember reinforcement...
  • Page 7 BODY CONSTRUCTION BODY MAIN CROSS-SECTIONAL VIEWS AB700286AB Rear floor Roof side rail side sill reinforcement inner front Side sill reinforcement outer rear Front floor Front upper Side outer side sill inner pillar panel inner Side outer panel AB700539AB AB602354AB Rear pillar Rear wheel reinforcement house panel...

  • Page 8: Maintenance, Serviceability

    BODY CONSTRUCTION MAINTENANCE, SERVICEABILITY MAINTENANCE, SERVICEABILITY M4010003000948 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 assem- bling workability during panel replacement.
  • 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. Panel positioning notch AB201388AB AB700289AB 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.

  • Page 10: Body Construction Characteristics

    BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS BODY CONSTRUCTION CHARACTERISTICS FRONT BODY M4010010001200 • The bolt-on headlight support panel upper is HEADLIGHT SUPPORT used to improve maintainability. • The crush box structure, which has an octagonal • An aluminum front bumper reinforcement has cross-section at the front end of the front side- been adopted to improve the body rigidity, han- member, has been adopted.
  • 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. (Right side) AB700410 (Left side) AB700409 TSB Revision...
  • Page 12 1-10 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS 18. Spring house harness bracket Upper side bar front 19. Suction hose bracket Front end upper bar side 20. Spring house panel Front fender bracket 21. Power steering reservoir tank bracket Upper frame bulkhead front 22.
  • Page 13 1-11 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS • The 590-MPa class high tensile strength steel FRONT SIDEMEMBER REINFORCEMENT panels have been adopted for the front sidemem- • The front sidemember structure has been ber extension, front sidemember rear bulkhead changed to a straight frame structure with an and front sidemember rear to improve the body octagon cross section that efficiently absorbs rigidity.
  • Page 14 1-12 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS AB602309 AB602310 (Left side) *: Indicates 590MPa-high-tensile steel panels. AB700920 AB700931AC 12. Front suspension crossmember bracket front I plate bracket 13. Front sidemember inner Dash crossmember extension lower 14. Front sidemember brace upper Front body frame to side sill brace 15.
  • Page 15 1-13 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS AB700583AC AB700584 • Rigidity was heightened and driving stability was FRONT DECK improved by bonding the fender shield frame • The impact absorbing opening on the cowl top upper outer and front pillar by the upper frame to outer reinforcement upper has been added to effi- front pillar brace.
  • Page 16 1-14 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS 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 rein- forcement and dash crossmember side to improve the body rigidity. *: Indicates 590MPa-high-tensile steel panels.

  • Page 17: Side Body

    1-15 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS SIDE BODY M4010011001087 • A rear shelf lower brace is used to connect the SIDE STRUCTURE spring house middle panel and rear shelf upper • The 590-MPa class high tensile strength steel brace, so that the body rigidity, handling stability, panels or 980-MPa class ultra high tensile and riding comfort are improved.
  • Page 18 1-16 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS 37. Rear wheel house panel front lower outer Front pillar inner lower 38. Curtain air bag bracket Front pillar inner center 39. Quarter panel lower inner (Left side) Hood opener bracket (Left side) 40. Quarter inner panel Cowl side trim bracket (Right side) 41.

  • Page 19: Rear Body

    1-17 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS SIDE STRUCTURE REINFORCEMENT The ring structure of the side structure reinforcement has been adopted to improve the collision character- istics and the rigidity of the whole vehicle. Roof side rail reinforcement rear Roof side rail reinforcement front Rear pillar reinforcement Rear pillar reinforcement lower Side sill reinforcement outer rear...

  • Page 20: Roof

    1-18 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS REAR END PANEL 5.0 ± 1.0 N·m 44 ± 9 in-lb AB700570AB Rear end panel outer Rear bumper side bracket Rear bumper reinforcement Rear end panel inner Trunk lid striker reinforcement ROOF M4010013001306 • An aluminum roof panel has been adopted to •...
  • Page 21 1-19 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS <Vehicles without sunroof (aluminum panel)> *: Indicates 590MPa-high-tensile steel panels. AB700936AB <Vehicles with sunroof (steel panel)> AB700863AE Roof bow center lower Sunvisor bracket Dome light bracket Reading light bracket 10. Roof panel reinforcement Roof rail front lower 11.

  • Page 22: Under Body

    1-20 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS UNDER BODY M4010014001202 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.
  • Page 23 1-21 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS • The rear floor rear end crossmember has been REAR FLOOR straightened to heighten body rigidity, improve • The 590-MPa class high tensile strength steel handling stability and riding comfort, and to panels have been adopted for the rear floor reduce vibration and noise.
  • Page 24 1-22 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS 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.
  • Page 25 1-23 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS 18. Rear floor side sill inner Rear floor side panel 19. Rear suspension bracket front Rear bumper beam reinforcement 20. Trailing arm bracket lower Rear floor crossmember extension rear 21. Rear floor sidemember lower Rear suspension bracket center 22.

  • Page 26: Door

    1-24 BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS DOOR M4010015000893 An uneven thickness steel sheet* has been used for NOTE: *: A steel sheet of varying thickness that is the front and rear door panel inners to make the for- welded into one steel sheet. ward part of the vehicle thicker for reduction in vehi- cle weight and higher rigidity.

  • Page 27: Silencer Application Locations

    1-25 BODY CONSTRUCTION SILENCER APPLICATION LOCATIONS SILENCER APPLICATION LOCATIONS M4010005001271 • A silencer (MD-12, RSS and melting sheet) has been RSS (Rubber Special Sheet) is a product name affixed on the upper surface of the floor for vibration of Nihon Tokushu Toryo Co., Ltd. The product damping.

  • Page 28: Foaming Material Usage Locations

    1-26 BODY CONSTRUCTION FOAMING MATERIAL USAGE LOCATIONS FOAMING MATERIAL USAGE LOCATIONS M4010006000163 The sound dampening foam material have been CAUTION adopted to the upper and lower sections of the front The sound dampening foam material may burn pillar, center pillar lower section, rear pillar and wheel when heated.

  • Page 29: Stiffener And Damp Sheet Application Locations

    1-27 BODY CONSTRUCTION STIFFENER AND DAMP SHEET APPLICATION LOCATIONS STIFFENER AND DAMP SHEET APPLICATION LOCATIONS M4010001400263 A damp sheet (roof insulator) <Vehicles without sun- NOTE: • roof (aluminum panel)> on the inner side of the roof The main contents of a stiffener are epoxy resin. panel and a stiffener on the inner side of the rear It comes in a sheet form and contains a mixture door panel outer have been adopted for higher sur-...

  • Page 30: Theft Protection

    1-28 BODY CONSTRUCTION THEFT PROTECTION THEFT PROTECTION M4010017000145 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.
  • Page 31 1-29 BODY CONSTRUCTION THEFT PROTECTION LOCATIONS AC710510 TSB Revision...
  • Page 32 1-30 BODY CONSTRUCTION THEFT PROTECTION Label area (x: for original equipment parts, y: for replacement parts) Engine AC609841 AC612304AB Twin clutch sportronic shift transmission (TC-SST) Manual transaxle (M/T) AC708134 AC707965 View B (Hood) View A (Front fender) Section a - a Section b - b The illustration indicates left outer side.
  • Page 33 1-31 BODY CONSTRUCTION THEFT PROTECTION Label area (x: for original equipment parts, y: for replacement parts) View C (Trunk lid) AC612302 View D (Front bumper) View D' AC710511 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 E' AC608729AB AC608730AB View F (Side outer panel) View F' The illustration indicates left outer side. The illustration indicates left outer side. Right side is symmetrically opposite.
  • Page 35 GROUP 2 BODY DIMENSIONS CONTENTS BODY DIMENSIONS AND TYPE B (ACTUAL-MEASUREMENT MEASUREMENT METHODS..DIMENSIONS)....2-10 UNDER BODY..... . . 2-10 TYPE A SUSPENSION INSTALLATION...

  • Page 36: Body Dimensions And Measurement Methods

    BODY DIMENSIONS BODY DIMENSIONS AND MEASUREMENT METHODS BODY DIMENSIONS AND MEASUREMENT METHODS M4020001000448 • Type A (projected dimensions) is the dimension when a Projected dimension measurement location is projected onto the plane. NOTE: The height indicates a distance from the assumed Height standard line established 100 mm (3.9in) below the lowest measurement point.
  • Page 37 BODY DIMENSIONS BODY DIMENSIONS AND MEASUREMENT METHODS NOTES TSB Revision...

  • Page 38: Under Body

    BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS) TYPE A (PROJECTED DIMENSIONS) UNDER BODY M4020005002156 mm (in) (3.0) (24.3) (32.8) (18.2) (26.3) (36.6) (28.3) (21.3) (20.1) 1,262 (24.6) (38.1) (49.7) (34.5) (35.8) (35.2) (7.8) 1,022 (34.4) 564 (35.2) (37.8) (39.0) (40.2) (22.2) (13.8) (21.5) (15.5)
  • Page 39 BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS) No. Standard measurement point Hole shape Size mm (in) Center of front floor sidemember positioning hole (rear) Round 16 (0.63) Center of rear floor sidemember lower positioning hole (front) Oblong 33.9×18 (1.335×0.71) Center of rear suspension bracket front water draining hole Round 16 (0.63) Center of rear floor sidemember lower positioning hole (rear)
  • Page 40 BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS) 11, 12 AB700474AB AB700475 AB TSB Revision...
  • Page 41 BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS) NOTES TSB Revision...

  • Page 42: Suspension Installation Dimensions

    BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS) SUSPENSION INSTALLATION DIMENSIONS M4020013001783 mm (in) (13.0) (20.1) (20.8) (30.2) 1,298 1,000 (51.1) 1,004 (31.0) (39.4) (35.8) (34.4) (39.5) 1,132 1,138 (35.2) (34.9) (35.6) (44.6) (44.8) (17.4) (18.9) (12.9) (8.5) (29.9) (11.5) (3.3) Center line of the vehicle AB700578AB 1,116 1,200...
  • Page 43 BODY DIMENSIONS TYPE A (PROJECTED DIMENSIONS) Vehicle center Vehicle center 6˚54´ 15˚34´ mm (in) (21.3) 3˚06´ 1,087 (42.8) 0˚ (18.3) (30.2) (26.9) (13.9) (11.6) (11.2) (7.4) (7.4) (6.4) (4.1) (3.9) 1,066 (8.5) (42.0) (19.3) Standard line (20.1) (30.9) 1,223 (48.1) AB700848 NOTE: The assumed standard line is established 100 mm (3.9in) below the measurement point No.5.

  • Page 44: Type B (Actual-Measurement Dimensions)

    2-10 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) UNDER BODY M4020005002167 mm (in) (4.0) (33.7) (24.3) (26.3) (36.7) (29.1) (21.3) (21.5) (19.2) (25.4) (38.1) 1,262 1,022 (35.2) (34.4) (35.2) (49.7) (40.2) (35.8) (34.5) (39.0) (8.7) (37.8) (14.9) (22.3) (13.8) (21.5)
  • Page 45 2-11 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) No. Standard measurement point Hole shape Size mm (in) Center of front end crossmember lower water draining hole (left side) Round 8 (0.31) Center of front end crossmember lower water draining hole (right side) Round 8 (0.31) Center of front sidemember inner positioning hole Round...

  • Page 46: Suspension Installation Dimensions

    2-12 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) SUSPENSION INSTALLATION DIMENSIONS M4020013001794 mm (in) (13.6) (21.5) (21.1) (30.9) (31.8) (34.9) 1,298 1,138 1,000 (39.4) (51.1) (35.2) (44.8) (35.6) (35.8) (34.4) (17.6) (19.2) (13.5) (30.6) (8.9) (12.7) (3.3) AB700580AB 1,120 1,203 (44.1) 1,283 (47.4) (50.5)
  • Page 47 2-13 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) 5, 15 AB700472 AB601180 16, 17 18, 20 AB700480 AB700481 TSB Revision...

  • Page 48: Front Body

    2-14 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) FRONT BODY M4020006001101 mm (in) 1,094* 1,106* (43.1) (43.5) Body center point 995 * 1,174 (39.2) (46.2) 994 * (39.1) 1,625 * (64.0) 1,630 * (64.2) 1,508 (59.4) (20.0) 1,072 (42.2) 1,438 (16.7) (56.6) 1,485 (58.5)
  • Page 49 2-15 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) mm (in) 1,556 (61.3) (23.7) (21.9) (13.4) (34.4) (33.7) (32.7) (37.5) (36.9) (33.9) (38.6) 1,026 (40.4) (21.6) (30.5) (30.8) (21.4) Body center point AB700603AB No. Standard measurement point Hole shape Size mm (in) Center of front end crossmember positioning notch (Body center −...
  • Page 50 2-16 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) 21, 22 24, 25 AB700488 AB700489 AB700434 26, 27 AB700435 AB700436 AB700437 30, 31 32, 33 34, 35 AB601016 AB601020 AB700438 AB601022 AB700439 AB700440 TSB Revision...
  • Page 51 2-17 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) AB601024 AB601235 AB700849 TSB Revision...

  • Page 52: Side Body

    2-18 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) SIDE BODY M4020007001018 mm (in) (38.2) (30.0) 1,044 1,159 (41.1) (45.6) (34.1) (34.0) (25.9) (28.1) (25.0) 1,076 1,290 (42.4) (50.8) (32.4) (30.5) AB700854 1,049 (41.3) (25.2) 1,096 (43.1) 1,176 1,106 (30.7) (46.3) (43.5) (14.0) (14.3) (32.9)
  • Page 53 2-19 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) No. Standard measurement point Hole shape Size mm (in) Center of rear door upper hinge mounting hole Round 11.5 (0.45) Center of rear door lower hinge mounting hole Round 11 (0.43) Center of rear door switch mounting hole Round 5 (0.20) 43, 53...

  • Page 54: Rear Body

    2-20 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) REAR BODY M4020008001055 mm (in) 1,056* 1,045* (41.6) (41.1) 743 * (29.3) 1,361 * (53.6) 1,365 * 742 * (53.7) (29.2) Body center point (7.8) 1,244 (49.0) 1,252 (49.3) 1,190 (46.9) 1,268 (49.9) (25.8) 1,100 (4.6)
  • Page 55 2-21 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) No. Standard measurement point Hole shape Size mm (in) Center of trunk lid hinge mounting hole (front) Round 9 (0.35) Center of trunk lid hinge mounting hole (rear) Round 9 (0.35) Corner of side outer panel −...

  • Page 56: Interior

    2-22 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) INTERIOR M4020009001230 mm (in) 1,171 1,190 (46.1) (46.9) 1,330 1,375 1,357 (52.4) (54.1) (53.4) 1,430 1,430 (56.3) (56.3) 1,430 (56.3) 1,430 1,430 (56.3) (56.3) AB700461AB 1,135 1,130 (44.7) (44.5) Body center point Body center point 1,059 1,190 (41.7)
  • Page 57 2-23 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) No. Standard measurement point Hole shape Size mm (in) Front pillar positioning notch (upper) − − Front pillar positioning notch (lower) − − Roof side rail positioning notch (front) − − Side sill positioning notch (front) −...
  • Page 58 2-24 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) AB601033 AB700858 AB700463 AB601056AC AB601063 AB700464 AB700465AB TSB Revision...
  • Page 59 2-25 BODY DIMENSIONS TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) mm (in) 1,401 1,397 (55.2) (55.0) 1,392 (54.8) (5.5) (5.1) 1,392 (54.8) AB600984AE No. Standard measurement point Hole shape Size mm (in) Center of deck crossmember mounting hole (left-upper) Round 13 (0.51) Center of deck crossmember mounting hole (left-lower) Round 13 (0.51) Center of deck crossmember mounting hole (right-upper)
  • Page 60 NOTES...
  • Page 61 GROUP 9 BASE OF BODY REPAIR CONTENTS GENERAL ..... USING A FRAME STRAIGHTENER ..9-27 FRAME REPAIR PROCEDURES .

  • Page 62: General

    BASE OF BODY REPAIR GENERAL GENERAL M4090000100018 Group 9 is applicable for all models. WELDING WELDING M4090001000058 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.

  • Page 63: Electric Resistance Spot Welding

    BASE OF BODY REPAIR WELDING ELECTRIC RESISTANCE SPOT WELDING M4090002000040 ADVANTAGES OF ELECTRIC Electric resistance spot welding is a method for fus- ing metal parts together. Two or three metal sheets RESISTANCE SPOT WELDING are positioned between two copper-alloy electrode •...
  • Page 64 BASE OF BODY REPAIR WELDING NUGGET FORMATION Cooling water More than Elect- 1.6 mm rode Melting point (0.063 in) Steel panel 1.6 mm (0.063 in) or less Nugget Elect- rode C Is The Scatter Point Water 1,095 1,650˚C Small ← Welding current → Large Cooling water temperature (1,000)
  • Page 65 BASE OF BODY REPAIR WELDING NOTES REGARDING WELDING 90 – 120˚ Diameter of the electrode tip Thickness of the panel AB301455AE • Make the spot welds at the center of the 1. Selection of the electrode tips flanges to provide sufficient adhesion. When •...
  • Page 66 BASE OF BODY REPAIR WELDING The number of weld points are as below when the outer and inner center pillars are repaired by weld- ing. Factory welds (F) Repair welds (R) 8 Points 8 Points 11 Points 11 Points As shown by the Welding Requirements table, the number of repair welds is as follows. 8 (points) ×...
  • Page 67 BASE OF BODY REPAIR WELDING 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. Panel Number of repair weld (percentage of factory weld) thickness*...

  • Page 68: Gas Shield Arc Welding

    BASE OF BODY REPAIR WELDING CHECKING NUGGET STRENGTH FOLLOWING SPOT WELDING CAUTION • Stop wedging the tip or the chisel or flat-tipped screw- driver as soon as the size of the nuggets can be deter- 3 mm (0.12 in) mined; do not wedge it in more than 30 mm (1.18 inches).
  • Page 69 BASE OF BODY REPAIR WELDING MIG SPOT WELDING Wire Gas cup Gas outlet AB200036 This welding method is used in areas where regular 1. Position the tip of the nozzle at a right angle to the spot welding cannot be done. The two panels are surface to be welded.
  • Page 70 9-10 BASE OF BODY REPAIR WELDING Item Mig spot welding Electric resistance spot welding • Same as base material Welding strength Depends on strength of welding • Little oxidation wire itself. • Uniform welding quality Weld traces Button head (slightly convex) Slight concave (Almost no indentation if swivel tip used.)
  • Page 71 9-11 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. AB200041 Torch angle and welding technique There are two welding techniques: forehand welding and back-...

  • Page 72: Other Types Of Welding

    9-12 BASE OF BODY REPAIR WELDING NOTES REGARDING MIG WELDING 3. Select a welding current to match the thickness of the panels being welded. Note the following notes regarding MIG welding. 4. For continuous welding, maintain a constant weld 1. The surface to be welded must be perfectly speed and keep both the height and the width of clean;...
  • Page 73 9-13 BASE OF BODY REPAIR WELDING GAS WELDING Gas welding is a method in which a high temperature flame is Oxy-acetylene used to melt both a welding rod and the base metal (panels) to flame make a fused joint. Oxy-acetylene is the most common type of gas welding.

  • Page 74: Body Repair

    9-14 BASE OF BODY REPAIR BODY REPAIR BODY REPAIR STANDARD BODY REPAIR PROCEDURES M4090006000075 STANDARD PROCEDURES FOR The following is an explanation of the standard repair procedures for the monocoque body and the REPLACEMENT OF WELDED PANELS frame-type body. Furthermore, please refer to the In order to maintain the proper levels of strength, replacement of welded panels for the applicable rigidity, and precision when making welded panel...
  • Page 75 9-15 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.
  • 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.
  • Page 77 9-17 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...
  • Page 78 9-18 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 care- fully and correctly.
  • Page 79 9-19 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.
  • Page 80 9-20 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. Hemming tool AB200072AD (2) After completing the hemming work, make MIG spot welds at 50 −...
  • Page 81 9-21 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.
  • Page 82 9-22 BASE OF BODY REPAIR BODY REPAIR CAUTIONS REGARDING BODY REPAIR PREVENTION OF CORROSION AND OF Because each component part of a single-unit con- WATER OR DUST ENTRY struction body makes some contribution, more or 1. After any work is completed, it is important to less, to the overall strength of that body, it is neces- completely remove any welding residue, particles sary to sufficiently understand the actual function of...

  • Page 83: Theft Protection

    9-23 BASE OF BODY REPAIR BODY REPAIR 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 Theft protection label the engine, transaxle, and main of the outer body: For original parts Engine cylinder block, Transaxle housing, Fender, Doors, Quarter panel, Hood, Liftgate, Trunk lid,...

  • Page 84: Attachment Of Silencers

    9-24 BASE OF BODY REPAIR BODY REPAIR ATTACHMENT OF SILENCERS M4090009000052 Dash panel interior side Thickness: 1.6 mm (0.063 in) AB200097 Thickness: 3.2 mm (0.126 in) (two 1.6 mm (0.063 in) silencers overlapped) Silencers (petroleum-asphalt sheets) are attached to welded panel, cut and attach replacement material the upper surface of the floor and at the interior side (in the shape shown in the figure).

  • Page 85: Positioning Dimensions For Openings

    9-25 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).

  • Page 86: Standard Procedures For Sheet Metal Work

    9-26 BASE OF BODY REPAIR BODY REPAIR STANDARD PROCEDURES FOR SHEET METAL WORK M4090012000030 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.

  • Page 87: Using A Frame Straightener

    9-27 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.

  • Page 88: Frame Repair Procedures

    9-28 BASE OF BODY REPAIR BODY REPAIR FRAME STRAIGHTENING NOTES • For safety, no one must be standing in the direction of the pull. Wires for protection • Wires or chains should be used for protection in the event of an accident. •...
  • Page 89 9-29 BASE OF BODY REPAIR BODY REPAIR 1. Remove the components near the crack. Crack-stop hole 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.
  • Page 90 9-30 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 10 mm (0.39 in) crossmember or spring hanger installation part, etc. could easily occur.

  • Page 91: Notes Regarding Repair Work

    9-31 BASE OF BODY REPAIR BODY REPAIR NOTES REGARDING REPAIR WORK M4090015000039 SAFETY MEASURES 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.
  • Page 92 9-32 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.
  • Page 93 9-33 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. •...

  • Page 94: Heat-Withstand Temperatures Of Resin-Plastic Parts

    9-34 BASE OF BODY REPAIR BODY REPAIR HEAT-WITHSTAND TEMPERATURES OF RESIN-PLASTIC PARTS M4090016000054 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.
  • Page 95 9-35 BASE OF BODY REPAIR BODY REPAIR Material name Abbreviation Heat-deformation Where mainly used temperature °C (°F) 80 − 100 (176 − 212) Polyurethane Bumper, Steering wheel 80 − 100 (176 − 212) Polyurethane PUR-E Seat cushion, Arm rest, Door trim, (formed) Instrument panel 100 −...

  • Page 96: How To Distinguish Types Of Plastics

    9-36 BASE OF BODY REPAIR BODY REPAIR 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.

  • Page 97: Corrosion Protection

    9-37 BASE OF BODY REPAIR CORROSION PROTECTION CORROSION PROTECTION ANTICORROSION TREATMENT AT THE FACTORY M4090019000064 Anticorrosion treatment at the time of production includes the following measures. THE USE OF GALVANIZED STEEL PLATE : locations where galvanized steel plate is used. AB200136 AB Because galvanized steel plate has excellent corro- sion resistance, it is used in areas which have a high...
  • Page 98 9-38 BASE OF BODY REPAIR CORROSION PROTECTION CATIONIC ELECTRODEPOSITION UNDERCOATING Cationic Anionic coating coating Alkali Counteragent Counteragent solution Anionic electrodeposition Cationic electrodeposition AB200110AD AB200110 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.
  • Page 99 9-39 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. AB200113 ANTICORROSION PRIMER AB701034 AB701034 1. Rocker panel primer application Anticorrosion primer is used at the side sill outer pan- els in order to prevent corrosion and to suppress vibration.

  • Page 100: Anticorrosion Treatment At The Time Of Body Repair Work

    9-40 BASE OF BODY REPAIR CORROSION PROTECTION ANTICORROSION TREATMENT AT THE TIME OF BODY REPAIR WORK M4090020000046 The following procedures should be followed for anticorrosion protection when making repairs. AB200116 CORROSION PROTECTION FOR HOLLOW PARTS CAUTION • Wipe away any excess anticorrosion agent on the coated surface, because it can adversely affect the coating.
  • Page 101 9-41 BASE OF BODY REPAIR CORROSION PROTECTION 2. Use a brush to apply spot sealer to the contact surfaces of the panels (both the new panel and the panel remaining on the body) to be spot welded. AB200119 3. Do not spot welding. NOTE: The spot welding can be done as the spot sealer is dry to the touch.
  • Page 102 9-42 BASE OF BODY REPAIR CORROSION PROTECTION • After applying sealant to the door-stop, etc., clean away any excess so as to be sure that there is no interference with installed parts, etc. AB200123 UNDERCOATING : Undercoating application locations AB301464 AB301464 •...

  • Page 103: Repair Of Synthetic-Resin Parts

    9-43 BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS REPAIR OF SYNTHETIC-RESIN PARTS SYNTHETIC-RESIN PARTS REPAIR PROCEDURES M4090000300090 Bumper is taken as a repair work example for expla- nation. FLOWCHART Scratch (length 200 mm x Hole (diameter 50 mm Crack, tear (length width 120 mm (7.8 x 4.7 in) (1.97 in) or smaller) 200 mm (7.8 in) or smaller)
  • Page 104 9-44 BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS REPAIR JUDGMENT REPAIRABLE AREA • In case of a hole, the damaged area is reshaped to be a cir- cle or ellipse for easier filling of the repair agent. The diame- ter or major diameter should be 50 mm (1.97 inches) or smaller.
  • Page 105 9-45 BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS 2. RESHAPING OF DAMAGED AREA CAUTION The grind surface area should be larger than the resin putty application area. Remove burrs on the rear surface reinforcement point, and grind with a sandpaper #60 to #80, as a surface preparation for painting.
  • Page 106 9-46 BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS 6. ROUGH GRINDING Grind the base surface area with a sandpaper #80 as a surface preparation for painting. 7. FILLING (PUTTY APPLICATION) CAUTION When mixing the two kinds of liquid, be sure that the air is not mixed in.
  • Page 107 9-47 BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS 9. SURFACE PREPARATION FOR PRIMER-SURFACER Grind with a sandpaper #180 to #240. Grind the primer-sur- facer application area as a surface preparation for painting. In addition, remove the grind mark. AB401297AB 10.
  • Page 108 9-48 BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS 2. Apply the putty to cover pinholes, grind marks, and slight distortion. Do not apply an excessive amount at a time. Repeat application of small amount, taking a drying time. AB401300AB 3.
  • Page 109 GROUP 3 WELDED PANEL REPLACEMENT CONTENTS ULTRA HIGH STRENGTH STEEL REAR FLOOR....3-37 PLATE ......QUARTER INNER.

  • Page 110: Ultra High Strength Steel Plate

    WELDED PANEL REPLACEMENT ULTRA HIGH STRENGTH STEEL PLATE ULTRA HIGH STRENGTH STEEL PLATE M4030002800073 • For the part in which the ultra high strength steel ADVANTAGES OF ULTRA HIGH plate is used, do not repair it by cutting and bond- STRENGTH STEEL PLATE ing to avoid the reduction in strength by heat.

  • Page 111: Front End Crossmember

    WELDED PANEL REPLACEMENT FRONT END CROSSMEMBER FRONT END CROSSMEMBER M4030003100237 Symbol Operation description Spot welding MIG plug welding : indicates two panels to be welded : indicates three panels to be welded MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) AB700420AB...

  • Page 112: Fender Shield

    WELDED PANEL REPLACEMENT FENDER SHIELD FENDER SHIELD M4030004001203 Symbol Operation description Spot welding MIG plug welding : indicates two panels to be welded : indicates three panels to be welded MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) AB700421AB REPAIR WELDS...
  • Page 113 WELDED PANEL REPLACEMENT FENDER SHIELD AB700994 TSB Revision...
  • Page 114 WELDED PANEL REPLACEMENT FENDER SHIELD Right side only Right side AB700933 TSB Revision...
  • Page 115 WELDED PANEL REPLACEMENT FENDER SHIELD NOTE: Partial replacement of the front upper frame is possible Front upper frame depending on the range of damage. When performing partial inner replacement, cut the fender shield frame upper outer 152 mm 25 mm (6.0 inches) forward of the positioning hole center, and cut the (0.98 in) front upper frame inner 25 mm (0.98 inches) forward of the...

  • Page 116: Front Sidemember (Partial Replacement)

    WELDED PANEL REPLACEMENT FRONT SIDEMEMBER (PARTIAL REPLACEMENT) FRONT SIDEMEMBER (PARTIAL REPLACEMENT) M4030000100700 Symbol Operation description Spot welding MIG plug welding : indicates two panels to be welded : indicates three panels to be welded MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

  • Page 117: Front Pillar

    WELDED PANEL REPLACEMENT FRONT PILLAR FRONT PILLAR M4030005001563 Symbol Operation description Spot welding MIG plug welding : indicates two panels to be welded : indicates three panels to be welded MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) AB700423AB REPAIR WELDS...
  • Page 118 3-10 WELDED PANEL REPLACEMENT FRONT PILLAR CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn. Sound dampening foam material Sound dampening foam material Cutting position Cutting position AB601219 AB700381 (With the side outer panel removed)
  • Page 119 3-11 WELDED PANEL REPLACEMENT FRONT PILLAR NOTE ON REPAIR WORK REMOVAL After removing the front pillar, cut the side outer panel 140 mm 140 mm (5.5 inches) behind the positioning notch to remove the side sill Front pillar inner lower (5.51 in) reinforcement outer front, side sill inner support front, and front pillar inner lower remaining on the body side.
  • Page 120 3-12 WELDED PANEL REPLACEMENT FRONT PILLAR 5. Align the new roof side rail reinforcement parts to the body side to cut and install. After that, machine the body loose panel cushion (MR535301 or MR435765) as shown and apply it to the body side to prevent the sound dampening 50 mm foam material from dropping when the material is filled into (1.97 in)
  • Page 121 3-13 WELDED PANEL REPLACEMENT FRONT PILLAR 8. When installing the new front outer pillar parts, machine the 35 mm body loose panel cushion (MR535301 or MR435765) for (1.37 in) 80 mm (3.14 in) replacement as shown and apply it to the body side because 10 mm 90 mm (0.39 in)
  • Page 122 3-14 WELDED PANEL REPLACEMENT FRONT PILLAR 10.Assemble the front outer pillar, bolt and tape the hole and flange with aluminum tape, then fill the hole with sound dampening foam material as shown in the figure of the instructions. Sound dampening foam material: 3M™ AAD ULTRA- PRO Panel foam-Yellow AB601214 Front pillar reinforcement lower...
  • Page 123 3-15 WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT) FRONT PILLAR (PARTIAL REPLACEMENT) M4030001200089 Symbol Operation description Spot welding MIG plug welding : indicates two panels to be welded : indicates three panels to be welded MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
  • Page 124 3-16 WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT) AB601219 Cutting position (With the side outer panel removed) AB700941 NOTE ON REPAIR WORK REMOVAL After removing the front pillar, cut the side outer panel 140 mm 140 mm (5.5 inches) behind the positioning notch to remove the side sill Front pillar inner lower (5.51 in) reinforcement outer front, side sill inner support front, and front...
  • Page 125 3-17 WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT) 3. Assemble the new side sill reinforcement front parts. After that, cover the hole with aluminum tape to prevent the sound Side sill reinforcement front dampening foam material from dropping when the material is filled into the front pillar in the next process.
  • Page 126 3-18 WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT) 7. Assemble the front outer pillar, bolt and tape the hole and flange with aluminum tape, then fill the hole with sound dampening foam material as shown in the figure of the instructions.

  • Page 127: Center Pillar

    3-19 WELDED PANEL REPLACEMENT CENTER PILLAR CENTER PILLAR M4030006001016 Symbol Operation description Spot welding MIG plug welding : indicates two panels to be welded : indicates three panels to be welded MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) AB700424...
  • Page 128 3-20 WELDED PANEL REPLACEMENT CENTER PILLAR NOTE ON REPAIR WORK REMOVAL 1. To cut the welding points between the center pillar Side outer reinforcement and side sill reinforcement outer rear, cut the panel Center pillar side outer panel as shown. reinforcement Side sill reinforcement outer rear...
  • Page 129 3-21 WELDED PANEL REPLACEMENT CENTER PILLAR CAUTION Weld and repair if the rear door hinge reinforcement is Rear door hinge damaged. reinforcement 50 mm (1.97 in) 3. Cut the new center pillar reinforcement parts by aligning them with the cut area of center pillar reinforcement in the body-side.
  • Page 130 3-22 WELDED PANEL REPLACEMENT CENTER PILLAR 6. Assemble the center outer pillar, bolt and tape the hole and flange with aluminum tape, then fill the hole with sound dampening foam material as shown in the figure of the instructions. Sound dampening foam material: 3M™ AAD ULTRA- PRO Panel foam-Yellow Center pillar reinforcement Side sill reinforcement...

  • Page 131: Side Sill

    3-23 WELDED PANEL REPLACEMENT SIDE SILL SIDE SILL M4030007001280 Symbol Operation description Spot welding MIG plug welding : indicates two panels to be welded : indicates three panels to be welded MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) AB700425...
  • Page 132 3-24 WELDED PANEL REPLACEMENT SIDE SILL CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn. AB601437 Sound dampening foam material (With the side outer panel removed) AB700455 NOTE: Partial replacement is possible depending on the range of damage.
  • Page 133 3-25 WELDED PANEL REPLACEMENT SIDE SILL NOTE ON REPAIR WORK REMOVAL 1. When installing the side sill reinforcement outer rear, cut the 80 mm center pillar reinforcement 80 mm (3.15 inches) downward (3.15 in) from the installation hole of the rear door hinge because the center pillar reinforcement interferes with it.
  • Page 134 3-26 WELDED PANEL REPLACEMENT SIDE SILL INSTALLATION 1. Remove the center pillar inner upper from the new center inner pillar, and install the center inner pillar to the body. Center pillar inner upper AB601249 2. Remove the side sill reinforcement outer front from the new side sill reinforcement, and install the side sill reinforcement Side sill reinforcement outer front to the body.
  • Page 135 3-27 WELDED PANEL REPLACEMENT SIDE SILL 4. When installing the new front floor side sill outer, machine 50 mm (2.0 in) the body loose panel cushion (MR535301 or MR435765) for 50 mm 35 mm 50 mm replacement as shown and apply it to the body side because (2.0 in) (1.4 in) (2.0 in)
  • Page 136 3-28 WELDED PANEL REPLACEMENT SIDE SILL 6. Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminum tape, then melt the sound dampening foam material with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with sound dampening foam material.

  • Page 137: Quarter Outer

    3-29 WELDED PANEL REPLACEMENT QUARTER OUTER QUARTER OUTER M4030008001090 Symbol Operation description Spot welding : indicates two panels to be welded MIG plug welding : indicates three panels to be welded MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) AB700427...
  • Page 138 3-30 WELDED PANEL REPLACEMENT QUARTER OUTER CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn. AB602342AD TSB Revision...
  • Page 139 3-31 WELDED PANEL REPLACEMENT QUARTER OUTER NOTE ON REPAIR WORK INSTALLATION 1. When installing the new quarter panel outer, machine the 40 mm body loose panel cushion (MR535301 or MR435765) for (1.57 in) replacement as shown and apply it to the body side because 185 mm (7.28 in) the sound dampening foam material cannot be filled into the...
  • Page 140 3-32 WELDED PANEL REPLACEMENT QUARTER OUTER 3. When installing the new quarter panel outer, apply the body sealant in advance to the areas as shown. Left side only : Body sealant AB700619 4. Partial replacement is possible depending on the range of damage.

  • Page 141: Rear End Panel

    3-33 WELDED PANEL REPLACEMENT REAR END PANEL REAR END PANEL M4030009000409 Symbol Operation description Spot welding MIG plug welding : indicates two panels to be welded : indicates three panels to be welded MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)

  • Page 142: Roof

    3-34 WELDED PANEL REPLACEMENT ROOF ROOF M4030011001205 Operation description Symbol Spot welding MIG plug welding : indicates two panels to be welded : indicates three panels to be welded MIG spot welding MIG arc welding (continuous) Rivet Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) AB700285AB REPAIR WELDS...
  • Page 143 3-35 WELDED PANEL REPLACEMENT ROOF NOTE ON REPAIR WORK <Vehicles without sunroof (aluminum panel)> REMOVAL 1. Grind the self piercing rivet foot with a belt sander [belt width Self piercing rivet of 10 mm (0.39 inch)] or the like. Roof panel Foot Belt sander AB501298...
  • Page 144 3-36 WELDED PANEL REPLACEMENT ROOF (1) Insert the rivets into the roof. Recommended tool (2) Mount the recommended tool on the A-section of the rivet. (3) Operate the tool's handle while pushing the flange Roof panel surface of the rivet by the recommended tool. AB302218 (4) Part A of the rivet is cut and the rivet is tightened.

  • Page 145: Rear Floor

    3-37 WELDED PANEL REPLACEMENT REAR FLOOR REAR FLOOR M4030010001053 Symbol Operation description Spot welding MIG plug welding : indicates two panels to be welded : indicates three panels to be welded MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) AB700429...
  • Page 146 3-38 WELDED PANEL REPLACEMENT REAR FLOOR AB700940 NOTE ON REPAIR WORK REMOVAL When removing the rear floor side panel, cut it 290 mm (11.4 (With the rear floor rear removed) inches) behind the installation hole of the child restraint bracket. 290 mm (11.4 in) AB700599...

  • Page 147: Quarter Inner

    3-39 WELDED PANEL REPLACEMENT QUARTER INNER QUARTER INNER M4030012001093 Symbol Operation description Spot welding MIG plug welding : indicates two panels to be welded : indicates three panels to be welded MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) AB700430...
  • Page 148 3-40 WELDED PANEL REPLACEMENT QUARTER INNER Right side only Right side only Right side Right side only Right side Right side Right side Right side only (With the rear pillar reinforcement and the rear pillar reinforcement lower removed) Right side only Right side only AB701000AB TSB Revision...
  • Page 149 3-41 WELDED PANEL REPLACEMENT QUARTER INNER (Right side) (Left side) (With the rear wheel house panel front lower outer removed) AB700546 AB TSB Revision...
  • Page 150 3-42 WELDED PANEL REPLACEMENT QUARTER INNER NOTE ON REPAIR WORK INSTALLATION 1. When installing the new quarter panel inner, machine the body loose panel cushion (MR535301 or MR435765) as shown and apply it to the body side to prevent the sound dampening foam material from dropping when the material is filled into the rear pillar in the next process.
  • Page 151 3-43 WELDED PANEL REPLACEMENT QUARTER INNER 3. Assemble the rear quarter panel inner, bolt and tape the hole and flange with aluminum tape, then fill the hole with sound dampening foam material as shown in the figure of the instructions. Sound dampening foam material: 3M™...
  • Page 152 3-44 WELDED PANEL REPLACEMENT QUARTER INNER (PARTIAL REPLACEMENT) QUARTER INNER (PARTIAL REPLACEMENT) M4030000200127 Symbol Operation description Spot welding MIG plug welding : indicates two panels to be welded : indicates three panels to be welded MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
  • Page 153 3-45 WELDED PANEL REPLACEMENT QUARTER INNER (PARTIAL REPLACEMENT) NOTE ON REPAIR WORK REMOVAL 1. Adhere tape along the wheel arch of the quarter inner panel as shown in the figure of the instructions, use the tape as a guide so about 20 mm (0.79 inch) of the flange remains, then cut and remove.

  • Page 154: Front Door Outer Panel (Welded Type)

    3-46 WELDED PANEL REPLACEMENT FRONT DOOR OUTER PANEL (WELDED TYPE) FRONT DOOR OUTER PANEL (WELDED TYPE) M4030001500671 Symbol Operation description Spot welding MIG plug welding : indicates two panels to be welded : indicates three panels to be welded MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations...

  • Page 155: Front Door Outer Panel (Adhesion Type)

    3-47 WELDED PANEL REPLACEMENT FRONT DOOR OUTER PANEL (ADHESION TYPE) FRONT DOOR OUTER PANEL (ADHESION TYPE) M4030001700686 Symbol Operation description Spot welding MIG plug welding : indicates two panels to be welded : indicates three panels to be welded MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations...

  • Page 156: Rear Door Outer Panel (Welded Type)

    3-48 WELDED PANEL REPLACEMENT REAR DOOR OUTER PANEL (WELDED TYPE) REAR DOOR OUTER PANEL (WELDED TYPE) M4030001600548 Symbol Operation description Spot welding MIG plug welding : indicates two panels to be welded : indicates three panels to be welded MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations...

  • Page 157: Rear Door Outer Panel (Adhesion Type)

    3-49 WELDED PANEL REPLACEMENT REAR DOOR OUTER PANEL (ADHESION TYPE) REAR DOOR OUTER PANEL (ADHESION TYPE) M4030001800520 Symbol Operation description Spot welding MIG plug welding : indicates two panels to be welded : indicates three panels to be welded MIG spot welding MIG arc welding (continuous) Braze welding Anti-corrosion agent application locations...

  • Page 158: Aluminum Panel

    3-50 WELDED PANEL REPLACEMENT ALUMINUM PANEL ALUMINUM PANEL ALUMINUM PANEL CHARACTERISTICS M4030000500173 Description of aluminum panel 2. More durable: Aluminum has the property of creating oxide coating on its surface when it A new aluminum panel with higher strength and bet- contacts with the air.

  • Page 159: Aluminum Panel Repair

    3-51 WELDED PANEL REPLACEMENT ALUMINUM PANEL ALUMINUM PANEL REPAIR M4030000700230 Precautions upon sheet metal processing 1. Major difference in processing between sheet metal and steel sheet (On the basis of general body shop) Work Aluminum alloy panel Steel sheet description Hammering Mallet or plastic Sheet metal...
  • Page 160 3-52 WELDED PANEL REPLACEMENT ALUMINUM PANEL 9. General tools and sanding tools shall not be shared for both aluminum alloy and steel panels. (Iron powder remaining on the surface may cause electric corrosion with a different type of metal). 10.During MIG welding, protect the vicinity because the spatters are hard to see and spread father than expected.
  • Page 161 3-53 WELDED PANEL REPLACEMENT ALUMINUM PANEL 3. Straightening: Remove distortion by the draw correction procedure with a flattening hammer and a burner. CAUTION • The heating temperature should be approximately 250°C (482°F). • Pay particular attention to heating, because it is melted without discolouration by heat.
  • Page 162 3-54 WELDED PANEL REPLACEMENT ALUMINUM PANEL CAUTION To minimize distortion and meltdown, divide a welding area into several short segments, and weld one segment at a time. 2. Welding: Use an aluminum dedicated welding machine or a shared welding machine for aluminum and steel sheet for the operation.
  • Page 163 3-55 WELDED PANEL REPLACEMENT ALUMINUM PANEL CAUTION Remove any spark spot or carbon residue on the surface by a stainless steel wire brush, because they will cause improper painting in the following process. AB302174AB 6. Finishing: Finish it with a #100 to #120-grit disc sander. AB202109 Other welding TIG WELDING...
  • Page 164 3-56 WELDED PANEL REPLACEMENT ALUMINUM PANEL CAUTION Keep the welding surface as horizontal as possible, because the melted welding rod flows readily. 2. While melting the flux with the burner to remove the oxide coat, conduct the welding. 3. Remove the flux residue from the panel with a stainless steel wire brush.

  • Page 165: Aluminum Panel Paint

    3-57 WELDED PANEL REPLACEMENT ALUMINUM PANEL ALUMINUM PANEL PAINT M4030000800163 Painting in production line Same as painting for normal steel sheets. Precautions upon sheet metal processing CAUTION • Avoid hasty grinding and minimize grinding heat. • Do not dry it forcibly at higher than 60°C (140°F). 1.
  • Page 166 NOTES...
  • Page 167 GROUP 4 CORROSION PROTECTION CONTENTS BODY SEALING LOCATIONS ..UNDERCOAT APPLICATION LOCATIONS ....4-10...
  • Page 168 CORROSION PROTECTION BODY SEALING LOCATIONS BODY SEALING LOCATIONS M4040001001443 If the sealant application is directly visible on the NOTE: The bold dotted line indicates the application outer plate and requires appearance quality of the area on the underside. application in areas such as the drip rail, pillar, clinch and so on, then apply the sealant so that it is flat, or wipe off any excess mounding after the application.
  • Page 169 CORROSION PROTECTION BODY SEALING LOCATIONS SIDE BODY Left side only AB701025AB AB701017 AB701001 TSB Revision...
  • Page 170 CORROSION PROTECTION BODY SEALING LOCATIONS AB701002 AB701005 AB701018 AB701004 TSB Revision...
  • Page 171 CORROSION PROTECTION BODY SEALING LOCATIONS AB700615 AB701006AB AB701007AB AB701008AB TSB Revision...
  • Page 172 CORROSION PROTECTION BODY SEALING LOCATIONS AB701003AB AB701009AB Right side only Left side only AB701010 AB AB701011AB TSB Revision...
  • Page 173 CORROSION PROTECTION BODY SEALING LOCATIONS AB701012AB AB701013AB AB700340AD AB701019AB TSB Revision...
  • Page 174 CORROSION PROTECTION BODY SEALING LOCATIONS AB701015AB AB701016 Hood AB701020AB Front door AB601134AC TSB Revision...
  • Page 175 CORROSION PROTECTION BODY SEALING LOCATIONS Rear door AB601135AC Trunk lid (outer) AB601136AC Trunk lid (inner) AB700344AB TSB Revision...
  • Page 176 4-10 CORROSION PROTECTION UNDERCOAT APPLICATION LOCATIONS UNDERCOAT APPLICATION LOCATIONS M4040003001030 • The under parts of the body is undercoated for • Tape the areas marked with an asterisks to pro- anti-corrosive, anti-rust, anti-chipping, and tect those areas from getting any undercoating anti-vibration performance.
  • Page 177 GROUP 5 SYNTHETIC-RESIN PARTS CONTENTS LOCATION OF SYNTHETIC-RESIN PARTS ......
  • Page 178 SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS M4050001001433 The location and material of each of the principal synthetic-resin parts are shown below. AB700997AB AB700998AB TSB Revision...
  • Page 179 SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS Part name Name of resin Abbreviation Heat- resistant temp [°C (°F)] Radiator grille Acrylonitrile butadiene styrene 80 (176) Door mirror Rear spoiler Antenna base <Vehicles without Acrylonitrile ethylene styrene 80 (176) satellite radio tuner> Front delta garnish Acrylonitrile styrene acrylate ASA (AAS)
  • Page 180 SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS Part name Name of resin Abbreviation Heat- resistant temp [°C (°F)] Front pillar trim Talc filled rubber modified PP+E/P-TD15 80 (176) polypropylene (15%) Side air dam Talc filled rubber modified PP+E/P-TD20 110 (230) polypropylene (20%) Rear wheel splash shield rear Talc filled polypropylene PP-TD (PPF)
  • Page 181 GROUP 6 BODY COLOR CONTENTS BODY COLOR CODE ... . RADIATOR GRILLE ....GARNISH .

  • Page 182: Body Color Code

    BODY COLOR BODY COLOR CODE BODY COLOR CODE M4060001000679 Body color code is stamped on the name plate, which is attached on the underside of the center pillar (Right side). Body color code AB601277 BODY COLOR CHARTS M4060002002021 Color Color Color number Color name Coating film Composition of...

  • Page 183: Body Coloring

    BODY COLOR BODY COLORING BODY COLORING RADIATOR GRILLE M4060007000967 6 mm (0.24 in) Gray (CMH18036) Dark warm gray (AC10895) Chrome plating Dark warm gray (AC10895) Chrome plating 3 Material color AB700597AB TSB Revision...

  • Page 184: Garnish

    BODY COLOR BODY COLORING GARNISH M4060001300034 HOOD AIR SCOOP Cool Silver Metallic (CMA10031) Except Cool Silver Metallic (CMA10031) White (CMW10037) White (CMW10037) Body Color Body Color Gray (CMH18036) Body Color AB700800 AB TSB Revision...

  • Page 185: Bumper Net

    BODY COLOR BODY COLORING BUMPER NET M4060001400020 Black (AC10657) Gray (CMH18038) Black (AC10657) LH Black (AC10657) Material color RH AB701086 WHEEL HOUSE M4060012000598 AB601150 : Black (AC10657) AB700926AC TSB Revision...
  • Page 186 NOTES...

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