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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 Applicable models: 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, dont 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.
Section categories
:
INTRODUCTION
IN-1
WORK PRECAUTIONS
(a) VEHICLE PROTECTION (1) When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fireproof covers.
Seat Cover
F10001A
(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 mechanics 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 A B Name Dust-Prevention Mask Face Protector Eye Protector Safety Shoes Welders Glasses Ear Plugs Head Protector Welders Gloves
F10004A
C D E F G H
IN-2
INTRODUCTION
2.
(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* resistant temperature limit _C (_F) 80 (176)
Code
Material name
Notes
AAS
Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts.
ABS
80 (176)
AES
80 (176)
ASA
80 (176)
CAB
80 (176)
Avoid gasoline and organic or aromatic solvents. Most solvents are harmless but avoid dipping in gasoline, solvents, etc.
EPDM
Ethylene Propylene Fiber Reinforced Plastics Ethylene Acetate Ethylene / Vinyl Acetate Copolymer Resin Polyamide (Nylon) Polybutylene Terephthalate
100 (212)
FRP
180 (356)
Avoid alkali.
EVA
70 (158)
Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
E / VAC
70 (158)
Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
PA
PBT
Most solvents are harmless. Avoid gasoline, brake fluid, wax, wax removers and organic solvents. Avoid alkali.
PC
Polycarbonate
Alcohol is harmless.
*Temperatures higher than those listed here may result in material deformation during repair.
INTRODUCTION
Heat* resistant temperature limit _C (_F) 80 (176) 75 (167) 80 (176) 100 (212) 80 (176) 80 (176)
IN-3
Code
Material name
Notes
PE
Polyethylene Polyethylene Terephthalate Polymethyl Methacrylate Polyoxymethylene (Polyacetal) Polypropylene Composite Reinforced Polypropylene Modified Polyphenylene Oxide
PET
Avoid dipping in water. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. Most solvents are harmless.
PMMA
POM
PP
PPF
PPO
100 (212)
Alcohol is harmless.
Gasoline is harmless if applied only for quick wiping to remove grease. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. Most solvents are harmless but avoid dipping in gasoline, solvents, etc. Avoid dipping or immersing in alcohol, gasoline, solvents, etc.
PS
Polystyrene
60 (140)
Alcohol and gasoline are harmless if applied only for short time in small amounts. Alcohol is harmless if applied only for very short time in small amounts (e.g., quick wiping to remove grease). Alcohol and gasoline are harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts. Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
PUR
Polyurethane
80 (176)
PVC
Polyvinylchloride (Vinyl)
80 (176)
SAN
Styrene Acrylonitrile
80 (176)
TPO
Thermoplastic Olefine
80 (176)
TPU
80 (176)
TSOP
UP
Avoid alkali.
*Temperatures higher than those listed here may result in material deformation during repair.
IN-4
INTRODUCTION
3.
INTRODUCTION
IN-5
REMOVAL
POINT
1. Remove the [A] at the same time.
PART NAME
[A] Fuel filler opening lid 200 mm (7.87 in.)
REMOVAL GUIDE
Provides additional information to more efficiently help you perform the removal.
F13890A
IN-6
INTRODUCTION
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 34 mm (0.120.16 in.) in diameter 3) For other sealing points, refer to section PC.
INSTALLATION GUIDE
Provides additional information to more efficiently help you perform the installation.
SYMBOLS
(See page IN-7)
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
CUT AND JOIN LOCATION (Saw Cut)
ILLUSTRATION
CUT LOCATION
BRAZE (Removal)
BRAZE (Installation)
WELD POINTS SPOT WELD OR MIG PLUG WELD (See page IN-9) CONTINUOUS MIG WELD (BUTT WELD) CONTINUOUS MIG WELD (TACK WELD)
BODY SEALER
F13893A
IN-8
INTRODUCTION
SYMBOLS
MEANING
ILLUSTRATION
Assembly Mark
F13894A
INTRODUCTION
IN-9
REMOVAL
INSTALLATION
Weld points Remove weld point and panel position SYMBOLS MEANING ILLUSTRATION
Weld points Weld method and panel position SYMBOLS MEANING ILLUSTRATION
Spot Weld
HINT: Panel position symbols are as seen from the working posture.
F13892A
IN-10
INTRODUCTION
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
(b) CUTTING AREA (1) Always cut in a straight line and avoid reinforced areas.
Corners
F10008A
(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 Handling Precautions on Related Components on page IN-15.
WRONG
F10009A
(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 Handling Precautions on Related Components on page IN-15.
F10010A
INTRODUCTION
IN-11
2.
Less than 3 mm
(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 1.0 (0.04) under Size of plug hole 5 (0.20) over 6.5 (0.26) over 8 (0.31) over 10 (0.39) over
Puncher
F10013A
1.0 (0.04) 1.6 (0.06) 1.7 (0.07) 2.3 (0.09) 2.4 (0.09) over
(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.
F10014A
20 30 mm
Air Saw
Overlap
(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.
F10015A
IN-12
INTRODUCTION
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.
F10016A
(b) WELDING PRECAUTIONS (1) The number of welding spots should be as follows. Spot weld: 1.3 X No. of manufacturers spots. Plug weld: More than No. of manufacturers 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
(d) SPOT WELD LOCATIONS (1) Avoid welding over previously welded areas.
F10020A
Tip Cutter
F10019A
(e) SPOT WELDING PRECAUTIONS (1) The shape of the tip point of the spot welder significantly 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. (3) Use a sander to remove any burrs that are created during spot welding.
INTRODUCTION
Sealer Gun
IN-13
4.
(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.
F10021A
(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.
(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-shaped cross sections of the side members, body pillar, etc.
F10023A
IN-14
INTRODUCTION
6.
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 the top coat. Anti-Chipping Paint Top Coat Second Coat Under Coat (ED Primer) Steel Metal Anti-Chipping Paint Under Coat (ED Primer) Steel Metal
F10024A
: Apply the anti-chipping paint before the second coat. Top Coat Second Coat
INTRODUCTION
IN-15
2.
3.
4.
IN-16
INTRODUCTION
1.
2.
INTRODUCTION
IN-17
3.
IN-18
INTRODUCTION
BP-1
F22816A
REMOVAL
F22816
BP-2
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 1 Inspect 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
BP-3
1,324 mm
530 mm
944 mm
742 mm
F22818
POINT 1 Measure the dimensions before installing the headlight. 2 These 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
REMOVAL
F22819
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 1 Inspect the fitting of the front fender and other related parts before welding as this affects the appearance of the finish.
BP-110
REMOVAL
130 mm
F22867
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
REMOVAL
F23327
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.)
BP-114
REMOVAL
F24846-1
POINT 1 Remove [A] at the same time. PART NAME [A] Rear Floor Pan Extension
BP-115
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.
(10 mm x 2)
F24846-2
10 mm (0.39 in.)
BP-123
REMOVAL
F22875
POINT 1 After removing the rear floor side panel extension, remove [A]. PART NAME [A] Quarter Wheel Housing Extension
BP-124
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.
F22876
POINT 1 After installing [A], install the new parts. PART NAME [A] Quarter Wheel Housing Extension
BP-116
F22871A
REMOVAL
F23347
BP-117
[U.S.A., CANADA]
F23345
POINT 1 After removing [A], remove the rear floor pan. PART NAME [A] Rear Floor Brace Braket
BP-118
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.
F23348
[C]
BP-119
[U.S.A., CANADA]
F23346
POINT 1 After installing the new parts, install [A]. PART NAME [A] Rear Floor Brace Bracket [D] Fuel Tube No.2 Bracket [B] Spare Wheel Clamp Bracket [E] Fuel Tube Bracket
BP-125
REMOVAL
50 mm
F24852-1
POINT 1 Remove [A] at the same time. PART NAME [A] Floor Side Rail Front Panel 50 mm (1.97 in.)
BP-126
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.
F24852-2
BP-120
F24848A
REMOVAL
F24848
BP-121
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.
[U.S.A., CANADA]
F24849-1
PART NAME [A] Actuator Cover No.3 Bracket [C] Weld Bolt [E] Fuel Tube No.2 Bracket
[B] [D]
BP-122
F24849-2
BP-127
REMOVAL
F22877
BP-128
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.
F22878
BP-129
REMOVAL
F24853-1
BP-130
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.
F24853-2
BP-135
F22885A
REMOVAL
3 Door : 5 Door :
3 Door : 5 Door :
F23331
BP-136
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.
3 Door : 5 Door :
3 Door : 5 Door :
F23332
POINT 1 Before temporarily installing the new parts, apply body sealer to the window shield header panel, roof panel reinforcement and back window upper frame. HINT: 1) Apply just enough sealer for the new parts to make contact.
BP-6
F22821A
REMOVAL
[RH]
[LH]
F22821
BP-7
F22822
BP-8
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.
[RH]
[LH]
F22823
POINT 1 Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front wheel alignment. 2 Inspect the fitting of the front fender, hood and other related parts before welding as this affects the appearance of the finish.
BP-9
F22824
BP-137
F24859A
REMOVAL
F24859-1
BP-138
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.
F248860-1
POINT 1 Before temporarily installing the new parts, apply body sealer to the window shield header panel, roof panel reinforcement and back window upper frame. HINT: 1) Apply just enough sealer for the new parts to make contact.
BP-131
REMOVAL
110 mm
40 mm
F23329
POINT 1 After removing [A], remove the rear floor sidemember. PART NAME [A] Floor Side Rail Front Panel 40 mm (1.57 in.) 110 mm (4.33 in.)
BP-132
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.
F23330
BP-139
T = 13.0 N.m
T = 5.5 N.m
T = 5.5 N.m
T = 5.0 N.m
F22801
5.0
N.m
(51
kgf.cm,
44
in..lbf)
5.5
N.m
(56
kgf.cm,
49
in..lbf)
11.5
N.m
(117
kgf.cm,
ft..lbf)
BP-140
[Sedan]
T = 13.0 N.m
T = 5.5 N.m
T = 5.5 N.m
T = 5.5 N.m
F24861-1
5.0
N.m
(51
kgf.cm,
44
in..lbf)
5.5
N.m
(56
kgf.cm,
49
in..lbf)
11.5
N.m
(117
kgf.cm,
ft..lbf)
BP-141
[Hatchback 3 Door]
F23333
26.0
N.m
(265
kgf.cm,
19
ft..lbf)
BP-142
[Hatchback 5 Door]
F23334
26.0
N.m
(265
kgf.cm,
19
ft..lbf)
BP-143
[Sedan]
F24862-1
26.0
N.m
(265
kgf.cm,
19
ft..lbf)
BP-144
[Hatchback]
T = 11.5 N.m
T = 27.0 N.m
T = 19.0 N.m
F22803
11.5
N.m
(117
kgf.cm,
ft..lbf)
19.0
N.m
(194
kgf.cm,
14
ft..lbf)
27.0
N.m
(275
kgf.cm,
20
ft..lbf)
BP-145
[Sedan]
T = 7.0 N.m
T = 19.0 N.m
F24863-1
7.0
N.m
(71
kgf.cm,
62
in..lbf)
19.0
N.m
(194
kgf.cm,
14
ft..lbf)
BP-133
F24855A
REMOVAL
F24855-1
BP-134
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.
F24855-2
BP-146
FIT STANDARDS
[Hatchback]
6.0 mm
5.4 mm
2.8 mm
6.0 mm
F23343
BP-147
[Sedan]
11.85 mm
4.1 mm 2.7 mm
4.0 mm
6.45 mm
F24864-1
BP-148
[Hatchback 3 Door]
5.0 mm
4.0 mm
4.0 mm
5.6 mm
[Hatchback 5 Door]
5.0 mm 5.0 mm
5.6 mm
5.6 mm
F23335
BP-149
[Sedan]
4.7 mm
4.7 mm
4.0 mm
4.8 mm 4.0 mm
5.7 mm
5.7 mm
F24865-1
PAINT : COATING
PC-1
1.
ENGINE COMPARTMENT
[Hatchback]
F22806
PC-2
PAINT : COATING
[Sedan]
F24801-1
PC-3
[Hatchback]
F22336
PC-4
PAINT : COATING
[Sedan]
F24802-1
PC-5
[Hatchback]
F22337
PC-6
PAINT : COATING
[Sedan]
F24803-1
PC-7
[Hatchback 3 Door]
F22338
PC-8
PAINT : COATING
[Hatchback 5 Door]
F23339
PAINT : COATING
PC-9
[Sedan]
F24804-1
PC-10
PAINT : COATING
[Hatchback]
F22810
PAINT : COATING
PC-11
[Sedan]
F24805-1
PC-12
PAINT : COATING
[Hatchback]
[LH]
[RH]
F23340
POINT 1 The film thickness of the interior portion of the rear wheel housing should be 1.0 mm (0.04 in.) or more for the front half and 2.0 mm (0.08 in.) of more for the rear half. REFERENCE The under coating should be applied according to the specifications for your country while referring to the notes above.
PAINT : COATING
PC-13
[Sedan]
[LH]
[RH]
F24806-1
POINT 1 The film thickness of the interior portion of the rear wheel housing should be 1.0 mm (0.04 in.) or more for the front half and 1.3 mm (0.05 in.) of more for the rear half. REFERENCE The under coating should be applied according to the specifications for your country while referring to the notes above.
PC-14
PAINT : COATING
[Hatchback]
[5 Door Only]
F23341
PAINT : COATING
PC-15
[Sedan]
F24808-1
PC-16
PAINT : COATING
[Hatchback]
F23344
PAINT : COATING
PC-17
[Sedan]
F24809-1
PC-18
PAINT : COATING
F24810-1
BP-10
REMOVAL
[LH]
140 mm
65 mm
F23301
POINT 1 Remove [A] at the same time. PART NAME [A] Front Sidemember Outer Plate 65 mm (2.56 in.) 140 mm (5.51 in.)
BP-11
[RH]
70 mm
140 mm
F23302
POINT 1 Remove [B] before conducting this work. 2 Remove [A] at the same time. PART NAME [B] Engine Front Mounting Bracket [A] Front Sidemember Outer Plate 70 mm (2.76 in.) 140 mm (5.51 in.)
BP-12
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.
[LH]
F23303
BP-13
[RH]
F23304
POINT 1 Remove the [B] from the new parts of the front sidemember reinforcement. 2 After installing the new parts, install [B]. PART NAME [A] Front Sidemember Outer Plate [B] Engine Front Mounting Bracket
PAINT : COATING
PC-19
[Hatchback]
F24811-1
Urethane
Adheshion Primer
F23342
PC-20
MEMO
PC-21
MEMO
BODY DIMENSIONS
DI-3
745 (29.33)
1,361 (53.58)
690 (27.17) 576 (22.68) 1,261 (49.65) 620 (24.41) 1,433 (56.42) 1,131 (44.53) 572 (22.52) 749 (29.49) 1,026 (40.39) 1,126 (44.33) 1,047 (41.22) 680 (26.77)
646 (25.43)
766 (30.16)
584 (22.99)
944 (37.17)
Vehicle Dimensions
A-a 1,324 (52.13) A-C or a-c 170 (6.69) B-C or b-c 209 (8.23) B-c or b-C 1,261 (49.65) B-K or b-k 564 (22.20) B-k or b-K 942 (37.09) K-k 505 (19.88)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D E, e F, f Name Front fender installation nut Front spring support holeinner Hood hinge installation nut-rear Cowl panel center mark Front side member standard hole Front side member standard hole Hole dia. M6 (0.24) 11 (0.43) M8 (0.31) 15 (0.59) 10 (0.39) Symbol G, g H, h I, i J, j K, k Name Headlight bracket standard hole Radiator side support installation hole Radiator seal installation hole Front fender mounting bracket standard hole Front bumper installation hole
DI-4
BODY DIMENSIONS
1,374 (54.09)
178 (7.01)
1,347 (53.03)
692 (27.24)
684 (26.93)
1,126 (44.33)
820 (32.28)
597 (23.50)
957 (37.68)
262 (10.31)
Vehicle Dimensions
B-C or b-c 223 (8.78) B-c or b-C 1,264 (49.76) B-D or b-D 575 (22.64) B-K or b-k 998 (39.29) B-k or b-K 597 (23.50) C-L or c-l 381 (15.00)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D E, e F, f Name Front fender installation nut Front spring support hole-inner Hood hinge installation nut-rear Cowl panel center mark Front side member standard hole Front side member standard hole Hole dia. M6 (0.24) 11 (0.43) M8 (0.31) 15 (0.59) 10 (0.39) Symbol G, g H, h I, i J, j K, k L, l Name Headlight bracket installation hole Radiator side support inatallation hole Radiator seal installation hole Front fender mounting bracket standard hole Radiator upper support standard hole Front fender installation nut
mm (in.) Hole dia. :9 (0.35) 6.3 (0.248) 9 (0.35) 10 (0.39) 13 (0.51) M6 (0.24)
BODY DIMENSIONS
DI-5
1,050 (41.34) 903 (35.55) 1,502 (59.13) 982 (38.66) 1,373 (54.06) 1,239 (48.78) 1,266 (49.84) 1,060 (41.73) 1,145 (45.08) 1,085 (42.72) 663 (26.10)
894 (35.20)
Vehicle Dimensions
E-e 1,147 (45.16) E-f or e-F 1,532 (60.31) F-f 1,379 (54.29) E-h or e-H 1,609 (63.35) G-g 1,417 (55.79) E-j or e-J 1,372 (54.02) H-h 1,417 (55.79) E-k or e-K 1,549 (60.98) I-i 1,090 (42.91) F-j or f-J 1,826 (71.89) J-j 1,258 (49.53) F-k or f-K 1,745 (68.70) K-k 1,395 (54.92) G-h or g-H 1,440 (56.69) H-i or h-I 1,650 (64.96) J-k or j-K 1,429 (56.26)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D, d E, e F, f Roof panel corner Hood hinge installation nut Front door hinge installation nut Front door hinge installation nut Front body pillar assembly mark Front body pillar assembly mark Name Hole dia. M8 (0.31) M8 (0.31) M8 (0.31) Symbol G, g H, h I, i J, j K, k Name Rocker panel assembly mark Rocker panel assembly mark Roof side rail assembly mark Quarter panel assembly mark Quarter panel assembly mark
DI-6
BODY DIMENSIONS
1,085 (42.72)
999 (39.33)
Vehicle Dimensions
E-e 1,147 (45.16) E-f or e-F 1,532 (60.31) F-f 1,379 (54.29) E-h or e-H 1,609 (63.35) G-g 1,417 (55.79) E-j or e-J 1,312 (51.65) H-h 1,417 (55.79) F-j or f-J 1,748 (68.82) I-i 1,090 (42.91) F-k or f-K 1,628 (64.09) J-j 1,263 (49.72) H-i or h-I 1,650 (64.96) K-k 1,391 (54.76) I-q or i-Q 1,260 (49.61) J-k or j-K 1,431 (56.34)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D, d E, e F, f G, g Roof panel corner Hood hinge installation nut Front door hinge installation nut Front door hinge installation nut Front body pillar assembly mark Front body pillar assembly mark Rocker panel assembly mark Name Hole dia.
M8 (0.31) M8 (0.31) M8 (0.31)
mm (in.) Name Rocker panel assembly mark Roof side rail assembly mark Center body pillar assembly mark Center body pillar assembly mark Rear door hinge installation nut Rear door hinge installation nut Roof side rail assembly mark Hole dia.
M8 (0.31) M8 (0.31)
Symbol H, h I, i J, j K, k L, l M, m Q, q
BODY DIMENSIONS
DI-7
598 (23.54)
Vehicle Dimensions
N-n 1,263 (49.72) G-p or g-P 1,717 (67.60) O-o 1,381 (54.37) N-r or n-R 1,397 (55.00) P-p 1,417 (55.79) N-s or n-S 1,578 (62.13) Q-q 1,068 (42.05) O-r or o-R 1,584 (62.36) R-r 1,130 (44.49) O-s or o-S 1,516 (59.69) S-s 1,405 (55.31) P-q or p-Q 1,634 (64.33) R-s or r-S 1,451 (57.13)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol G, g N, n O, o P, p Name Rocker panel assembly mark Center body pillar assembly mark Center body pillar assembly mark Quarter panel assembly mark Hole dia. Symbol Q, q R, r S, s Name Roof side rail assembly mark Quarter panel assembly mark Quarter panel assembly mark
DI-8
BODY DIMENSIONS
1,044 (41.10) 914 (35.98) 1,507 (59.33) 853 (33.58) 946 (37.24) 1,173 (46.18) 1,112 (43.78)
1,064 (41.89)
1,374 (54.09)
918 (36.14)
1,069 (42.09)
1,040 (40.94)
Vehicle Dimensions
E-e 1,266 (49.84) E-f or e-F 1,443 (56.81) F-f 1,378 (54.25) E-h or e-H 1,596 (62.83) G-g 1,418 (55.83) E-j or e-J 1,515 (59.65) H-h 1,418 (55.83) F-j or f-J 1,756 (69.13) I-i 1,128 (44.41) F-k or f-K 1,656 (65.20) J-j 1,240 (48.82) H-i or h-I 1,579 (62.17) K-k 1,378 (54.25) J-k or j-K 1,403 (55.24) L-l 1,480 (58.27)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D, d E, e F, f G, g Roof panel corner Hood hinge installation nut Front door hinge installation nut Front door hinge installation nut Front body pillar assembly mark Front body pillar assembly mark Rocker panel assembly mark Name Hole dia. M8 (0.31) M8 (0.31) M8 (0.31) Symbol H, h I, i J, j K, k L, l M, m N, n Name Rocker panel assembly mark Roof side rail assembly mark Center body pillar assembly mark Center body pillar assembly mark Front door lock striker installation nut Rear door hinge installation nut Rear door hinge installation nut
BODY DIMENSIONS
DI-9
736 (28.98)
863 827 (33.98) (32.56)
641 (25.24)
1,009 (39.72)
Vehicle Dimensions
O-o 1,240 (48.82) G-q or g-Q 1,770 (69.69) P-p 1,373 (54.06) I-r or i-R 1,375 (54.13) Q-q 1,418 (55.83) O-s or o-S 1,424 (56.06) R-r 1,084 (42.68) O-t or o-T 1,577 (62.09) S-s 1,197 (47.13) P-t or p-T 1,529 (60.20) T-t 1,405 (55.31) Q-r or q-R 1,593 (62.72) U-u 1,489 (58.62) S-t or s-T 1,430 (56.30)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol G, g I, i M, m N, n O, o P, p Name Rocker panel assembly mark Roof side rail assembly mark Rear door hinge installation nut Rear door hinge installation nut Center body pillar assembly mark Center body pillar assembly mark Hole dia. M8 (0.31) M8 (0.31) Symbol Q, q R, r S, s T, t U, u Name Rocker panel assembly mark Roof side rail assembly mark Quarter panel assembly mrak Quarter panel assembly mark Rear door lock striker installation nut
BODY DIMENSIONS
DI-11
1,624 (63.94) 1,122 (44.17) 441 (17.36) 1,020 (40.16) 1,247 (49.09) 917 (36.10) 1,333 (52.48) 1,090 (42.91) 649 (25.55) 1,103
(43.43)
410 (16.14)
678 (26.69)
787 (30.98)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D, d Name Back door hinge installation hole Back door stay installation nut Back door opening trough standard hole Back door opening trough/Body lower back panel adjoining point Hole dia.
10.2 (0.402): RH 10.2 (0.402) 12 (0.47): LH
mm (in.) Name Back door lock striker installation nut Rear shock absorber installation holeinner Center body pillar assembly mark Hole dia. M8 (0.31) 18 (0.71)
Symbol E, e F, f G, g
M6 (0.24) 10 (0.39)
DI-10
BODY DIMENSIONS
1,793 (70.59) 1,020 (40.16) 1,423 (56.02) 441 (17.36) 1,247 (49.09) 907 (35.71) 1,333 (52.48) 1,090 (42.91) 410 (16.14)
1,103 (43.43)
678 (26.69)
649 (25.55)
787 (30.98)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D, d Name Back door hinge installation hole Back door stay installation nut Back door opening trough standard hole Back door opening trough/Body lower back panel adjoining point Hole dia.
10.2 (0.402): RH 10.2 (0.402) 12 (0.47): LH
mm (in.) Name Back door lock striker installation nut Rear shock absorber installation holeinner Roof side rail assembly mark Hole dia. M8 (0.31) 18 (0.71)
Symbol E, e F, f G, g
M6 (0.24) 10 (0.39)
BP-14
REMOVAL
F22829
POINT 1 Remove [A] at the same time. PART NAME [A] Front Sidemember Outer Plate
BP-15
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.
F22830
POINT 1 Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front wheel alignment.
BP-16
[LH]
[RH]
F22831
DI-12
BODY DIMENSIONS
441 (17.36)
1,432 (56.38)
805 (31.69)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D, d Roof panel corner Upper back panel corner Back door opening trough corner Luggage door opening front trough corner Name Hole dia. Symbol E, e F, f G, g H, h Name Quarter panel standard hole Body lower back reinforcement corner Rear shock absorber installation hole Center body pillar assembly mark
BODY DIMENSIONS
DI-13
598 (23.54)
453 (17.83)
RH
991 (39.02) 967 930 (38.07) (36.61) 1,096 (43.15) 1,068 (42.05)
872 (34.33)
957 (37.68)
536 276 796 (10.87) (21.10) (31.34) 844 (33.23) 796 (31.34) 727 759 854 (28.62) (29.88) 637 (33.62) (25.08) 1,100 (43.31) 645 768 478 (25.39) (30.24) (18.82) 453 (17.83)
1,120 (44.09)
410 (16.14)
LH
1,085 (42.72)
1,331 (52.40)
415 (16.34)
310 (12.20)
653 (25.71)
Front
1 100 (3.94)
2 100 (3.94)
3 100 (3.94)
G, g H, h 75 51 (2.95) (2.01)
I, i 56 (2.20)
M, m 271 (10.67)
N, n 288 (11.34)
Imaginary Standard Line HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D, d E, e F, f G, g Name Radiator side support installation nut Radiator side support installation hole Front side member standard hole Front suspension installation nut Front suspension installation nut Torque box front standard hole Front floor pan standard hole Hole dia. M6 (0.24) 6.3 (0.248) 18 (0.71) M12 (0.47) M14 (0.55) 25 (0.98) 18 (0.71) Symbol H, h I, i J, j K, k L, l M, m N, n Name Front side member standard hole Front floor pan standard hole Floor side inner rear member standard hole Rear axle beam installation outer hole-inner Rear floor side member standard hole Rear spring plate standard hole Rear floor side member standard hole
mm (in.) Hole dia. 18 (0.71) 18 (0.71) 18 (0.71) 15 (0.59) 18 (0.71) 18 (0.71) 18 (0.71)
DI-14
BODY DIMENSIONS
957 (37.68)
869 (34.21) 536 (21.10) 796 (31.34) 1,182 (46.54) 410 (16.14) 1,341 (52.80) 1,318 (51.89) 950 (37.40) 1,156 (45.51)
RH
872 (34.33)
LH
991 (39.02) 440 893 (17.32) (35.16) 930 (36.61) 1,068 (42.05) 415 (16.34)
1,060 (41.73)
1,227 (48.31)
854 (33.62)
1,231 (48.46)
453 (17.83)
1,141 (44.92)
1,331 (52.40)
979 (38.54)
462 (18.19)
638 (25.12)
653 (25.71)
Vehicle Dimensions
C-f or c-F 1,305 (51.38) F-h or f-H 1,065 (41.93) G-h or g-H 637 (25.08) 1 100 (3.94) 2 100 (3.94) 3 100 (3.94)
Front
I,i 56 (2.20)
J,j K,k M,m 98 137 269 (3.86) (5.39) (10.59) L,l 3 276 (10.87)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D, d E, e F, f G, g Name Radiator lower support standard hole Radiator side support inatallation hole Front side member standard hole Front suspension member installation nut Front suspension member installation nut Torque box front standard hole Front floor pan standard hole Hole dia. 18 (0.71) 6.3 (0.248) 18 (0.71) M12 (0.47) M14 (0.55) 25 (0.98) 18 (0.71) Symbol H, h I, i J, j K, k L, l M, m N, n Name Front side member standard hole Front floor pan standard hole Floor side inner rear member standard hole Rear axle beam installation outer hole-inner Rear floor side member standard hole Rear spring plate standard hole Rear floor side member standard hole
BODY DIMENSIONS
DI-15
1,271 (50.04)
925 (36.42)
490 (19.29)
1,149 (45.24)
RH
484 465 (19.06) (18.31) 614 (24.17)
550 (21.65)
530 (20.87)
546 (21.50)
479 (18.86)
436 (17.17)
384 (15.12)
LH
614 (24.17)
489 (19.25)
460 (18.11)
1,781 (70.12)
1,298 (51.10)
1,080 (42.52)
645 (25.39)
718 (28.27)
1,037 (40.83)
1,345 (52.95)
Front
Wheel Base
2,460 (96.85)
1 100 (3.94)
2 100 (3.94)
3 100 (3.94)
A, a B, b C, c E, e D, d F, f G, g 152 396 304 734 243 141 54 (5.98) (15.59) (11.97) (28.90) (9.57) (5.55) (2.13)
H, h I, i 75 51 (2.95) (2.01)
J, j 56 (2.20)
K, k 98 (3.86)
L, l 137 (5.39)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D, d E, e F, f G, g H, h Name Radiator side support installation nut Radiator side support installation hole Front side member standard hole Front suspension member installation nut Front spring support plate standard holeouter Front suspension member installation nut Torque box front standard hole Front floor pan standard hole Hole dia. M6 (0.24) 6.3 (0.248) 18 (0.71) M12 (0.47) 11 (0.43) M14 (0.55) 25 (0.98) 18 (0.71) Symbol I, i J, j K, k L, l M, m N, n O, o P, p Name Front side member standard hole Front floor pan standard hole Floor side inner rear member standard hole Rear axle beam installation outer hole-inner Rear floor side member standard hole Rear spring plate standard hole Rear shock absorber installation hole Rear floor side member standard hole
mm (in.) Hole dia. 18 (0.71) 18 (0.71) 18 (0.71) 15 (0.59) 18 (0.71) 18 (0.71) 18 (0.71) 18 (0.71)
DI-16
BODY DIMENSIONS
RH
465 (18.31)
220 (8.66)
614 (24.17)
550 (21.65)
422 (16.61)
546 (21.50)
LH
479 (18.86)
195 (7.68)
614 (24.17)
489 (19.25)
475 (18.70)
1,781 (70.12)
645 (25.39)
808 (31.81)
1,127 (44.37)
1,765 (69.49)
2 100 (3.94)
3 100 (3.94)
Front
J,j 56 (2.20)
N,n O,o K,k L,l 269 607 98 137 (3.86) (5.39) (10.59) (23.90)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D, d E, e F, f G, g H, h Name Radiator lower support standard hole Radiator side support inatallation hole Front side member standard hole Front suspension member installation nut Front spring support plate standard hole Front suspension member installation nut Torque box front standard hole Front floor pan standard hole Hole dia. 18 (0.71) 6.3 (0.248) 18 (0.71) M12 (0.47) 11 (0.43) M14 (0.55) 25 (0.98) 18 (0.71) Symbol I, i J, j K, k L, l M, m N, n O, o P, p Name Front side member standard hole Front floor pan standard hole Floor side inner rear member standard hole Rear axle beam installation outer hole-inner Rear floor side member standard hole Rear spring plate standard hole Rear shock absorber installation hole Rear floor side member standard hole
mm (in.) Hole dia. 18 (0.71) 18 (0.71) 18 (0.71) 15 (0.59) 18 (0.71) 18 (0.71) 18 (0.71) 18 (0.71)
BODY DIMENSIONS
DI-17
REFERENCE VALUE
ENGINE COMPARTMENT Hatchboack
(Three-Dimensional Distance)
1,324 (52.13) 1,361 (53.58) 618 (24.33) 1,025 (40.35) 1,008 (39.69)
590 (23.23)
505 (19.88)
HINT: These values are actual measurements made on a vehicle. Use these reference values.
Symbol A, a B, b Name Front bumper cover installation bolt Front end of fender Hole dia. Symbol C, c D, d Name Headlight installation bolt Front fender installation bolt
DI-18
BODY DIMENSIONS
REFERENCE VALUE
ENGINE COMPARTMENT Sedan
(Three-Dimensional Distance)
234 (9.21)
1,357 (53.43)
1,347 (53.03) 1,357 (53.43) 1,327 (52.24) 1,336 (52.60) 205 (8.07)
533 (20.98)
965 (37.99)
1,070 (42.13)
979 (38.54)
682 (26.85)
512 (20.16)
504 (19.84)
HINT: These values are actual measurements made on a vehicle. Use these reference values.
Symbol A, a B, b Name Front bumper cover installation clip Headlight installation bolt Hole dia. Symbol C, c D, d Name Front fender installation bolt Front fender installation bolt
BODY DIMENSIONS
DI-19
UNDER BODY
(Two-Dimensional Distance)
M10 NUT
0.6
2.8
52
mm
BP-17
F22832A
REMOVAL
F22832
BP-18
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.
(20 mm)
(25 mm)
(30 mm)
(15 mm)
F22833
15 mm (0.59 in.)
20 mm (0.79 in.)
25 mm (0.98 in.)
30 mm (1.18 in.)
BP-19
F22834A
REMOVAL
F22834
BP-20
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.
(25 mm)
(25 mm)
F22835
POINT 1 Inspect the fitting of the hood and related parts before welding as this affects the appearance of the finish.
25 mm (0.98 in.)
BP-21
F22836A
REMOVAL
100 mm 80 mm
160 mm 70 mm
F22836
POINT 1 *1: This part of the outer panel is reused because the rocker panel section is cut off at a position behind the service part cut position of the outer panel. 70 mm (2.76 in.) 80 mm (3.15 in.) 100 mm (3.94 in.) 160 mm (6.30 in.)
BP-22
F22837
BP-23
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 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 spots.
230 mm
(10 mm
3)
(15 mm
3)
F22838
POINT 1 Before temporarily installing the new parts, weld [A], [B], [C] and [D] with standard welding number. PART NAME [B] Front Body Pillar Lower Reinforce [A] Rocker Outer Reinforce [D] Front Body Outer Pillar [C] Front Body Inner Pillar 10 mm (0.39 in.) 15 mm (0.59 in.) 230 mm (9.06 in.)
BP-24
(10 mm)
(15 mm
2)
F22839
POINT 1 Inspect the fitting of the front fender, front door, windshield glass and other related parts before welding as this affects the appearance of the finish. 10 mm (0.39 in.) 15 mm (0.59 in.)
BP-25
F22840A
REMOVAL
50 mm 30 mm 30 mm
50 mm 50 mm
F22840
30 mm (1.18 in.)
50 mm (1.97 in.)
BP-26
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.
80 mm
45 mm
(10 mm
7)
F22841
POINT 1 Before temporarily installing the new parts, weld [A], [B] and [C] with standard welding number. PART NAME [B] Center Body Pillar Reinforcement [A] Rocker Outer Reinforce 10 mm (0.39 in.) 45 mm (1.77 in.) 80 mm (3.15 in.) [C] Center Body Inner Pillar
BP-27
(10 mm
4)
F22842
POINT 1 Inspect the fitting of the front door, rear door and other related parts before welding as this affects the appearance of the finish. 2 After welding [A], [B] and [C] to the vehicle, install [D]. PART NAME [A] Rocker Outer Reinforce [C] Center Body Inner Pillar [B] [D] Center Body Pillar Reinforcement Center Body Outer Pillar
10 mm (0.39 in.)
BP-28
F23305A
REMOVAL
Hemming Location
Disc Sander
F23305
POINT 1 After grinding off the hemming location, remove the outer panel.
BP-29
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
Cloth Tape
30_
Hemming Tool
F23306
POINT 1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact. 2 Bend the flange hem about 30_ with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly.
BP-30
F23307A
REMOVAL
Hemming Location
Disc Sander
F23307
POINT 1 After grinding off the hemming location, remove the outer panel.
BP-31
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
Cloth Tape
30_
Hemming Tool
F23308
POINT 1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact. 2 Bend the flange hem about 30_ with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly.
BP-32
F23309A
REMOVAL
Hemming Location
Disc Sander
F23309
POINT 1 After grinding off the hemming location, remove the outer panel.
BP-33
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
Cloth Tape
30_
Hemming Tool
F23310
POINT 1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact. 2 Bend the flange hem about 30_ with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly.
BP-34
F22843A
REMOVAL
380 mm
F22843
BP-35
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.
F22844
POINT 1 Inspect the fitting of the front door and other related parts before welding as this affects the appearance of the finish.
BP-36
F23311A
REMOVAL
F23311
BP-37
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.
F23312
POINT 1 Inspect the fitting of the front door and other related parts before welding as this affects the appearance of the finish.
BP-38
F22845A
REMOVAL
100 mm
F22845
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 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.
F22846
POINT 1 Inspect the fitting of the front door, rear door and other related parts before welding as this affects the appearance of the finish.
BP-40
1.
Adhesive Application Area
Cut and Join Location
(A) Remove the body sealer from the Quarter Panel and cut at the cut and join location. Remove the spot welded portions. (B) After rough cutting the Wheel Arch portion, heat the adhesive applied area and remove the panel. {Heat the Wheel Arch portion of the Quarter Panel at 110 to 140 C (230 to 284 F) with a dryer or gas burner and remove the Quarter Panel.}
2.
010L06
(A) Heat at 110 to 140 C (230 to 284 F) with a dryer or gas burner. (B) Scrape away the adhesive with a scraper, and scuff while sanding with a disc grinder or a belt sander. NOTE _ Make sure to use either a disc grinder or belt sander to sand coarsely and deeply to improve adhesiveness. _ Scuff at a width of approximately 10 mm (0.39 in.) over the previous adhesive coating.
3.
(A) After the adhesive has been removed from the body, remove the paint from the underside of the spot welded points blow air and degrease. (B) Apply spot sealer at the joined portion between panels.
approx.10 mm After sanding
010L07a
BP-41
4.
(A) Temporarily attach the new panel and check the fitting condition, the cut and join locations, the welded areas, and the adhesive applied area. NOTE _ Check the adhesive applied condition to ensure adhesive strength. _ Conduct hammering to fix the non-adhered portions.
Cross-Sectional view
Adhesive
1 mm gap
010L10a
5.
Application Area Scuffed Area
10 mm 28 mm
010L11a
(A) Scuff with #60-120 grit sandpaper at the adhesive application area. POINT Sand deeply into the ED coat. (B) Blow air around the scuffed portion and then degrease. (C) Apply adhesive. POINT Apply adhesive at a width of approximately 10 mm (0.39 in.) at a location 28 mm (1.10 in.) from the panel flange edge. Spread the adhesive flatly within the scuffed area {approximately 10 mm (0.39 in.) in width} to remove trapped air.
010L12
Approx. 3 mm
3 mm Adhesive
010L12-1a
010L13
BP-42
6.
010L15
(A) Degrease the adhesive aplication area. (B) Apply adhesive. _ Refer to the diagram of step 5 for the application amount. _ The application location is 7.5 mm (0.295 in.) from the flange edge. (C) Flatten out the applied adhesive with a spatula until it is at an even level. _ Apply adhesive at exposed metal plate portions to prevent corrosion. _ It is not necessary to flatten out adhesive after it has been reapplied.
7.5 mm
Flange Edge
010L16 010L17a
7.
(A) Set the new panel in the position for temporary attachment. (Be careful of where you hold the panel so as not to touch the adhesive applied surfaces.) (B) Secure in a vice grip or equivalent and check the fitting condition. (C) Press on the entire surface so that the adhesive between the Quarter Panel and Quarter Wheel Housing Outer panel becomes an even thickness. NOTE Be careful that adhesive that spills over does not contact the Brake Drum. (D) Tack weld at the cut and join welded portion. (E) Tack weld by spot welding at one point on both ends of the adhesive applied portions. (F) Conduct actual welding using procedures in the BP section of this manual.
Tack Weld
010L20a
BP-43
8.
Infrared Ray Hearter
Drying
010L22a
(A) Clean away adhesive that has spilled over with a degreaser or equivalent. (B) After all welding works have been completed, dry the adhesive with a heater. _ Hardening Time : Forced drying 60 C (140 F) at 90 minutes. : Natural drying 24 C (75 F) (room temperature) for 24 hours.
9.
Other work
(A) After applying Primer Surfacer to the underside of the Wheel Arch of the Quarter Panel, apply body sealer to the locations indicated in the body repair manual.
Adhesive
Body Sealer
010L21a
BP-44
F23313A
REMOVAL
205 mm 645 mm
F23313
POINT 1 *1: The hatched area indicates the adhesive application area. PART NAME [A] Quarter Wheel Housing Outer Panel 205 mm (8.07 in.) 645 mm (25.39 in.)
BP-45
F23314
BP-46
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.
1.0 mm
F23315
POINT 1 *1: The hatched area indicates the adhesive application area. PART NAME [A] Quarter Wheel Housing Outer Panel 1.0 mm (0.04 in.) [B] Fuel Filler Opening Lid [C] Rivet
BP-47
F23316
POINT 1 Inspect the front door, back door, rear combination light and other related parts before welding as this affects the appearance of the finish.
BP-48
F22847A
REMOVAL
F23317
POINT 1 *1: The hatched area indicates the adhesive application area. PART NAME [A] Quarter Wheel Housing Outer Panel
BP-49
150 mm
F23318
150 mm (5.91in.)
BP-50
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.
1.0 mm
F23319
POINT 1 *1: The hatched area indicates the adhesive application area. PART NAME [A] Quarter Wheel Housing Outer Panel 1.0 mm (0.04 in.) [B] Fuel Filler Opening Lid [C] Rivet
BP-51
F23320
POINT 1 Inspect the front door, back door, rear combination light and other related parts before welding as this affects the appearance of the finish.
BP-52
REMOVAL
[LH]
3 Door : 5 Door :
3 Door : 5 Door :
F23321
POINT 1 After removing [A], remove the quarter wheel housing outer panel. PART NAME [A] Rocker Outer Extension
BP-53
[LH]
40 mm
F22852
POINT 1 After removing [B], remove the quarter wheel housing outer panel. PART NAME [B] Roof Side Outer Panel 40 mm (1.57 in.)
BP-54
[RH]
3 Door : 5 Door :
3 Door : 5 Door :
F23322
POINT 1 After removing [A], remove the quarter wheel housing outer panel. PART NAME [A] Rocker Outer Extension
BP-55
[RH]
30 mm
F22854
POINT 1 After removing [B], remove the quarter wheel housing outer panel. PART NAME [B] Roof Side Outer Panel 30 mm (1.18 in.)
BP-56
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.
[LH]
F22856
POINT 1 After installing the new parts, install [B]. PART NAME [B] Roof Side Outer Panel
BP-57
[LH]
3 Door : 5 Door :
3 Door : 5 Door :
F23323
POINT 1 After installing the new parts, install [A]. PART NAME [A] Rocker Outer Extension
BP-58
[RH]
F22858
POINT 1 After installing the new parts, install [B]. PART NAME [B] Roof Side Outer Panel
BP-59
[RH]
3 Door : 5 Door :
3 Door : 5 Door :
F23324
POINT 1 After installing the new parts, install [A]. PART NAME [A] Rocker Outer Extension
BP-60
F22859A
REMOVAL
F22859
BP-61
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.
F22860
BP-62
F22861A
REMOVAL
F23325
BP-63
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.
F23326
POINT 1 Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects the appearance of the finish.
BP-64
F22865A
REMOVAL
F22865
POINT 1 Remove [A] at the same time. PART NAME [A] Back Door Opening Lower Reinforcement
BP-65
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.
F22866
POINT 1 Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects the appearance of the finish. PART NAME [A] Back Door Opening Lower Reinforcement [B] Rear Bumper Side Retainer
BP-66
F22867A
REMOVAL
130 mm
F22867
BP-67
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-68
F22869A
REMOVAL
F23327
BP-69
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.)
BP-70
F22871A
REMOVAL
F23347
BP-71
[U.S.A., CANADA]
F23345
POINT 1 After removing [A], remove the rear floor pan. PART NAME [A] Rear Floor Brace Braket
BP-72
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.
F23348
[C]
BP-73
[U.S.A., CANADA]
F23346
POINT 1 After installing the new parts, install [A]. PART NAME [A] Rear Floor Brace Bracket [D] Fuel Tube No.2 Bracket [B] Spare Wheel Clamp Bracket [E] Fuel Tube Bracket
BP-74
REMOVAL
F22875
POINT 1 After removing the rear floor side panel extension, remove [A]. PART NAME [A] Quarter Wheel Housing Extension
BP-75
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.
F22876
POINT 1 After installing [A], install the new parts. PART NAME [A] Quarter Wheel Housing Extension
BP-76
F22877A
REMOVAL
F22877
BP-77
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.
F22878
BP-78
F22881A
REMOVAL
110 mm
40 mm
F23329
POINT 1 After removing [A], remove the rear floor sidemember. PART NAME [A] Floor Side Rail Front Panel 40 mm (1.57 in.) 110 mm (4.33 in.)
BP-79
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.
F23330
BP-80
F22885A
REMOVAL
3 Door : 5 Door :
3 Door : 5 Door :
F23331
BP-81
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.
3 Door : 5 Door :
3 Door : 5 Door :
F23332
POINT 1 Before temporarily installing the new parts, apply body sealer to the window shield header panel, roof panel reinforcement and back window upper frame. HINT: 1) Apply just enough sealer for the new parts to make contact.
BP-82
T = 13.0 N.m
T = 5.5 N.m
T = 5.5 N.m
T = 5.0 N.m
F22801
5.0
N.m
(51
kgf.cm,
44
in..lbf)
5.5
N.m
(56
kgf.cm,
49
in..lbf)
11.5
N.m
(117
kgf.cm,
ft..lbf)
BP-83
[3 Door]
F23333
26.0
N.m
(265
kgf.cm,
19
ft..lbf)
BP-84
[5 Door]
F23334
26.0
N.m
(265
kgf.cm,
19
ft..lbf)
BP-85
T = 11.5 N.m
T = 27.0 N.m
T = 19.0 N.m
F22803
11.5
N.m
(117
kgf.cm,
ft..lbf)
19.0
N.m
(194
kgf.cm,
14
ft..lbf)
27.0
N.m
(275
kgf.cm,
20
ft..lbf)
BP-86
FIT STANDARDS
6.0 mm
5.4 mm
2.8 mm
6.0 mm
F23343
BP-87
[3 Door]
5.0 mm
4.0 mm
4.0 mm
5.6 mm
[5 Door]
5.0 mm 5.0 mm
5.6 mm
5.6 mm
F23335
PAINT : COATING
PC-1
1.
ENGINE COMPARTMENT
F22806
PC-2 2. INSIDE
PAINT : COATING
F22336
PC-3
F22337
PAINT : COATING
[3 Door]
F22338
PAINT : COATING
PC-5
[5 Door]
F23339
PC-6
PAINT : COATING
F22810
PAINT : COATING
PC-7
[LH]
[RH]
F23340
POINT 1 The film thickness of the interior portion of the rear wheel housing should be 1.0 mm (0.04 in.) or more for the front half and 2.0 mm (0.08 in.) of more for the rear half. REFERENCE The under coating should be applied according to the specifications for your country while referring to the notes above.
PC-8
PAINT : COATING
[5 Door Only]
F23341
PAINT : COATING
PC-9
F23344
PC-10
PAINT : COATING
F23342
PVC
BODY DIMENSIONS
Three-dimensional distance Center-to-center straight-line distance
DI-1
GENERAL INFORMATION
1. BASIC DIMENSIONS
(a) There are two types of dimensions in the diagram. (1) (Three-dimensional distance) : Straight-line distance between the centers of two measuring points.
Two-dimensional distance
(2) (Two-dimensional distance) : Horizontal distance in forward/rearward direction between the centers of two measuring points. : The height from an imaginary standard line. (b) In cases in which only one dimension is given, left and right are symmetrical. (c) The dimensions in the following drawing indicate actual distance. Therefore, please use the dimensions as a reference. (d) The line that connects the places listed below is the imaginary standard line when measuring the height. (The dimensions are printed in the text.)
SYMBOL 1
Name The place that was lowered A mm from the under surface of the rocker panel centered on the front jack up point. The place that was lowered B mm from the under surface of the rocker panel centered between 1 and 3. The place that was lowered C mm from the under surface of the rocker panel centered on the rear jack up point.
A mm
B mm
C mm
2 3
DI-2
Plate Looseness Body Looseness
(a) Basically, all measurements are to be done with a tracking gauge. For portions where it is not possible to use a tracking gauge, a tape measure should be used. (b) Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers.
Wrong
Correct
Pointer
HINT: 1) The height of the left and right pointers must be equal. 2) Always calibrate the tracking gauge before measuring or after adjusting the pointer height. 3) Take care not to drop the tracking gauge or otherwise shock it. 4) Confirm that the pointers are securely in the holes. (c) When using a tape measure, avoid twists and bends in the tape.
BODY DIMENSIONS
DI-3
1,373 (54.06)
745 (29.33)
1,361 (53.58)
690 (27.17) 576 (22.68) 1,261 (49.65) 620 (24.41) 1,433 (56.42) 1,131 (44.53) 572 (22.52) 749 (29.49) 1,026 (40.39) 1,126 (44.33) 1,047 (41.22) 680 (26.77)
646 (25.43)
766 (30.16)
584 (22.99)
944 (37.17)
Vehicle Dimensions
A-a 1,324 (52.13) A-C or a-c 170 (6.69) B-C or b-c 209 (8.23) B-c or b-C 1,261 (49.65) B-K or b-k 564 (22.20) B-k or b-K 942 (37.09) K-k 505 (19.88)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D E, e F, f Name Front fender installation nut Front spring support holeinner Hood hinge installation nut-rear Cowl panel center mark Front side member standard hole Front side member standard hole Hole dia. M6 (0.24) 11 (0.43) M8 (0.31) 15 (0.59) 10 (0.39) Symbol G, g H, h I, i J, j K, k Name Headlight bracket standard hole Crush box installation hole Radiator seal installation hole Front fender mounting bracket standard hole Front bumper installation hole
DI-4
BODY DIMENSIONS
1,050 (41.34) 903 (35.55) 1,502 (59.13) 982 (38.66) 1,373 (54.06) 1,239 (48.78) 1,266 (49.84) 1,060 (41.73) 1,145 (45.08) 1,085 (42.72) 663 (26.10)
894 (35.20)
Vehicle Dimensions
E-e 1,147 (45.16) E-f or e-F 1,532 (60.31) F-f 1,379 (54.29) E-h or e-H 1,609 (63.35) G-g 1,417 (55.79) E-j or e-J 1,372 (54.02) H-h 1,417 (55.79) E-k or e-K 1,549 (60.98) I-i 1,090 (42.91) F-j or f-J 1,826 (71.89) J-j 1,258 (49.53) F-k or f-K 1,745 (68.70) K-k 1,395 (54.92) G-h or g-H 1,440 (56.69) H-i or h-I 1,650 (64.96) J-k or j-K 1,429 (56.26)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D, d E, e F, f Roof panel corner Hood hinge installation nut Front door hinge installation nut Front door hinge installation nut Front body pillar assembly mark Front body pillar assembly mark Name Hole dia. M8 (0.31) M8 (0.31) M8 (0.31) Symbol G, g H, h I, i J, j K, k Name Rocker panel assembly mark Rocker panel assembly mark Roof side rail assembly mark Quarter panel assembly mark Quarter panel assembly mark
BODY DIMENSIONS
DI-5
1,085 (42.72)
999 (39.33)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D, d E, e F, f G, g Roof panel corner Hood hinge installation nut Front door hinge installation nut Front door hinge installation nut Front body pillar assembly mark Front body pillar assembly mark Rocker panel assembly mark Name Hole dia.
M8 (0.31) M8 (0.31) M8 (0.31)
mm (in.) Name Rocker panel assembly mark Roof side rail assembly mark Center body pillar assembly mark Center body pillar assembly mark Rear door hinge installation nut Rear door hinge installation nut Roof side rail assembly mark Hole dia.
M8 (0.31) M8 (0.31)
Symbol H, h I, i J, j K, k L, l M, m Q, q
DI-6
BODY DIMENSIONS
598 (23.54)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol G, g N, n O, o P, p Name Rocker panel assembly mark Center body pillar assembly mark Center body pillar assembly mark Quarter panel assembly mark Hole dia. Symbol Q, q R, r S, s Name Roof side rail assembly mark Quarter panel assembly mark Quarter panel assembly mark
BODY DIMENSIONS
DI-7
1,793 (70.59) 1,020 (40.16) 1,423 (56.02) 441 (17.36) 1,247 (49.09) 907 (35.71) 1,333 (52.48) 1,090 (42.91) 410 (16.14)
1,103 (43.43)
678 (26.69)
649 (25.55)
787 (30.98)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D, d Name Back door hinge installation hole Back door stay installation nut Back door opening trough standard hole Back door opening trough/Body lower back panel adjoining point Hole dia.
10.2 (0.402): RH 10.2 (0.402) 12 (0.47): LH
mm (in.) Name Back door lock striker installation nut Rear shock absorber installation holeinner Roof side rail assembly mark Hole dia. M8 (0.31) 18 (0.71)
Symbol E, e F, f G, g
M6 (0.24) 10 (0.39)
DI-8
BODY DIMENSIONS
1,624 (63.94) 1,122 (44.17) 441 (17.36) 1,020 (40.16) 1,247 (49.09) 917 (36.10) 1,333 (52.48) 1,090 (42.91) 649 (25.55) 1,103
(43.43)
410 (16.14)
678 (26.69)
787 (30.98)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D, d Name Back door hinge installation hole Back door stay installation nut Back door opening trough standard hole Back door opening trough/Body lower back panel adjoining point Hole dia.
10.2 (0.402): RH 10.2 (0.402) 12 (0.47): LH
mm (in.) Name Back door lock striker installation nut Rear shock absorber installation holeinner Center body pillar assembly mark Hole dia. M8 (0.31) 18 (0.71)
Symbol E, e F, f G, g
M6 (0.24) 10 (0.39)
BODY DIMENSIONS
DI-9
UNDER BODY
(Three-Dimensional Distance)
598 (23.54)
453 (17.83)
RH
991 (39.02) 967 930 (38.07) (36.61) 1,096 (43.15) 1,068 (42.05)
872 (34.33)
957 (37.68)
536 276 796 (10.87) (21.10) (31.34) 844 (33.23) 796 (31.34) 727 759 854 (28.62) (29.88) 637 (33.62) (25.08) 1,100 (43.31) 645 768 478 (25.39) (30.24) (18.82) 453 (17.83)
1,120 (44.09)
410 (16.14)
LH
1,085 (42.72)
1,331 (52.40)
415 (16.34)
310 (12.20)
653 (25.71)
1 100 (3.94)
2 100 (3.94)
3 100 (3.94)
Front
G, g H, h 75 51 (2.95) (2.01)
I, i 56 (2.20)
M, m 271 (10.67)
N, n 288 (11.34)
Imaginary Standard Line HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D, d E, e F, f G, g Name Radiator side support installation nut Crush box installation hole Front side member standard hole Front suspension installation nut Front suspension installation nut Torque box front standard hole Front floor pan standard hole Hole dia. M6 (0.24) 6.3 (0.248) 18 (0.71) M12 (0.47) M14 (0.55) 25 (0.98) 18 (0.71) Symbol H, h I, i J, j K, k L, l M, m N, n Name Front side member standard hole Front floor pan standard hole Floor side inner rear member standard hole Trading arm installation outer holeinner Rear floor sidemember standard hole Rear spring plate standard hole Rear floor sidemember standard hole
mm (in.) Hole dia. 18 (0.71) 18 (0.71) 18 (0.71) 15 (0.59) 18 (0.71) 18 (0.71) 18 (0.71)
DI-10
BODY DIMENSIONS
UNDER BODY
(Two-Dimensional Distance)
1,271 (50.04)
925 (36.42)
490 (19.29)
1,149 (45.24)
RH
484 465 (19.06) (18.31) 614 (24.17)
550 (21.65)
530 (20.87)
546 (21.50)
479 (18.86)
436 (17.17)
384 (15.12)
LH
614 (24.17)
489 (19.25)
460 (18.11)
1,781 (70.12)
1,298 (51.10)
1,080 (42.52)
645 (25.39)
718 (28.27)
1,037 (40.83)
1,345 (52.95)
Wheel Base
2,460 (96.85)
1 100 (3.94)
2 100 (3.94)
3 100 (3.94)
Front
A, a B, b C, c E, e D, d F, f G, g 152 396 304 734 243 141 54 (5.98) (15.59) (11.97) (28.90) (9.57) (5.55) (2.13)
H, h I, i 75 51 (2.95) (2.01)
J, j 56 (2.20)
K, k 98 (3.86)
L, l 137 (5.39)
HINT: For symbols, capital letters indicate right side of vehicle, small letters indicate left side of vehicle (seen from rear).
Symbol A, a B, b C, c D, d E, e F, f G, g H, h Name Radiator side support installation nut Crush box installation hole Front side member standard hole Front suspension member installation nut Front spring support plate standard holeouter Front suspension member installation nut Torque box front standard hole Front floor pan standard hole Hole dia. M6 (0.24) 6.3 (0.248) 18 (0.71) M12 (0.47) 11 (0.43) M14 (0.55) 25 (0.98) 18 (0.71) Symbol I, i J, j K, k L, l M, m N, n O, o P, p Name Front side member standard hole Front floor pan standard hole Floor side inner rear member standard hole Trading arm installation outer holeinner Rear floor sidemember standard hole Rear spring plate standard hole Rear shock absorber installation hole Rear floor sidemember standard hole
mm (in.) Hole dia. 18 (0.71) 18 (0.71) 18 (0.71) 15 (0.59) 18 (0.71) 18 (0.71) 18 (0.71) 18 (0.71)
BODY DIMENSIONS
DI-11
REFERENCE VALUE
ENGINE COMPARTMENT
(Three-Dimensional Distance)
1,324 (52.13) 1,361 (53.58) 618 (24.33) 1,025 (40.35) 1,008 (39.69)
590 (23.23)
505 (19.88)
HINT: These values are actual measurements made on a vehicle. Use these reference values.
Symbol A, a B, b Name Front bumper cover installation bolt Front end of fender Hole dia. Symbol C, c D, d Name Headlight installation bolt Front fender installation bolt
DI-12
BODY DIMENSIONS
UNDER BODY
(Two-Dimensional Distance)
M10 NUT
0.6
2.8
52
mm
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, 92, 93 series SCP90 series NLP90 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, dont 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.
Section categories
:
INTRODUCTION
IN-1
WORK PRECAUTIONS
(a) VEHICLE PROTECTION (1) When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fireproof covers.
Seat Cover
F10001A
(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 mechanics 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 A B Name Dust-Prevention Mask Face Protector Eye Protector Safety Shoes Welders Glasses Ear Plugs Head Protector Welders Gloves
F10004A
C D E F G H
IN-2
INTRODUCTION
2.
(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* resistant temperature limit _C (_F) 80 (176)
Code
Material name
Notes
AAS
Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts.
ABS
80 (176)
AES
80 (176)
ASA
80 (176)
CAB
80 (176)
Avoid gasoline and organic or aromatic solvents. Most solvents are harmless but avoid dipping in gasoline, solvents, etc.
EPDM
Ethylene Propylene Fiber Reinforced Plastics Ethylene Acetate Ethylene / Vinyl Acetate Copolymer Resin Polyamide (Nylon) Polybutylene Terephthalate
100 (212)
FRP
180 (356)
Avoid alkali.
EVA
70 (158)
Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
E / VAC
70 (158)
Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
PA
PBT
Most solvents are harmless. Avoid gasoline, brake fluid, wax, wax removers and organic solvents. Avoid alkali.
PC
Polycarbonate
Alcohol is harmless.
*Temperatures higher than those listed here may result in material deformation during repair.
INTRODUCTION
Heat* resistant temperature limit _C (_F) 80 (176) 75 (167) 80 (176) 100 (212) 80 (176) 80 (176)
IN-3
Code
Material name
Notes
PE
Polyethylene Polyethylene Terephthalate Polymethyl Methacrylate Polyoxymethylene (Polyacetal) Polypropylene Composite Reinforced Polypropylene Modified Polyphenylene Oxide
PET
Avoid dipping in water. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. Most solvents are harmless.
PMMA
POM
PP
PPF
PPO
100 (212)
Alcohol is harmless.
Gasoline is harmless if applied only for quick wiping to remove grease. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. Avoid dipping or immersing in alcohol, gasoline, solvents, etc. Most solvents are harmless but avoid dipping in gasoline, solvents, etc. Avoid dipping or immersing in alcohol, gasoline, solvents, etc.
PS
Polystyrene
60 (140)
Alcohol and gasoline are harmless if applied only for short time in small amounts. Alcohol is harmless if applied only for very short time in small amounts (e.g., quick wiping to remove grease). Alcohol and gasoline are harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease). Alcohol is harmless. Gasoline is harmless if applied only for short time in small amounts. Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease).
PUR
Polyurethane
80 (176)
PVC
Polyvinylchloride (Vinyl)
80 (176)
SAN
Styrene Acrylonitrile
80 (176)
TPO
Thermoplastic Olefine
80 (176)
TPU
80 (176)
TSOP
UP
Avoid alkali.
*Temperatures higher than those listed here may result in material deformation during repair.
IN-4
INTRODUCTION
3.
INTRODUCTION
IN-5
REMOVAL
POINT
1. Remove the [A] at the same time.
PART NAME
[A] Fuel filler opening lid 200 mm (7.87 in.)
REMOVAL GUIDE
Provides additional information to more efficiently help you perform the removal.
F13890A
IN-6
INTRODUCTION
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 34 mm (0.120.16 in.) in diameter 3) For other sealing points, refer to section PC.
INSTALLATION GUIDE
Provides additional information to more efficiently help you perform the installation.
SYMBOLS
(See page IN-7)
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
CUT AND JOIN LOCATION (Saw Cut)
ILLUSTRATION
CUT LOCATION
BRAZE (Removal)
BRAZE (Installation)
WELD POINTS SPOT WELD OR MIG PLUG WELD (See page IN-9) CONTINUOUS MIG WELD (BUTT WELD) CONTINUOUS MIG WELD (TACK WELD)
BODY SEALER
F13893A
IN-8
INTRODUCTION
SYMBOLS
MEANING
ILLUSTRATION
Assembly Mark
F13894A
INTRODUCTION
IN-9
REMOVAL
INSTALLATION
Weld points Remove weld point and panel position SYMBOLS MEANING ILLUSTRATION
Weld points Weld method and panel position SYMBOLS MEANING ILLUSTRATION
Spot Weld
HINT: Panel position symbols are as seen from the working posture.
F13892A
IN-10
INTRODUCTION
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
(b) CUTTING AREA (1) Always cut in a straight line and avoid reinforced areas.
Corners
F10008A
(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 Handling Precautions on Related Components on page IN-15.
WRONG
F10009A
(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 Handling Precautions on Related Components on page IN-15.
F10010A
INTRODUCTION
IN-11
2.
Less than 3 mm
(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 1.0 (0.04) under Size of plug hole 5 (0.20) over 6.5 (0.26) over 8 (0.31) over 10 (0.39) over
Puncher
F10013A
1.0 (0.04) 1.6 (0.06) 1.7 (0.07) 2.3 (0.09) 2.4 (0.09) over
(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.
F10014A
20 30 mm
Air Saw
Overlap
(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.
F10015A
IN-12
INTRODUCTION
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.
F10016A
(b) WELDING PRECAUTIONS (1) The number of welding spots should be as follows. Spot weld: 1.3 X No. of manufacturers spots. Plug weld: More than No. of manufacturers 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
(d) SPOT WELD LOCATIONS (1) Avoid welding over previously welded areas.
F10020A
Tip Cutter
F10019A
(e) SPOT WELDING PRECAUTIONS (1) The shape of the tip point of the spot welder significantly 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. (3) Use a sander to remove any burrs that are created during spot welding.
INTRODUCTION
Sealer Gun
IN-13
4.
(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.
F10021A
(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.
(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-shaped cross sections of the side members, body pillar, etc.
F10023A
IN-14
INTRODUCTION
6.
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 the top coat. Anti-Chipping Paint Top Coat Second Coat Under Coat (ED Primer) Steel Metal Anti-Chipping Paint Under Coat (ED Primer) Steel Metal
F10024A
: Apply the anti-chipping paint before the second coat. Top Coat Second Coat
INTRODUCTION
IN-15
2.
3.
4.
IN-16
INTRODUCTION
1.
2.
INTRODUCTION
IN-17
3.
IN-18
INTRODUCTION
BP-1
F22816A
REMOVAL
F22816
BP-2
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 1 Inspect 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
BP-3
[Hatchback]
1,324 mm
530 mm
944 mm
[Sedan]
1,327 mm
380 mm 950 mm
F22818-1
POINT 1 Measure the dimensions before installing the headlight. 2 These values are reference values. 380 mm (14.96 in.) 1,324 mm (52.13 in.) 530 mm (20.87 in.) 1,327 mm (52.24 in.) 944 mm (37.17 in.) 950 mm (37.40 in.)
BP-10
REMOVAL
[LH]
140 mm
65 mm
F23301
POINT 1 Remove [A] at the same time. PART NAME [A] Front Sidemember Outer Plate 65 mm (2.56 in.) 140 mm (5.51 in.)
BP-11
[RH]
70 mm
140 mm
F23302
POINT 1 Remove [B] before conducting this work. 2 Remove [A] at the same time. PART NAME [B] Engine Front Mounting Bracket [A] Front Sidemember Outer Plate 70 mm (2.76 in.) 140 mm (5.51 in.)
BP-12
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.
[LH]
F23303
BP-13
[RH]
F23304
POINT 1 Remove the [B] from the new parts of the front sidemember reinforcement. 2 After installing the new parts, install [B]. PART NAME [A] Front Sidemember Outer Plate [B] Engine Front Mounting Bracket
BP-4
REMOVAL
F22819
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 1 Inspect the fitting of the front fender and other related parts before welding as this affects the appearance of the finish.
BP-6
F22821A
REMOVAL
[RH]
[LH]
F22821
BP-7
F22822
BP-8
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.
[RH]
[LH]
F22823
POINT 1 Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front wheel alignment. 2 Inspect the fitting of the front fender, hood and other related parts before welding as this affects the appearance of the finish.
BP-9
F22824
BP-14
REMOVAL
F22829
POINT 1 Remove [A] at the same time. PART NAME [A] Front Sidemember Outer Plate
BP-15
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.
F22830
POINT 1 Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front wheel alignment.
BP-16
[LH]
[RH]
F22831
BP-17
F22832A
REMOVAL
F22832
BP-18
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.
(20 mm)
(25 mm)
(30 mm)
(15 mm)
F22833
15 mm (0.59 in.)
20 mm (0.79 in.)
25 mm (0.98 in.)
30 mm (1.18 in.)
BP-19
F24821A
REMOVAL
F24821-1
BP-20
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.
(20 mm)
(25 mm)
(30 mm)
(15 mm)
F24821-2
15 mm (0.59 in.)
20 mm (0.79 in.)
25 mm (0.98 in.)
30 mm (1.18 in.)
BP-21
REMOVAL
F22834
BP-22
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.
(25 mm)
(25 mm)
F22835
POINT 1 Inspect the fitting of the hood and related parts before welding as this affects the appearance of the finish.
25 mm (0.98 in.)
BP-23
REMOVAL
F24822-1
BP-24
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.
(23 mm)
F24822-2
POINT 1 Inspect the fitting of the hood and related parts before welding as this affects the appearance of the finish.
23 mm (0.91 in.)
BP-34
REMOVAL
50 mm 30 mm 30 mm
50 mm 50 mm
F22840
30 mm (1.18 in.)
50 mm (1.97 in.)
BP-35
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.
80 mm
45 mm
(10 mm
7)
F22841
POINT 1 Before temporarily installing the new parts, weld [A], [B] and [C] with standard welding number. PART NAME [B] Center Body Pillar Reinforcement [A] Rocker Outer Reinforce 10 mm (0.39 in.) 45 mm (1.77 in.) 80 mm (3.15 in.) [C] Center Body Inner Pillar
BP-36
(10 mm
4)
F22842
POINT 1 Inspect the fitting of the front door, rear door and other related parts before welding as this affects the appearance of the finish. 2 After welding [A], [B] and [C] to the vehicle, install [D]. PART NAME [A] Rocker Outer Reinforce [C] Center Body Inner Pillar [B] [D] Center Body Pillar Reinforcement Center Body Outer Pillar
10 mm (0.39 in.)
BP-25
F22836A
REMOVAL
100 mm 80 mm
160 mm 70 mm
F22836
POINT 1 *1: This part of the outer panel is reused because the rocker panel section is cut off at a position behind the service part cut position of the outer panel. 70 mm (2.76 in.) 80 mm (3.15 in.) 100 mm (3.94 in.) 160 mm (6.30 in.)
BP-26
F22837
BP-27
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.
230 mm
(10 mm
3)
(15 mm
3)
F22838
POINT 1 Before temporarily installing the new parts, weld [A], [B], [C] and [D] with standard welding number. PART NAME [B] Front Body Pillar Lower Reinforce [A] Rocker Outer Reinforce [D] Front Body Outer Pillar [C] Front Body Inner Pillar 10 mm (0.39 in.) 15 mm (0.59 in.) 230 mm (9.06 in.)
BP-28
(10 mm)
(15 mm
2)
F22839
POINT 1 Inspect the fitting of the front fender, front door, windshield glass and other related parts before welding as this affects the appearance of the finish. 10 mm (0.39 in.) 15 mm (0.59 in.)
BP-29
F24823A
REMOVAL
140 mm
160 mm 40 mm
F24823-1
POINT 1 After removing [A], remove the front body pillar. 2 *1: This part of the outer panel is reused because the rocker panel section is cut off at a position behind the service part cut position of the outer panel. PART NAME [A] Front Panel No.1 Bracket
40 mm (1.57 in.)
BP-30
F24824
BP-31
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.
200 mm
(10 mm
3)
(15 mm
2)
(15 mm)
F24825-1
POINT 1 Before temporarily installing the new parts, weld [B], [C], [D] and [E] with standard welding number. PART NAME [B] Rocker Outer Reinforce [D] Front Body Inner Pillar 10 mm (0.39 in.) [C] [E] Front Body Pillar Lower Reinforce Front Body Upper Outer Pillar 200 mm (7.87 in.)
15 mm (0.59 in.)
BP-32
(10 mm)
F24826
10 mm (0.39 in.)
15 mm (0.59 in.)
BP-33
F24827-1
POINT 1 Inspect the fitting of the front fender, front door, window shield glass and other related parts before welding as this affects the appearance of the finish. 2 After installing the new parts, install [A] PART NAME [A] Front Panel No.1 Bracket
BP-43
REMOVAL
Hemming Location
Disc Sander
F23307
POINT 1 After grinding off the hemming location, remove the outer panel.
BP-44
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
Cloth Tape
30_
Hemming Tool
F23308
POINT 1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact. 2 Bend the flange hem about 30_ with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly.
BP-37
F24828A
REMOVAL
40 mm 30 mm 70 mm
90 mm
F24828-1
30 mm (1.18 in.)
40 mm (1.57 in.)
70 mm (2.76 in.)
90 mm (3.54 in.)
BP-38
15 mm 130 mm
F24829
15 mm (0.59 in.)
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 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.
110 mm 50 mm
(10 mm 15 mm 130 mm
7)
F24830-1
POINT 1 Before temporarily installing the new parts, weld [A], [B] and [C] with standard welding number. PART NAME [A] Rocker Outer Reinforce [C] Center Body Inner Pillar 10 mm (0.39 in.) [B] Center Body Pillar Reinforcement 50 mm (1.97 in.) 110 mm (4.33 in.) 130 mm (5.12 in.)
15 mm (0.59 in.)
BP-40
10 mm
2)
(10 mm)
(10 mm)
F24831-1
POINT 1 Inspect the fitting of the front door, rear door and other related parts before welding as this affects the appearance of the finish. 2 After welding [A], [B] and [C] to the vehicle, install [D]. PART NAME [A] Rocker Outer Reinforce [C] Center Body Inner Pillar [B] [D] Center Body Pillar Reinforcement Rocker Outer Panel
10 mm (0.39 in.)
BP-45
REMOVAL
Hemming Location
Disc Sander
F24875
POINT 1 Afer grinding off the hemming location, remove the outer panel.
BP-46
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.
10 mm
Cloth Tape
30_
Hemming Tool
F24876
POINT 1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact. 2 Bend the flange hem about 30_ with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly.
BP-41
REMOVAL
Hemming Location
Disc Sander
F23305
POINT 1 After grinding off the hemming location, remove the outer panel.
BP-42
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
Cloth Tape
30_
Hemming Tool
F23306
POINT 1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact. 2 Bend the flange hem about 30_ with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly.
BP-47
REMOVAL
Hemming Location
Disc Sander
F24877
POINT 1 After grinding off the hemming location, remove the outer panel.
BP-48
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.
10 mm
Cloth Tape
30_
Hemming Tool
F24878
POINT 1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact. 2 Bend the flange hem about 30_ with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly.
BP-49
REMOVAL
Hemming Location
Disc Sander
F23309
POINT 1 After grinding off the hemming location, remove the outer panel.
BP-50
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
Cloth Tape
30_
Hemming Tool
F23310
POINT 1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact. 2 Bend the flange hem about 30_ with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly.
BP-51
REMOVAL
Hemming Location
Disc Sander
F24879
POINT 1 After grinding off the hemming location, remove the outer panel.
BP-52
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.
10 mm
Cloth Tape
30_
Hemming Tool
F24880
POINT 1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact. 2 Bend the flange hem about 30_ with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly.
BP-53
REMOVAL
Hemming Location
Disc Sander
F24881
POINT 1 After grinding off the hemming location, remove the outer panel.
BP-54
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.
10 mm
Cloth Tape
30_
Hemming Tool
F24882
POINT 1 Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection beam and backside of the new parts. HINT: 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact. 2 Bend the flange hem about 30_ with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT: 1) Perform hemming in three steps, being careful not to warp the panel. 2) If a hemming tool cannot be used, hem with a hammer and dolly.
BP-55
REMOVAL
380 mm
F22843
BP-56
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.
F22844
POINT 1 Inspect the fitting of the front door and other related parts before welding as this affects the appearance of the finish.
BP-61
REMOVAL
100 mm
F22845
BP-62
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.
F22846
POINT 1 Inspect the fitting of the front door, rear door and other related parts before welding as this affects the appearance of the finish.
BP-57
F24832A
REMOVAL
420 mm
F24832-1
BP-58
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.
F24832-2
POINT 1 Inspect the fitting of the front door and other related parts before welding as this affects the appearance of the finish.
BP-59
REMOVAL
F23311
BP-60
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.
F23312
POINT 1 Inspect the fitting of the front door and other related parts before welding as this affects the appearance of the finish.
BP-69
F23313A
REMOVAL
205 mm 645 mm
F23313
POINT 1 *1: The hatched area indicates the adhesive application area. PART NAME [A] Quarter Wheel Housing Outer Panel 205 mm (8.07 in.) 645 mm (25.39 in.)
BP-70
F23314
BP-71
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.
1.0 mm
F23315
POINT 1 *1: The hatched area indicates the adhesive application area. PART NAME [A] Quarter Wheel Housing Outer Panel 1.0 mm (0.04 in.) [B] Fuel Filler Opening Lid [C] Rivet
BP-72
F23316
POINT 1 Inspect the front door, back door, rear combination light and other related parts before welding as this affects the appearance of the finish.
BP-63
F24833A
REMOVAL
245 mm
F24833-1
BP-64
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.
F24833-2
POINT 1 Inspect the fitting of the front door, rear door and other related parts before welding as this affects the appearance of the finish.
BP-82
REMOVAL
[LH]
3 Door : 5 Door :
3 Door : 5 Door :
F23321
POINT 1 After removing [A], remove the quarter wheel housing outer panel. PART NAME [A] Rocker Outer Reinforce
BP-83
[LH]
40 mm
F22852
POINT 1 After removing [B], remove the quarter wheel housing outer panel. PART NAME [B] Roof Side Outer Panel 40 mm (1.57 in.)
BP-84
[RH]
3 Door : 5 Door :
3 Door : 5 Door :
F23322
POINT 1 After removing [A], remove the quarter wheel housing outer panel. PART NAME [A] Rocker Outer Reinforce
BP-85
[RH]
30 mm
F22854
POINT 1 After removing [B], remove the quarter wheel housing outer panel. PART NAME [B] Roof Side Outer Panel 30 mm (1.18 in.)
BP-86
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.
[LH]
F22856
POINT 1 After installing the new parts, install [B]. PART NAME [B] Roof Side Outer Panel
BP-87
[LH]
3 Door : 5 Door :
3 Door : 5 Door :
F23323
POINT 1 After installing the new parts, install [A]. PART NAME [A] Rocker Outer Reinforce
BP-88
[RH]
F22858
POINT 1 After installing the new parts, install [B]. PART NAME [B] Roof Side Outer Panel
BP-89
[RH]
3 Door : 5 Door :
3 Door : 5 Door :
F23324
POINT 1 After installing the new parts, install [A]. PART NAME [A] Rocker Outer Reinforce
BP-73
F22847A
REMOVAL
F23317
POINT 1 *1: The hatched area indicates the adhesive application area. PART NAME [A] Quarter Wheel Housing Outer Panel
BP-74
150 mm
F23318
150 mm (5.91in.)
BP-75
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.
1.0 mm
F23319
POINT 1 *1: The hatched area indicates the adhesive application area. PART NAME [A] Quarter Wheel Housing Outer Panel 1.0 mm (0.04 in.) [B] Fuel Filler Opening Lid [C] Rivet
BP-76
F23320
POINT 1 Inspect the front door, back door, rear combination light and other related parts before welding as this affects the appearance of the finish.
BP-65
1.
Adhesive Application Area
Cut and Join Location
(A) Remove the body sealer from the Quarter Panel and cut at the cut and join location. Remove the spot welded portions. (B) After rough cutting the Wheel Arch portion, heat the adhesive applied area and remove the panel. {Heat the Wheel Arch portion of the Quarter Panel at 110 to 140 C (230 to 284 F) with a dryer or gas burner and remove the Quarter Panel.}
2.
010L06
(A) Heat at 110 to 140 C (230 to 284 F) with a dryer or gas burner. (B) Scrape away the adhesive with a scraper, and scuff while sanding with a disc grinder or a belt sander. NOTE _ Make sure to use either a disc grinder or belt sander to sand coarsely and deeply to improve adhesiveness. _ Scuff at a width of approximately 10 mm (0.39 in.) over the previous adhesive coating.
3.
(A) After the adhesive has been removed from the body, remove the paint from the underside of the spot welded points blow air and degrease. (B) Apply spot sealer at the joined portion between panels.
approx.10 mm After sanding
010L07a
BP-66
4.
(A) Temporarily attach the new panel and check the fitting condition, the cut and join locations, the welded areas, and the adhesive applied area. NOTE _ Check the adhesive applied condition to ensure adhesive strength. _ Conduct hammering to fix the non-adhered portions.
Cross-Sectional view
Adhesive
1 mm gap
010L10a
5.
Application Area Scuffed Area
10 mm 28 mm
010L11a
(A) Scuff with #60-120 grit sandpaper at the adhesive application area. POINT Sand deeply into the ED coat. (B) Blow air around the scuffed portion and then degrease. (C) Apply adhesive. POINT Apply adhesive at a width of approximately 10 mm (0.39 in.) at a location 28 mm (1.10 in.) from the panel flange edge. Spread the adhesive flatly within the scuffed area {approximately 10 mm (0.39 in.) in width} to remove trapped air.
010L12
Approx. 3 mm
3 mm Adhesive
010L12-1a
010L13
BP-67
6.
010L15
(A) Degrease the adhesive aplication area. (B) Apply adhesive. _ Refer to the diagram of step 5 for the application amount. _ The application location is 7.5 mm (0.295 in.) from the flange edge. (C) Flatten out the applied adhesive with a spatula until it is at an even level. _ Apply adhesive at exposed metal plate portions to prevent corrosion. _ It is not necessary to flatten out adhesive after it has been reapplied.
7.5 mm
Flange Edge
010L16 010L17a
7.
(A) Set the new panel in the position for temporary attachment. (Be careful of where you hold the panel so as not to touch the adhesive applied surfaces.) (B) Secure in a vice grip or equivalent and check the fitting condition. (C) Press on the entire surface so that the adhesive between the Quarter Panel and Quarter Wheel Housing Outer panel becomes an even thickness. NOTE Be careful that adhesive that spills over does not contact the Brake Drum. (D) Tack weld at the cut and join welded portion. (E) Tack weld by spot welding at one point on both ends of the adhesive applied portions. (F) Conduct actual welding using procedures in the BP section of this manual.
Tack Weld
010L20a
BP-68
8.
Infrared Ray Hearter
Drying
010L22a
(A) Clean away adhesive that has spilled over with a degreaser or equivalent. (B) After all welding works have been completed, dry the adhesive with a heater. _ Hardening Time : Forced drying 60 C (140 F) at 90 minutes. : Natural drying 24 C (75 F) (room temperature) for 24 hours.
9.
Other work
(A) After applying Primer Surfacer to the underside of the Wheel Arch of the Quarter Panel, apply body sealer to the locations indicated in the body repair manual.
Adhesive
Body Sealer
010L21a
BP-90
REMOVAL
[LH]
F24839-1
POINT 1 After removing [A], remove the quarter wheel housing outer panel. PART NAME [A] Rocker Outer Reinforce
BP-91
[LH]
F24840-1
POINT 1 After removing [B], remove the quarter wheel housing outer panel. PART NAME [B] Roof Side Outer Panel
BP-92
[RH]
F24841-1
POINT 1 After removing [A], remove the quarter wheel housing outer panel. PART NAME [A] Rocker Outer Reinforce
BP-93
[RH]
F24842-1
POINT 1 After removing [B], remove the quarter wheel housing outer panel. PART NAME [B] Roof Side Outer Panel
BP-94
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.
[LH]
F24840-2
POINT 1 After installing the new parts, install [B]. PART NAME [B] Roof Side Outer Panel
BP-95
[LH]
F24839-2
POINT 1 After installing the new parts,install [A]. PART NAME [A] Rocker Outer Reinforce
BP-96
[RH]
F24842-2
POINT 1 After installing the new parts, install [B]. PART NAME [B] Roof Side Outer Panel
BP-97
[RH]
F24841-2
POINT 1 After installing the new parts, install [A]. PART NAME [A] Rocker Outer Reinforce
BP-77
F24834A
REMOVAL
130 mm
150 mm
F24834-1
POINT 1 *1: in illustration above indicates where the adhesive is. 2 Roughly cut open the wheel arch of the panel so that the adhesive can be reached. Cut through the adhesive with a cut chisel to remove the panel. HINT: 1) If the cut chisel cannot reach the adhesive, heat the adhesive with a heat gun, oxygen-acetylene burner. When heating, do not deform the quarter housing outer panel. 130 mm (5.12 in.) 150 mm (5.91 in.)
BP-78
F24835
BP-79
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.
3 mm
Spot Tip
5 mm
F24836-1
POINT 1 Inspect the fitting of the rear door, luggage compartment door, rear combination light and other related parts before welding as this affects the appearance of the finish. 2 Apply adhesive (3MTM AutomixTM Panel Bonding Adhesive #8115) to the area indicated by *1 in illustration. HINT: 1) Apply enough adhesive for the panels to sick to each other. 3 Perform spot-welding on the flange indicated by *2 in the illustration. Modify/ cut the spot tip as shown in the illustration (*3) so that it can fit into the narrow flange. 3 mm (0.12 in.) 5 mm (0.20 in.)
BP-80
5 mm
F24837-1
POINT 1 Before temporarily installing the new parts, apply body sealer to the wheel arch. HINT: 1) Apply body sealer evenly about 5 mm (0.20 in.) form the flange, avoiding any oozing. 2) Apply sealer evenly, about 3 4 mm (0.12 0.16 in.) in diameter. 5 mm (0.20 in.)
BP-81
(13 mm)
F24838-1
[B]
Rivets
13 mm (0.51 in.)
BP-98
REMOVAL
F22859
BP-99
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.
F22860
BP-100
REMOVAL
F24843-1
BP-101
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.
F24843-2
BP-102
REMOVAL
F23325
BP-103
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.
F23326
POINT 1 Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects the appearance of the finish.
BP-104
F24844A
REMOVAL
F24844-1
BP-105
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.
F24844-2
POINT 1 Inspect the fitting of the back door and rear combination light and other related parts before welding as this affects the appearance of the finish.
BP-106
REMOVAL
F22865
POINT 1 Remove [A] at the same time. PART NAME [A] Back Door Opening Lower Reinforcement
BP-107
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.
F22866
POINT 1 Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects the appearance of the finish. PART NAME [A] Back Door Opening Lower Reinforcement [B] Rear Bumper Side Retainer
BP-108
REMOVAL
F24845-1
BP-109
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, apply anti-rust agent to the internal panel portion of the closed section structural weld points.
(13 mm)
F24845-2
POINT 1 Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects the appearance of the finish. 13 mm (0.51 in.)