WELDED PANEL REPLACEMENT CONTENTS

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1 -1 WELE PNEL REPLEMENT ONTENTS HELMP SUPPORT... 3 FENER SHIEL... 4 FRONT PILLR... 7 ENTER PILLR... 9 SIE SILL QURTER, OUTER ROOF RER EN PNEL RER FLOOR QURTER, INNER FRONT OOR OUTER PNEL RER OOR OUTER PNEL... 24

2 -2 NOTES

3 HELMP SUPPORT WELE PNEL REPLEMENT - Headlamp Support -3 Symbol Operation description Spot welding MIG plug welding (J: indicates two panels to be welded Y: indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) raze welding nti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) REPIR WELS (Right side)

4 -4 WELE PNEL REPLEMENT - Fender Shield FENER SHIEL Symbol Operation description Spot welding MIG plug welding (J: indicates two panels to be welded Y: indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) raze welding nti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) REPIR WELS F NOTE For the weld points for the headlamp support, refer to P.-3 Headlamp Support.

5 WELE PNEL REPLEMENT - Fender Shield -5 (With the upper frame extension outer removed) E

6 -6 WELE PNEL REPLEMENT - Fender Shield 17 points, left side only H E F G 5 points, left side only G H 4 points, left side only <LH> H <RH> I <RH(Right side)>

7 FRONT PILLR WELE PNEL REPLEMENT - Front Pillar -7 Symbol Operation description Spot welding MIG plug welding (J: indicates two panels to be welded Y: indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) raze welding nti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) REPIR WELS 180 ± 20 mm 2point passenger s side 60 ± 10 mm Foam acoustic material RS-II (With the upper frame extension outer removed) aution o not use heat at areas using foam material as the foam material may burn.

8 -8 WELE PNEL REPLEMENT - Front Pillar Front pillar reinforcement lower Weld points Side sill outer reinforcement front NOTE ON REPIR WORK REMOVL s the front pillar reinforcement lower and side sill outer reinforcement front are welded at the side sill, cut the side outer panel at the position shown in the illustration where the weld points of the reinforcement can be seen, remove, and then remove the weld points of the front pillar reinforcement lower. Front pillar inner upper Side outer panel 100 mm 50 mm INSTLLTION 1. To ensure the strength of the cut area of the front pillar, cut the front pillar inner 100 mm above the cut area, and the side outer panel 50 mm above the cut area as shown in the illustration. ut the new center pillar at the same positions. 2. ttach the front pillar inner upper assembly of the new front pillar to the body. Front pillar silencer protector 3. When installing a new front pillar outer, install a front pillar silencer protector filling up the gap with butyl tape<rs-ii> and then apply body sealant and structural adhesive on the area shown in the illustration. : ody sealant : dhesive dhesive Type RN Epoxyayresin adhesive 3M P-460, 3M P-420 or equivalent <The following service procedures are only applied to RS-II.> 4. fter attaching the front pillar outer, seal the holes and flanges with bolts and plate tape, fill the foam material through the holes as shown in the illustration. Foam material Type rand Used Foam acoustic Two - part expanded urethane Panel foam - 3M ULTRPRO material Yellow 5. bout two hours after filling the foam material, remove the bolts and plate tape, and solder the sealed holes until a clip, etc. can be inserted completely.

9 ENTER PILLR WELE PNEL REPLEMENT - enter Pillar -9 Symbol Operation description Spot welding MIG plug welding (J: indicates two panels to be welded Y: indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) raze welding nti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) REPIR WELS 125±10 mm Foam acoustic material <RS-II> 290 ± 10 mm 125 ± 10 mm aution o not use heat at areas using foam material as the foam material may burn.

10 -10 WELE PNEL REPLEMENT - enter Pillar enter pillar reinforcement Weld points Weld points Side sill outer reinforcement center NOTE ON REPIR WORK REMOVL 1. s the center pillar reinforcement and side sill outer reinforcement center are welded at the side sill, cut the side outer panel at the position shown in the illustration where the weld points of the reinforcement can be seen, remove, and then remove the weld points of the center pillar reinforcement. 2. To cut the weld points of the center pillar seatbelt reinforcement and center pillar reinforcement, cut at the bottom of the roof side rail inner as shown in the illustration. NOTE Keep the separated side roof rail inner () for the future use. () 30 mm INSTLLTION 1. Remove the side outer panel, side sill outer reinforcement center, side sill bulkhead, and side sill reinforcement support from the new center pillar. 2. To ensure the strength of the cut area of the front pillar, cut the side outer panel 30 mm above the cut area. ut the new center pillar at the same positions. enter pillar seatbelt reinforcement 3. To prevent damage of the center pillar seatbelt reinforcement, align the new center pillar reinforcement only to the body side and cut. aution If the center pillar seatbelt reinforcement has been damaged, repair by welding. enter pillar reinforcement 4. When attaching the center pillar reinforcement, apply adhesive to the locations indicated in the illustration. : dhesive dhesive Type RN Epoxyayresin adhesive 3M P-460, 3M P-420 or equivalent

11 WELE PNEL REPLEMENT - enter Pillar -11 enter pillar silencer protector <The following service procedures are only applied to RS-II.> 5. When attaching the center pillar inner, attach the center pillar silencer protector to the center pillar inner, and seal the holes of the center pillar silencer protector with butyl tape. 6. fter attaching the center pillar outer, seal the holes and flanges with bolts and plate tape, fill the foam material through the holes as shown in the illustration. Foam material Type rand Used Foam acoustic Two - part expanded urethane Panel foam - 3M ULTRPRO material Yellow 7. bout two hours after filling the foam material, remove the bolts and plate tape, and solder the sealed holes until a clip, etc. can be inserted completely.

12 -12 WELE PNEL REPLEMENT - Side Sill SIE SILL Symbol Operation description Spot welding MIG plug welding (J: indicates two panels to be welded Y: indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) raze welding nti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) REPIR WELS 70 mm E 70 mm 290 mm Foam acoustic material <RS-II> F E F aution o not use heat at areas using foam material as the foam material may burn.

13 WELE PNEL REPLEMENT - Side Sill -13 NOTE ON REPIR WORK INSTLLTION 1. Release the side outer panel from the new parts and remove unnecessary front pillar reinforcement lower, front pillar reinforcement lower extension, and center pillar reinforcement from the side sill outer reinforcement. Front pillar 2. When attaching the side sill outer reinforcement, apply adhesive to the areas indicated in the illustration. : dhesive dhe- sive Type Epoxyayresin adhesive RN 3M P-460, 3M P-420 or equivalent enter pillar 3. When attaching the side outer panel, apply body sealant to the areas indicated in the illustration. : ody sealant Reference epending on the damaged range, it is advisable to replace the side outer panel and side sill outer reinforcement parts. :uttable range aution ut the side sill outer reinforcement 50 mm away from the cut area of the side outer panel.

14 -14 WELE PNEL REPLEMENT - Quarter, Outer QURTER, OUTER Symbol Operation description Spot welding MIG plug welding (J: indicates two panels to be welded Y: indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) raze welding nti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) REPIR WELS Foam acoustic material <RS-II> 500±50 mm 3 pointsleft side 160±50mm Foam acoustic material <RS-II> E aution o not use heat at areas using foam material as the foam material may burn.

15 WELE PNEL REPLEMENT - Quarter, Outer -15 E F F Left side only NOTE ON REPIR WORK INSTLLTION 1. When attaching the quarter outer, apply sealant to the areas indicated in the illustration. For RS-II, attach the rear pillar silencer protector, and fill the gaps with butly tape. : ody sealant Rear pillar silencer protector

16 -16 WELE PNEL REPLEMENT - Quarter, Outer <The following service procedures are only applied to RS-II.> 2. fter attaching the quarter outer, seal the holes and flanges with bolts and plate tape, and fill foam material from hole shown in the illustration. Foam material Type rand Used Foam acoustic material Two-part wretane expanded 3M ULTRPRO Panel foam - Yellow 3. fter two hours after filling the foam material, remove the bolts and plate tape, and solder the sealed holes until a clip, etc. can be inserted completely. Reference Parts replacement is advised. depending on the damaged range. : uttable range aution void the fuel filler bracket (left side).

17 WELE PNEL REPLEMENT - Roof -17 ROOF Symbol Operation description Spot welding MIG plug welding (J: indicates two panels to be welded Y: indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) raze welding nti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) REPIR WELS : dhesive dhesive Type hloroprene-base drying sealant

18 -18 WELE PNEL REPLEMENT - Rear End Panel RER EN PNEL Symbol Operation description Spot welding MIG plug welding (J: indicates two panels to be welded Y: indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) raze welding nti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) REPIR WELS

19 WELE PNEL REPLEMENT - Rear Floor -19 RER FLOOR Symbol Operation description Spot welding MIG plug welding (J: indicates two panels to be welded Y: indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) raze welding nti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) REPIR WELS F E

20 -20 WELE PNEL REPLEMENT - Rear Floor (Vehicles with ) Right side only E F NOTE For details on the weld points with the rear end panel refer to RER EN PNEL on P.-18. Rear seat back reinforcement 200 ± 50 mm NOTE ON REPIR WORK REMOVL 1. ut the rear floor panel 320 ± 10 mm from the back of the rear seat back reinforcement. ut the rear floor pan 200 ± 50 mm from the back of the rear seat back reinforcement as shown in the illustration.

21 QURTER, INNER WELE PNEL REPLEMENT - Quarter, Inner -21 Symbol Operation description Spot welding MIG plug welding (J: indicates two panels to be welded Y: indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) raze welding nti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) REPIR WELS G F 9 points on left side E H I Right side only 6 points on right side Vehicles with (With the quarter outer removed) NOTE For the weld points to the quarter outer, refer to P.-14.

22 -22 WELE PNEL REPLEMENT - Quarter, Inner E F Left side (Vehicles with ) G H I (With the side sill outer reinforcement rear removed.)

23 WELE PNEL REPLEMENT - Front oor Outer Panel -23 FRONT OOR OUTER PNEL Symbol Operation description Spot welding MIG plug welding (J: indicates two panels to be welded Y: indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) raze welding nti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) REPIR WELS 50 mm : dhesive dhesive Type hloroprene-base drying sealant NOTE fter hemming the door outer panel, MIG spot weld the flange overlap section at a pitch of approx. 50 mm.

24 -24 WELE PNEL REPLEMENT - Rear oor Outer Panel RER OOR OUTER PNEL Symbol Operation description Spot welding MIG plug welding (J: indicates two panels to be welded Y: indicates three panels to be welded) MIG spot welding MIG arc welding (continuous) raze welding nti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.) REPIR WELS 50 mm : dhesive dhesive Type hloroprene-base drying sealant NOTE fter hemming the rear door outer panel, MIG spot weld the flange overlap section at a pitch of 50 mm.