WELDED PANEL REPLACEMENT GROUP 3 3-1

WELDED PANEL REPLACEMENT GROUP 3 3-1
3-1
GROUP 3
WELDED PANEL
REPLACEMENT
CONTENTS
HEADLAMP SUPPORT . . . . . . . . . . .
3-2
SIDE SILL . . . . . . . . . . . . . . . . . . . . . .
3-19
FENDER SHIELD. . . . . . . . . . . . . . . .
3-2
QUARTER OUTER . . . . . . . . . . . . . . .
3-21
ROOF . . . . . . . . . . . . . . . . . . . . . . . . .
3-23
REAR FLOOR. . . . . . . . . . . . . . . . . . .
3-25
REAR END PANEL. . . . . . . . . . . . . . .
3-27
FRONT SIDEMEMBER (PARTIAL
REPLACEMENT) . . . . . . . . . . . . . . . .
FRONT PILLAR (DRIVERS SIDE). . .
3-6
3-7
FRONT PILLAR (PASSENGERS SIDE)
.................................
3-11
QUARTER, INNER . . . . . . . . . . . . . . .
3-29
CENTRE PILLAR . . . . . . . . . . . . . . . .
3-15
FRONT DOOR OUTER PANEL . . . . .
3-33
REAR DOOR OUTER PANEL . . . . . .
3-34
3-2
WELDED PANEL REPLACEMENT
HEADLAMP SUPPORT
HEADLAMP SUPPORT
M4030003000274
Symbol
Operation description
Spot welding
MIG plug welding
(
: indicates two panels to be welded
: indicates three panels to be welded
)
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
AB300463AB
REPAIR WELDS
A
Right side
A
AB300525 AB
FENDER SHIELD
M4030004000307
Symbol
Operation description
Spot welding
MIG plug welding
(
: indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
AB300475 AB
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
)
3-3
WELDED PANEL REPLACEMENT
FENDER SHIELD
REPAIR WELDS
AB301896
A
G
A
NOTE: .
• Refer to the Headlamp Support Section on P.3-2
for the welding point with headlamp support.
AB300306
(R. H. Drive vehicles)
AB301898
(R. H. DriveAB300307
vehicles)
AB302007AB
3-4
WELDED PANEL REPLACEMENT
FENDER SHIELD
AB300395
AB300313
C
B
B
E
F
C
D
AB300308
AB301897
(R. H. Drive vehicles)
H
AB300309
(R. H. Drive vehicles)
D
AB301899
AB302008 AB
3-5
WELDED PANEL REPLACEMENT
FENDER SHIELD
AB300312
E
AB300314
(With the front upper frame extension outer removed)
F
AB300311
AB300310
H
G
NOTE ON REPAIR WORK
REMOVAL
AB302016 AB
INSTALLATION
Dash crossmember
extension upper
Dash crossmember
extension upper
AB302030AB
The welding point between front sidemember inner
and dash panel extension is hidden by the dash
crossmember extension upper. Therefore, when
removing the front sidemember, remove the dash
crossmember extension upper in advance.
Front sidemember
AB302029AB
1. Remove the front sidemember brace lower,
suspension crossmember bracket rear and dash
crossmember extension lower from the new front
sidemember.
2. Remove the dash crossmember extension upper
from the new front sidemember and install the
front sidemember, and then install the dash
crossmember extension upper.
3-6
WELDED PANEL REPLACEMENT
FRONT SIDEMEMBER (PARTIAL REPLACEMENT)
FRONT SIDEMEMBER (PARTIAL REPLACEMENT)
M4030000100175
Symbol
Operation description
Spot welding
MIG plug welding
(
: indicates two panels to be welded
: indicates three panels to be welded
)
MIG spot welding
MIG arc welding (continuous)
Braze welding
AB300507AB
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
REPAIR WELDS
A
85 mm (Right side)
105 mm (Left side)
Centre of front sidemember
inner positioning hole
A
AB300511AB
NOTE: Refer to the Headlamp Support Section on
P.3-2 for the welding point with headlamp support.
NOTE ON REPAIR WORK
REMOVAL
Front sidemember outer
50 mm
AB300491AB
To reinforce the strength of the front sidemember cut
area, cut the front sidemember outer 50 mm behind
the cut-out part.
3-7
WELDED PANEL REPLACEMENT
FRONT PILLAR (DRIVERS SIDE)
FRONT PILLAR (DRIVERS SIDE)
M4030005300011
Symbol
Operation description
Spot welding
MIG plug welding
(
: indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
AB300474AB
REPAIR WELDS
A
Foam acoustic
material
AB300392
A
B
120 ± 10 mm
D
115 ± 10 mm
B
AB300426
E
AB300427
C
F
(With the front upper frame extension outer removed)
AB300393
C
AB301982 AB
)
3-8
WELDED PANEL REPLACEMENT
FRONT PILLAR (DRIVERS SIDE)
CAUTION
When repairing the area using foam materials do not use firing tools since the foaming materials may
burn.
NOTE: .
• Refer to the Fender Shield Section on P.3-2 for
the welding point with front upper frame
extension outer.
AB300394
E
D
AB300425
AB300424
F
(With the side sill outer reinforcement removed)
AB301984 AB
NOTE ON REPAIR WORK
3-9
WELDED PANEL REPLACEMENT
FRONT PILLAR (DRIVERS SIDE)
INSTALLATION
CAUTION
Cover
Front pillar
reinforcement
outer upper
100 mm
Front pillar
support
Side outer
panel
Front pillar
reinforcement
outer upper
50 mm
50 mm
AB301997AB
AB301996AB
1. To reinforce the strength of the front pillar cut
area, cut the side outer panel 100 mm above the
cut-out part and front pillar reinforcement outer
upper 50 mm above the cut-out part.
Side sill
reinforcement
100 mm
Side outer panel
100 mm
50 mm
Weld and repair if the front pillar support is
damaged.
4. Cut the new front pillar reinforcement outer upper
and the front pillar support by aligning them with
the front pillar reinforcement outer upper of the
body side. Next, cut only the front pillar
reinforcement outer upper 100 mm downwards
from the cut area to create a cover, and then cut
the front pillar support 50 mm above the cut area.
Cover
AB300381AB
2. To reinforce the strength of the side sill cut area,
cut the side outer panel 100 mm behind the
cut-out part and the side sill reinforcement 50 mm
behind the cut-out part.
3. Cut the new front pillar inner upper by aligning it
with the body side, and then assemble it with the
new front pillar inner lower and install it to the
body. After that, install the front floor side sill inner
front.
Front pillar
support
AB301998 AB
5. To install the front pillar reinforcement outer upper,
weld the front pillar support, and then weld the
cover of front pillar reinforcement outer upper.
Urethane
AB300383AB
6. To prevent the foam materials dripping in filling
them, apply urethane in the area shown in the
figure to bury the inside of the front pillar.
3-10
WELDED PANEL REPLACEMENT
FRONT PILLAR (DRIVERS SIDE)
CAUTION
Side sill
reinforcement
front
Cover
50 mm
Side sill
reinforcement
100 mm
AB300384AB
Weld and repair if the side sill reinforcement front
is damaged.
7. Cut the new side sill reinforcement and the side
sill reinforcement front by aligning them with the
cut area of side sill reinforcement in the body side.
Next, cut only the side sill reinforcement 100 mm
forwards from the cut area to create a cover, and
then cut the side sill reinforcement front 50 mm
backwards from the cut area.
: Adhesive
AB300386AB
9. When assembling the new front pillar outer
reinforcement lower, apply structural adhesives in
the areas shown in the figure.
Adhesive: Epoxyayresin adhesive
Brand: 3M ATD Part No.8115 or equivalent
Cover
Side sill
reinforcement front
AB300385AB
8. To install the side sill reinforcement, weld the side
sill reinforcement front, and then weld the cover of
side sill reinforcement.
: Body sealant
AB302110AB
10.When assembling the new front pillar outer, apply
body sealant in the areas shown in the figure of
body side.
AB300389AB
3-11
WELDED PANEL REPLACEMENT
FRONT PILLAR (PASSENGERS SIDE)
11.Assemble the front pillar outer, then bolt and tape
the hole and flange with aluminium tape and fill
the hole with foam materials as shown in the
figure of the instructions.
FOAM: 3M ATD ULTRAPRO Panel
foam-Yellow
AB200418
12.Wait 2 hours after filling the foam materials to
remove the bolt and aluminium tape, then melt the
foam materials with a soldering gun so a clip, etc.
can thoroughly be inserted in the hole filled with
foam materials.
FRONT PILLAR (PASSENGERS SIDE)
M4030005400018
Symbol
Operation description
Spot welding
MIG plug welding
(
: indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
AB300652AB
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
)
3-12
WELDED PANEL REPLACEMENT
FRONT PILLAR (PASSENGERS SIDE)
REPAIR WELDS
A
AB300392
B
A
Foam acoustic
material
120 ± 10 mm
D
115 ± 10 mm
B
AB300426
E
AB300427
C
F
AB300393
(With the front upper frame extension outer removed)
C
CAUTION
When repairing the area using foam materials do
not use firing tools since the foaming materials
may burn.
NOTE: .
• Refer to the Fender Shield Section on P.3-2 for
the welding point with front upper frame
extension outer.
AB301983 AB
3-13
WELDED PANEL REPLACEMENT
FRONT PILLAR (PASSENGERS SIDE)
AB300394
E
AB300425
D
AB300424
F
(With the side sill outer reinforcement removed)
NOTE ON REPAIR WORK
INSTALLATION
AB301985 AB
Side outer panel
100 mm
50 mm
Side sill
reinforcement
100 mm
Side outer
panel
50 mm
Front pillar
reinforcement
outer upper
AB301993 AB
1. To reinforce the strength of the front pillar cut
area, cut the side outer panel 100 mm above the
cut-out part and front pillar reinforcement outer
upper 50 mm above the cut-out part.
AB300642 AB
2. To reinforce the strength of the side sill cut area,
cut the side outer panel 100 mm behind the
cut-out part and the side sill reinforcement 50 mm
behind the cut-out part.
3-14
WELDED PANEL REPLACEMENT
FRONT PILLAR (PASSENGERS SIDE)
3. Cut the new front pillar inner upper by aligning it
with the body side, and then assemble it with the
new front pillar inner lower and install it to the
body. After that, install the front floor side sill inner
front.
Front pillar
reinforcement upper
Cover
Side sill
reinforcement front
AB300645AB
7. To install the side sill reinforcement, weld the side
sill reinforcement front, and then weld the cover of
side sill reinforcement.
AB301994 AB
4. Cut the new front pillar reinforcement outer upper
in alignment with the body-side and install it.
Urethane
AB300643AB
5. To prevent the foam materials dripping in filling
them, apply urethane in the area shown in the
figure to bury the inside of the front pillar.
CAUTION
: Adhesive
Side sill
reinforcement front
8. When assembling the new front pillar outer
reinforcement lower, apply structural adhesives in
the areas shown in the figure.
Adhesive: Epoxyayresin adhesive
Brand: 3M ATD Part No.8115 or equivalent
Cover
50 mm
100 mm
AB300649 AB
Side sill
reinforcement
AB300644AB
Weld and repair if the side sill reinforcement front
is damaged.
6. Cut the new side sill reinforcement and the side
sill reinforcement front by aligning them with the
cut area of side sill reinforcement in the body side.
Next, cut only the side sill reinforcement 100 mm
forwards from the cut area to create a cover, and
then cut the side sill reinforcement front 50 mm
backwards from the cut area.
3-15
WELDED PANEL REPLACEMENT
CENTRE PILLAR
AB300660AB
10.Assemble the front pillar outer, then bolt and tape
the hole and flange with aluminium tape and fill
the hole with foam materials as shown in the
figure of the instructions.
FOAM: 3M ATD ULTRAPRO Panel
foam-Yellow
: Adhesive
: Body sealant
AB301995AB
9. When assembling the new front pillar outer, apply
body sealant and structural adhesives in the
areas shown in the figure of body side.
Adhesive: Epoxyayresin adhesive
Brand: 3M ATD Part No.8115 or equivalent
AB200418
11.Wait 2 hours after filling the foam materials to
remove the bolt and aluminium tape, then melt the
foam materials with a soldering gun so a clip, etc.
can thoroughly be inserted in the hole filled with
foam materials.
CENTRE PILLAR
M4030006000284
Symbol
Operation description
Spot welding
MIG plug welding
(
: indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
AB300464AB
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
)
3-16
WELDED PANEL REPLACEMENT
CENTRE PILLAR
REPAIR WELDS
195 mm
A
Foam acoustic
material
A
B
125 mm
160 mm
B
C
C
D
D
AB300517AB
CAUTION
When repairing the area using foam materials do not use firing tools since the foaming materials may
burn.
NOTE ON REPAIR WORK
REMOVAL
Centre pillar
inner
AB300443AB
After removing the centre pillar, remove the centre
pillar inner left on the body side.
3-17
WELDED PANEL REPLACEMENT
CENTRE PILLAR
2. To reinforce the strength of the side sill cut area,
cut the side outer panel 90 mm forwards and the
side sill reinforcement 40 mm forwards from the
cut-out part in the front side. Cut the side outer
panel 50 mm behind the cut-out part in the rear
side.
INSTALLATION
Side outer panel
CAUTION
60 mm
50 mm
AB300444 AB
1. To reinforce the strength of the centre pillar cut
area, cut the side outer panel 50 mm above the
cut-out part.
Side sill
reinforcement
front
Side sill
reinforcement
Cover
100 mm
Front side
90 mm
Side outer panel
40 mm
Side sill reinforcement
Rear side
50 mm
AB300440AB
Weld and repair if the side sill reinforcement front
is damaged.
3. Cut the new side sill reinforcement and the side
sill reinforcement front by aligning them with the
cut area of side sill reinforcement in the body side.
Next, cut only the side sill reinforcement 100 mm
behind the cut area to create a cover, and then cut
the side sill reinforcement front 60 mm forwards
from the cut area of the side sill reinforcement.
Cover
Side outer panel
AB300515AB
AB300441AB
4. To install the side sill reinforcement, weld the side
sill reinforcement front, and then weld the cover of
side sill reinforcement.
3-18
WELDED PANEL REPLACEMENT
CENTRE PILLAR
6. After assembling the new centre pillar outer, to
prevent the foaming materials from dripping in the
area shown in the figure of the instructions,
adhere urethane foam to fill (bury) the centre pillar
interior.
Outside
Centre pillar
reinforcement
outer
Inside
AB300470 AB
Rear door hinge
reinforcement
upper
AB300516AB
5. Cut the new centre pillar reinforcement outer and
the rear door hinge reinforcement upper by
aligning them with the cut-out part of body side,
and then weld the centre pillar reinforcement
outer from outside and rear door hinge
reinforcement upper from inside respectively.
7. After assembling the new centre pillar inner, seal
the hole and flange with bolt and sheet-metal
tape, and then fill the hole with foam materials as
shown in the figure of the instructions.
Foam: 3M ATD ULTRAPRO Panel
foam-Yellow
Urethane
foam
AB200418
AB300445AB
8. Wait 2 hours after filling the foam materials to
remove the bolt and sheet-metal tape, then melt
the foam materials with a soldering gun so a clip,
etc. can thoroughly be inserted in the hole filled
with foam materials.
3-19
WELDED PANEL REPLACEMENT
SIDE SILL
SIDE SILL
M4030007000340
Symbol
Operation description
Spot welding
MIG plug welding
(
: indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
AB300476AB
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
)
3-20
WELDED PANEL REPLACEMENT
SIDE SILL
REPAIR WELDS
Foam
acoustic
material
260 mm
50 mm
E
50 mm
C
B
A
D
AB300452
F
AB300459
AB300456
A
B
C
AB300457
AB300636
D
AB300455
E
F
AB300534 AB
NOTE:
on the range of damage.
Side sill reinforcement
(With the side outer panel removed)
: Cuttable range
AB300454 AB
Partial replacement of side sill is possible depending
CAUTION
Cut the side sill reinforcement by displacing 50
mm from the butt welding area with the side
outer panel.
3-21
WELDED PANEL REPLACEMENT
QUARTER OUTER
QUARTER OUTER
M4030008000279
Symbol
Operation description
Spot welding
MIG plug welding
: indicates two panels to be welded
: indicates three panels to be welded
(
)
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
AB300377AB
REPAIR WELDS
410 mm
4 points
right side
250 ± 100 mm
D
C
A
3 points
left side
300 mm
Foam acoustic material
B
A
B
C
D
AB300522AB
3-22
WELDED PANEL REPLACEMENT
QUARTER OUTER
CAUTION
When repairing the area using foam materials do not use firing tools since the foaming materials may
burn.
NOTE ON REPAIR WORK
REMOBAL
2. When assembling the new rear quarter outer
panel, apply in advance body sealant to the areas
shown in the figure of the instructions. In addition,
to prevent the foam materials from dripping, apply
urethane foam to bury the inside of the wheel
arch.
Gate pillar
reinforcement
50 mm
AB300548AB
When replacing the gate pillar reinforcement, cut it
50 mm downwards from the cut area of rear gate
pillar.
INSTALLATION
Side
outer
panel
100 mm
AB300361AB
3. Assemble the quarter outer panel, bolt and tape
the hole and flange with aluminium tape, then fill
the hole with foam materials as shown in the
figure of the instructions.
Foam: 3M ATD ULTRAPRO Panel
foam-Yellow
AB300360AB
1. To reinforce the strength of the rear gate pillar cut
area, cut the side outer panel 100 mm above the
cut-out part.
AB200418
Left side
4. Wait 2 hours after filling the foam materials to
remove the bolt and aluminium tape. Then melt
the foam materials with a soldering gun so a clip,
etc. can thoroughly be inserted in the hole that
was clogged with foam materials, to bore open
the hole.
Urethane foam
: Body sealant
AB300183 AB
3-23
WELDED PANEL REPLACEMENT
ROOF
ROOF
M4030011000280
Symbol
Operation description
Spot welding
MIG plug welding
(
: indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
AB300478AB
Repair welds
B
Except for sun roof
C
A
F
E
H
AB300494
D
7 Points
vehicles with roof rail
4 Points
vehicles with roof rail
Vehicles with
roof rail
6 Points
vehicles with roof rail
Vehicles with sun roof
F
G
E
H
AB300493
7 Points
vehicles with roof rail
: Adhesive
Adhesive: Urethane body sealer
4 Points
vehicles with roof rail
6 Points
vehicles with roof rail
AB302123 AB
Brand: 3M ATD Part No.8542 or equivalent
)
3-24
WELDED PANEL REPLACEMENT
ROOF
AB300499
AB300495
B
A
AB300500
AB300501
C
D
AB300496
AB300497
E
F
AB300502
AB300498
G
H
AB300536 AB
3-25
WELDED PANEL REPLACEMENT
REAR FLOOR
REAR FLOOR
M4030010000287
Symbol
Operation description
Spot welding
MIG plug welding
(
: indicates two panels to be welded
: indicates three panels to be welded
)
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
AB300417AB
REPAIR WELDS
A
C
D
E
B
AB300410
A
AB302125 AB
NOTE: Refer to the Rear End Panel Section on P.3-27 for the welding points with the rear end panel.
3-26
WELDED PANEL REPLACEMENT
REAR FLOOR
AB300411
Left side
AB301669
C
B
(With the rear floor pan removed)
E
D
(With the rear floor pan removed)
(With the rear floor sidemember
and rear floor side pan removed)
AB301940 AB
NOTE ON REPAIR WORK
REMOVAL
1. When cutting the rear floor pan, cut it 40 mm
behind the body centre point as shown.
40 mm
Body centre point
AB300396AB
3-27
WELDED PANEL REPLACEMENT
REAR END PANEL
3. Cut the rear floor sidemember 280 mm forward
from the hitch member mounting hole (This hole
also serves as a shipping bracket mounting hole
on left side). In addition, cut the rear floor side pan
in the same area.
Left side
AB300407
INSTALLATION
Seat pan support
Right side
AB301670
Shipping bracket
AB300408
Seat pan reinforcement
AB300404 AB
1. Remove the seat pan reinforcement from the new
rear floor crossmember (D).
AB301671
AB301941AB
2. Remove the seat pan support and shipping
bracket (right side) on the cut area in advance
when cutting the rear floor sidemember.
: Body sealant
AB300405AB
2. When assembling the new quarter inner
extension lower, apply in advance body sealant to
the areas shown in the figure of the instructions.
280 mm
AB300406AB
REAR END PANEL
M4030000300038
Symbol
Operation description
Spot welding
MIG plug welding
(
: indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
AB300379AB
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
)
3-28
WELDED PANEL REPLACEMENT
REAR END PANEL
REPAIR WELDS
A
B
80 mm
80 mm
C
A
B
C
AB300523 AB
NOTE ON REPAIR WORK
REMOVAL
30 mm
Rear end outer panel
After removing the rear end outer panel, to reinforce
the strength of the rear end panel cut area, cut the
rear end inner panel 30 mm centre of vehicle side
from the rear end outer panel cut areas to remove it.
Rear end
inner panel
AB300178AB
3-29
WELDED PANEL REPLACEMENT
QUARTER, INNER
INSTALLATION
Muffler hanger bracket rear
Remove the muffler hanger bracket rear from the
new rear end inner panel. Cut and install the rear end
inner panel while aligning it with the cut area of body
side, and then install the muffler hanger bracket rear.
AB300179AB
QUARTER, INNER
M4030012000272
Symbol
Operation description
Spot welding
MIG plug welding
(
: indicates two panels to be welded
: indicates three panels to be welded
MIG spot welding
MIG arc welding (continuous)
Braze welding
AB300378AB
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
)
3-30
WELDED PANEL REPLACEMENT
QUARTER, INNER
REPAIR WELDS
B
8 points
on left side
C
A
E
6 points
on right side
D
(With the quarter outer removed)
A
B
AB300524 AB
NOTE: Refer to the Quarter Outer Section on P.3-21 for the welding points with the quarter outer.
3-31
WELDED PANEL REPLACEMENT
QUARTER, INNER
C
(Right side)
C
D
E
AB300532 AB
NOTE ON REPAIR WORK
INSTALLATION
: Adhesive
1. When assembling the new quarter inner panel,
apply in advance structural adhesives to the areas
shown in the figure of the instructions.
Adhesive: Epoxyayresin adhesive
Brand: 3M ATD Part No.8115 or equivalent
AB300369 AB
3-32
WELDED PANEL REPLACEMENT
QUARTER, INNER
3. When assembling the new gate pillar
reinforcement, adhere in advance structural
adhesives and body sealant in the areas shown in
the figure.
Adhesive: Epoxyayresin adhesive
Brand: 3M ATD Part No.8115 or equivalent
: Adhesive
AB300370 AB
2. When assembling the new quarter inner
extension, apply in advance structural adhesives
to the areas shown in the figure of the
instructions.
Adhesive: Epoxyayresin adhesive
Brand: 3M ATD Part No.8115 or equivalent
AB300373 AB
4. When assembling the new shield plate front,
apply in advance structural adhesives to the areas
shown in the figure of the instructions.
Adhesive: Epoxyayresin adhesive
Brand: 3M ATD Part No.8115 or equivalent
Inside
: Body sealant
Outside
: Adhesive
: Adhesive
AB300533AB
3-33
WELDED PANEL REPLACEMENT
FRONT DOOR OUTER PANEL
FRONT DOOR OUTER PANEL
M4030013000264
Symbol
Operation description
Spot welding
MIG plug welding
(
: indicates two panels to be welded
: indicates three panels to be welded
)
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
AB300505AB
REPAIR WELDS
50 mm
AB300284
*
*
A
A
*
*
AB300288
B
C
AB300289
AB300285
C
B
D
AB300291
E
: Adhesive
Adhesive: Urethane body sealer
Brand: 3M ATD Part No.8542 or equivalent
AB300290
D
E
AB300530 AB
NOTE: .
• * : indicates the welding points of maker joint. (It
is not necessary for repair)
.
• After hemming the front door outer panel, MIG
spot weld the flange overlap section at a pitch of
50 mm.
3-34
WELDED PANEL REPLACEMENT
REAR DOOR OUTER PANEL
REAR DOOR OUTER PANEL
M4030014000256
Symbol
Operation description
Spot welding
MIG plug welding
(
: indicates two panels to be welded
: indicates three panels to be welded
)
MIG spot welding
MIG arc welding (continuous)
Braze welding
Anti-corrosion agent application locations
(Use access holes to apply liberally to butt-welded joints.)
AB300506AB
REPAIR WELDS
AB300286
50 mm
*
*
A
AB300292
A
*
B
*
B
AB300287
C
AB300290
D
: Adhesive
Adhesive: Urethane body sealer
Brand: 3M ATD Part No.8542 or equivalent
C
AB300294
D
AB300531 AB
NOTE: .
• * : indicates the welding points of maker joint. (It
is not necessary for repair)
.
• After hemming the rear door outer panel, MIG
spot weld the flange overlap section at a pitch of
50 mm.
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