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Hyundai 2008 Elantra Neos, Body Repair Manual, Page: 161 / 173

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Hyundai 2008 Elantra Neos Body Repair Manual Download Page 161

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BODY MODIFICATION TOOLS

ASSEMBLY  TOOLS

Vice pliers

Air bench

Quick bench

Flanging tool

Fix a panel or area to weld

Finish a hole for plug welding

Finish contact area of flange

Name

Used for

Figure

Finish contact area of  flange and finish

a hole for plug welding

MEASUREMENT  TOOLS

Centering gauge

Tracking gauge

Measure distortion of body and frame

Measure body and frame

Name

Used for

Figure

A3EB3512

A3EB3513

A3EB3514

A3EB3515

A3EB3516

A3EB3517

Summary of Contents for 2008 Elantra Neos

Page 1: ... reduce insurance costs and indirectly cost of ownership The vehicle should not be sectioned in locations other than those illustrated in this repair manual Furthermore these repair procedures DO NOT apply to any other vehicle The individualsperformingtheworkmustassumefullresponsibil ity for the quality of their workmanship WebelievethismanualtobehelpfulforHyundaidealers and anticipateittobeeffect...

Page 2: ...et in park unless instructed otherwise for a specific operation Place supporters against the front and rear surfaces of the tires to help prevent the vehicle from moving Operate the engine only in a well ventilated area to avoid the danger of carbon monoxide poisoning Keep yourself and your clothing away from moving parts when the engine is running especially the drive belts To prevent serious bur...

Page 3: ...I 3 SAFETY FACTORS GI 3 SRS AIR BAG GI 4 WELDING GI 5 BODY FRAME STRAIGHTENER GI 5 ELETRONIC PARTS GI 6 FOR BEST RESULTS REMOVAL GI 7 PREPARATION OF INSTALLATION GI 9 INSTALLATION GI 10 CORROSION PROTECTION AND SEALING GI 11 SIDE BODY PALELS GI 11 VEHICLE LIFT 2 SUPPORT TYPE AND SAFETY STAND POSITIONS GI 12 ...

Page 4: ... welded in place to support the structure During the repair of an actual vehicle the interior would be fully disassembled and standard jack screws or portable braces may be used for temporary support During the repair of an accident involved vehicle the vehicle must first be returned to pre impact dimensions prior to beginning the sectioning repair procedures The extent of damage that must be repa...

Page 5: ...one Block the front or rear wheels if the vehicle is not lifted off of the ground 4 When welding or performing other procedures that require the use of an open flame near the fuel tank disconnect and remove the tank and fuel pipe and cap the pipe to prevent fuel leakage 5 Insure proper ventilation of your working area Some paint and sealant can generate toxic gases when heated Use an air chisel or...

Page 6: ...h a back up power source so that if work is started within 30 seconds of disconnecting the negative terminal cable of the battery the airbag may be deployed When the negative terminal cable is disconnected from the battery memory of the clock and audio systems will be cancelled So before starting work make a record of the contents memorized by the audio memory system Then when work is finished res...

Page 7: ...he top welding side sheetmetal You then begin welding along the edges and the spiral towards the center see illustration This is important so that weld penetration between the two metal pieces takes place along the circumference of the circle Observe the following tips when welding 1 Wear appropriate eye protection 2 Carefully follow the manufacturers operating instructions for the welding machine...

Page 8: ...side Therefore take the following precautions during body repair to prevent damage to the CONTROL MODULES ECM TCM ABS CM SRS CM etc 1 Before removing and inspecting the electrical parts or before starting electric welding operations disconnect the negative terminal cable from the battery 2 Do not expose the CONTROL MODULES to ambient temperatures above 80 C 176 F If it is possible the ambient temp...

Page 9: ...djust dimensions with body frame adjuster if deformed Selecting cutting area Select a cutting area that is easily accessible and that is prone to the least amount of distortion when welding Select an area that would allow the new part to overlap repair area by 30 50 mm 1 2 2 0 in Protecting body from damage Secure the body with clamps and jacks to prevent damage to the body when working on it BFDG...

Page 10: ...im from the area to be worked Apply masking tape where needed to prevent damage to the part being removed or to the vehicle body Before starting repairs check if pipes hoses or electrical components are present near damaged area BVQGI6006 Wire harness Repair work area Cutting area ...

Page 11: ...cting a welding method If the thickness of the area to be welded with the panels overlapped is greater than 3 mm 0 1 in do plug welding using a carbon arc welding machine Protecting body from damage Secure the body with clamps and jacks to prevent damage to the body when working on it Adjusting a new part The new part should be cut larger than the repair area overlapping the repair area by 30 50 m...

Page 12: ...eatly affects welding strength When possible spot welding should be done between the existing spot welded points Before and after spot welding weld a test piece test pin of the same material as the body panel and check the welding strength 0 1in 3 mm Center diameter Good Existing welded spots New welded spots Using a hammer and a chisel Using a test piece test pin Nugget diameter to be 4 5 of chip...

Page 13: ...ections For exterior surfaces both metal conditioner and conversion coating treatments are applied to the exterior surface prior to application of the epoxy primer The procedure in applying the corrosion restoration process is important order to insure that moisture due to the water rinsing of the metal conditioner and conversion coating is not inadvertently trapped inside any closed section befor...

Page 14: ... Place the lift blocks under the support points as shown in the illustration 2 Raise the hoist a few inches and rock the vehicle to be sure it is firmly supported 3 Raise the hoist to full height to inspect the lift points for secure support LIFT BLOCK LIFT BLOCK FRONT REAR BFDGI6013 ...

Page 15: ...RONT SIDE MEMBER BC 2 FENDER APRON PANEL BC 6 SIDE BODY PANEL BC 10 DASH PANEL BC 13 CENTER FLOOR PANEL BC 17 REAR FLOOR PANEL BC 20 BACK COMPLETE PANEL BC 23 ROOF PANEL BC 26 HOOD BC 29 FRONT REAR DOOR BC 31 TAIL GATE BC 33 ...

Page 16: ...nner member assembly Crash member rear bracket assembly Crash member bracket assemby Engine mounting support assembly PART NAME No Front side member inner reinforcement assembly Front side outer member assembly Subframe rear mounting bracket assembly Front side rear lower member assembly Front side member rear lower extension assembly Front side inner rear reinforcement assemby Side sill inner fro...

Page 17: ...BODY CONSTRUCTION BC 3 Cross Sectional Views BFDBC6105 SIDE VIEW RH SIDE VIEW LH TOP VIEW RH TOP VIEW LH A A B B E E F F C C D D Z Y ...

Page 18: ...Front side inner memer assembly Transmission mounting reinforcement assembly Engine mounting support assembly Front side member inner reinforcement assembly Crash member bracket assembly Crash member rear bracket assembly Front crash member assembly Front side inner member assembly Side sill inner front extension Front side outer member assembly Front side member rear lower extension assembly Tran...

Page 19: ...BODY CONSTRUCTION BC 5 BFDBC6112 Z ...

Page 20: ...r front reinforcement assembly Fender apron inner panel assembly Shock absorber housing complete panel assembly Fender apron upper outer Fender apron upper rear gusset Fender apron upper inner panel assembly Shock absorber housing reinforcement PART NAME No PART NAME No 1 2 3 4 7 6 5 ...

Page 21: ...BODY CONSTRUCTION BC 7 Cross Sectional Views BFDBC6115 TOP VIEW RH SIDE VIEW RH B B C C A A ...

Page 22: ...BC 8 BODY CONSTRUCTION Cross Sectional Views BFDBC6117 TOP VIEW LH SIDE VIEW LH ...

Page 23: ...ont reinforcement assembly Fender apron inner front reinforcement assembly Front side complete member assembly Fender apron upper outer panel assembly Shock absorber housing complete panel assembly Fender apron inner panel assembly Fender apron upper inner panel assembly Shock absorber housing complete panel assembly Fender apron inner panel assembly Fender apron upper outer panel assembly Front s...

Page 24: ...BC6121 1 2 3 4 5 Side outer complete panel assembly Side inner complete panel assembly Quarter inner wheel house complete panel assembly PART NAME No Center inner complete panel assembly Front inner complete panel assembly PART NAME No 2 3 4 5 1 ...

Page 25: ...embly Side outer complete panel assembly Side inner complete panel assembly Side inner complete panel assembly Side outer complete panel assembly Side inner complete panel assembly Side outer complete panel assembly Side inner complete panel assembly Cross Sectional Views C C D D E E K K L L M M F F G G H H A A B B P P ...

Page 26: ...er complete panel assembly Side outer complete panel assembly Side outer complete panel assembly Side outer complete panel assembly Side inner complete panel assembly Side inner complete panel assembly Side inner complete panel assembly Side inner complete panel assembly Side inner complete panel assembly Side inner complete panel assembly Side inner complete panel assembly E E F F H H L L P P G G...

Page 27: ... 2 3 4 5 6 7 Dash lower member assembly Dash cross center member assembly Dash cross side member assembly Dash cross side member assembly PART NAME No Dash panel reinforcement assembly Dash panel assembly Dust cover panel PART NAME No 2 3 4 5 6 7 1 ...

Page 28: ...BC 14 BODY CONSTRUCTION Cross Sectional Views BFDBC6138 J J C C D D A A G G B B K K E E ...

Page 29: ...anel assembly Dash panel reinforcement assembly Dash cross center member assembly Dash cross center member assembly Dash lower member assembly Dash panel assembly Dash panel reinforcement assembly Dash panel reinforcement assembly Dash cross center member assembly Dash cross center member assembly Dash panel assemby Dash lower member assembly Dash lower member assembly Dash panel assembly ...

Page 30: ...sh panel assembly Dash panel assembly Dash panel assembly Dash lower member assembly Dash lower member assembly Dash lower member assembly Dash cross side member assembly Dash cross center member assemlby Dash cross center member assemlby Dash cross center member assemlby E E G G J J K K ...

Page 31: ...7 Center floor side member Center floor panel Side sill inner panel assembly LH Front seat mounting member assembly LH PART NAME No Center floor reinforcement assembly Front seat mounting member assembly RH Side sil inner panel assembly RH PART NAME No 3 2 4 5 6 7 1 ...

Page 32: ...BC 18 BODY CONSTRUCTION BFDBC6149 TOP VIEW SIDE VIEW F F A A B B C C D D E E ...

Page 33: ...rcement assembly Center floor side member Rear seat outer mounting bracket Side sill inner panel assembly Center floor panel Front seat mounting member assembly Seat rear inner mounting bracket Seat rear inner mounting bracket Front seat mounting member assembly Center floor panel Front seat mounting member assembly A A C C B B D D F F E E ...

Page 34: ...lete panel assembly Rear floor exteansion assemby Rear floor front panel Rear floor complete member assembly Rear floor rear complete panel assemby Rear floor center cross upper member assemby Rear floor rear panel assembly Rear floor side panel RH Rear floor side panel LH PART NAME No 1 3 4 7 8 9 5 2 6 ...

Page 35: ...BODY CONSTRUCTION BC 21 BFDBC6156 Cross Sectional Views A A ...

Page 36: ...160 BFDBC6161 A A Rear floor front panel Rear floor complete member assembly Rear floor center cross upper member assembly Rear floor rear panel assembly Spare tire mounting bracket assembly Cross Sectional Views REAR VIEW SIDE VIEW ...

Page 37: ...BODY CONSTRUCTION BC 23 BFDBC6162 1 2 Back panel assembly PART NAME No Rear transverse member assembly PART NAME No 1 2 BACK COMPLETE PANEL ...

Page 38: ...BC 24 BODY CONSTRUCTION Cross Sectional Views BFDBC6164 TOP VIEW REAR VIEW A A ...

Page 39: ...DY CONSTRUCTION BC 25 BFDBC6165 A A Tail gate blanking cover Transverse member tirm Latch Tail gate striker plate Rear bumper beam Back panel Rear bumper cover Transverse member Tail gate striker support ...

Page 40: ...STRUCTION BFDBC6166 1 2 3 4 5 6 Roof center No 2 rail Sun roof reinforcement ring assembly Roof center No 4 rail PART NAME No Roof center No 3 rail Roor center No 2 rail Roof panel PART NAME No 2 3 4 5 6 1 ROOF PANEL ...

Page 41: ...BODY CONSTRUCTION BC 27 Cross Sectional Views BFDBC6168 ROOF SUN ROOF C C E E A A B B Y Z ...

Page 42: ...169 A A B B D D C C E E Y Z D D 45 Sun roof assembly Sun roof panel Sun roof panel Sun roof panel Sun roof panel Sun roof panel Sun roof reinforcement ring assembly Sun roof reinforcement ring assembly Sun roof reinforcement ring assembly Sun roof reinforcement ring assembly Sun roof assembly ...

Page 43: ...BODY CONSTRUCTION BC 29 Cross Sectional Views BFDBC6197 C C A A B B HOOD ...

Page 44: ...ONSTRUCTION BFDBC6200 BFDBC6199 BFDBC6198 A A B B C C Radiator grille Hood panle assembly Hood panle assembly Fender panel assembly Hood panle assembly Head lamp Hood latch assembly _ 5 0 5 mm _ 3 0 5 mm _ 5 0 5 mm ...

Page 45: ... Sectional Views G G H H D D E E K K L L F F M M C C B B A A N N Side outer panel Side outer panel Side outer panel Front door panel assembly Fender panel Front door panel assembly Front door panel assembly Front door panel assembly _ 5 0 5 m m _ 5 0 5 m m _ 5 0 5 m m _ 3 8 0 5 mm FRONT REAR DOOR ...

Page 46: ... 3 8 0 5 mm _ 3 8 0 5 mm _ 4 5 0 5 mm Fender panel Rear door panel assembly Rear door panel assembly Side outer panel Front door panel Rear door panel assembly Rear door panel assembly Side sill outer panel Rear door panel assembly Rear door panel assembly Side sill outer panel Front door panel assemby Front door panel assemby Front door panel assemby Front door panel assemby Front door panel asse...

Page 47: ...BODY CONSTRUCTION BC 33 Cross Sectional Views BFDBC6190 D D B B A A E E C C TAIL GATE ...

Page 48: ... BFDBC6182 BFDBC6184 BFDBC6181 BFDBC6180 A A B B D D C C E E _ 5 0 5 mm 4 mm 2 m m 3 5 mm 5 mm _ 4 0 5 mm 0 5 m m Tail gate outer panel Tail gate inner panel Headlining High mounted stop lamp Rear glass assemby Tail gate panel assembly ...

Page 49: ...BD 2 PROJECTED DIMENSIONS BD 2 ACTUAL MEASUREMENT DIMENSIONS BD 2 MEASUREMENT POINT BD 2 FRONT BODY BD 3 SIDE BODY BD 5 INTERIOR A BD 7 INTERIOR B BD 10 REAR BODY BD 12 UNDER BODY PROJECTED DIMENSIONS BD 14 UNDER BODY ACTUAL MEASUREMENT DIMENSIONS BD 16 ...

Page 50: ...racking gauge 2 When a measuring tape is used check to be sure there is no elongation twisting or bending 3 For measuring dimensions both projected dimension and actual measurement dimension are used in this manual MEASUREMENT METHOD PROJECTED DIMENSIONS 1 These are the dimensions measured when the measurement points are projected into the reference plane and are the reference dimensions used for ...

Page 51: ...mensions Point symbol Length mm Point symbol Length mm Point symbol Length mm A A E E H J A B E F H J A B E F I I A H F F J J B B G G B H H H C C H J D F H J 1416 1479 1120 650 781 583 1605 1477 995 1283 1063 988 1520 1074 1628 1024 1181 483 1414 1150 BFDBD6101 I A B C D E F H G J I A B C D E F H G J ...

Page 52: ...r Tooling hole ø9 Front suspension mounting hole ø11 Roof front corner Transmission mounting bracket ø11 Transmission mounting bracket ø11 Engine mounting bracket hole ø13 Engine mounting bracket hole ø13 BFDBD6102 BFDBD6103 BFDBD6105 BFDBD6103A BFDBD6106 BFDBD6107 BFDBD6107A BFDBD6109 BFDBD6109A A A B B C C BFDBD6104 D D F F G G E E H H I J BFDBD6108 BFDBD6108A I J ...

Page 53: ...symbol Length mm Point symbol Length mm Point symbol Length mm Point symbol Length mm A B C F F H I K A C D E G H J K B C D G G I B D D H G J B E E F H I B F E G H J C D E H H K C E F G I J 155 858 1123 907 609 340 389 609 508 1123 941 1014 1110 868 955 303 1206 977 1196 954 611 1067 1521 684 1335 549 I A B C D E F H G J K ...

Page 54: ...ge lower mounting hole ø9 Rear door hinge lower mounting hole ø13 Tooling hole ø7 Fender mounting hole ø6 Quarter fixed glass mounting hole ø11 Rear door switch mounting hole ø6 6 Rear bumper mounting hole 8 5 X 8 5 BFDBD6110 BFDBD6110A BFDBD6112 BFDBD6113 BFDBD6113A BFDBD6114 BFDBD6114A BFDBD6111 BFDBD6115 BFDBD6116 A B C D E F G H I J K BFDBD6117 ...

Page 55: ... Point symbol Length mm A A I I P B Q E B B J J P D Q I C C K K P E D D L L Q E Q M E E M M Q I Q O F F N N Q J R R G G O O Q M H H P A Q O 1207 1156 1116 1072 S S 961 1406 1250 1003 1148 1487 1514 1134 Q J 1061 1418 1420 1083 1341 1211 1107 1158 1414 1354 1114 1073 1063 1481 996 1349 R S 1618 1370 1120 1421 R S 1907 BFDBD6301 I A B C D E F H G L J K M N O P Q R S I A B C D E F H G L J K M N O R S...

Page 56: ...elt retractor mounting hole ø12 Front door checker mounting hole ø9 Seat belt height adjust lower mounting hole ø12 Pillar trim mounting hole ø8 5 Seat striker passage hole ø9 Rear door striker mounting hole ø13 Wheel house trim mounting hole ø8 4 BFDBD6118 BFDBD6119 BFDBD6121 BFDBD6121A A A B B C C BFDBD6120 D D BEDBD6305 E E F F G G BFDBD6122 H H BFDBD6123 I I BFDBD6124 J J BFDBD6125 K K BFDBD61...

Page 57: ...Tooling and drain hole ø10 Roof rear corner Side trim mounting hole ø6 6 Fuel pump wire mounting hole ø7 Luggage side trim mounting hole ø8 Roof front corner BFDBD6130 M M BFDBD6128 O O N N BFDBD6129 BFDBD6129A P P Q BFDBD6131 R R BFDBD6132 S S BFDBD6133 ...

Page 58: ...NS INTERIOR B These dimensions indicated in this figure are actual measurement dimensions Point symbol Length mm A D A D E H E H I L M O I L M O 994 1643 871 1555 857 1541 517 1171 BFDBD6301A I A D E H L M O I A D H L M O ...

Page 59: ...im mounting hole ø8 5 Cowl cross bar mounting hole ø9 Pillar trim mounting hole ø8 5 Side trim mounting hole ø8 Seat belt height adjust upper mounting hole ø9 Wheel house trim mounting hole ø8 4 BFDBD6118 A A BFDBD6121 D D E E H H I I L L BEDBD6305 BFDBD6123 BFDBD6124 BFDBD6127 M M O O BFDBD6128 BFDBD6129A ...

Page 60: ... in this figure are actual measurement dimensions Point symbol Length mm Point symbol Length mm A A D D B B D F B D D F B D E E B E E F B G E F C C F F C G 625 1529 961 428 742 1371 1421 972 790 314 1034 1085 1219 1110 964 BFDBD6401 A B C D E F G A B C D E F G ...

Page 61: ...rear corner Tail gate striker mounting hole ø11 Roof rear corner Rear bumper mounting hole 7 5X7 5 Gas lifter mounting passage hole ø11 Rear bumper mounting hole 18X20 BFDBD6134 BFDBD6134B BFDBD6134A BFDBD6405 A A B B C C BFDBD6135 BFDBD6135A BFDBD6135B D D E E F F G G ...

Page 62: ...Point symbol Length mm Point symbol Length mm Point symbol Length mm A A I I O J B B J J A C C C O A C E D D O C E F E E O E F G F F O F G H G G O G H J H H O H 1004 1061 178 1000 998 295 1000 174 763 630 184 1312 832 73 363 848 81 420 1100 98 489 993 131 BFDBD6201A A C E F H G J 0 I A B C D E F H G J I A B C D E F H G J ...

Page 63: ...5 Subframe mounting bolt Rear suspension mounting hole ø21 Tooling hole ø25 Tooling hole ø11 Cross member mounting hole ø19 Spring mounting hole ø20 Tooling hole ø25 BFDBD6136 BFDBD6136A BEDBD6503 BFDBD6137 BFDBD6136B BEDBD6504 BFDBD6138 BFDBD6140 BFDBD6140A BFDBD6141 A A B B C C D D D D E E F F G G BFDBD6139 H H I I J J ...

Page 64: ... DIMENSIONS These dimensions indicated in this figure are actual measurement dimensions Point symbol Length mm Point symbol Length mm A C H J A E C E E F F G F H G H G J 1045 1110 1422 1219 1558 1055 1227 1128 1390 BFDBD6501A A C E F H G J A C E F H G J ...

Page 65: ...ling and paint drain hole ø20 Tooling hole ø25 Tooling hole ø25 Rear suspension mounting hole ø21 Tooling hole ø11 Cross member mounting hole ø19 BFDBD6137 BFDBD6136B BFDBD6140 BFDBD6141 BFDBD6136 A A C C E E BFDBD6138 F F G G BFDBD6139 H H J J ...

Page 66: ... DETERMINING A WELDING METHOD BP 5 SPOT WELDING BP 5 CARBON ARC WELDING BP 6 REPLACING BODY PANEL REMOVAL BP 7 PREPARATION FOR INSTALLATION BP 9 INSTALLATION BP 10 FENDER APRON PANEL BP 12 REMOVAL BP 13 INSTALLATION BP 15 FRONT SIDE MEMBER BP 18 REMOVAL BP 19 INSTALLATION BP 20 FRONT PILLAR BP 22 REMOVAL BP 23 INSTALLATION BP 27 SIDE SILL PANEL BP 31 REMOVAL BP 31 INSTALLATION BP 33 CENTER PILLAR ...

Page 67: ...P 2 BODY PANEL REPAIR PROCEDURE REPLACING BODY PANELS CODES FOR REMOVING AND INSTALLING BODY PANELS BVQBP6001A Location for cut and assembly Rough cutting location 20 30 mm 0 8 1 2 in 20 30 mm 0 8 1 2 in ...

Page 68: ...area it is best to remove the spot welded area from the body frame using a spot cutter or candle type edge drill bit Do not use a drill bit with a tapered edge Center punch middle of spot weld to insure the entire spot weld will be removed BVQBP6002 1 Spot cutter 1 Drill candle type edge 1 Drill taper edge 2 2 2 3 3 3 Correct Correct Not correct ...

Page 69: ...EDURE BVQBP6003 Center punch the middle nugget of the spot weld Otherwise Spot welded area can be removed from the body frame Spot welded area cannot be removed from the body frame This part will not be cut This part will be cut ...

Page 70: ... variance of joints welding method and or welding locations Therefore a new part should be fitted to the body frame using the proper procedures to avoid reducing the strength of the body DETERMINING A WELDING METHOD It is extremely important that appropriate welding methods which don t reduce the original strength and durability of the body be used when making repairs Try to use either spot weldin...

Page 71: ...e welded together tightly Do not exceed 1 mm of space between parts A tolerance greater than 1 mm will reduce the strength of the welded area 2 Weld in the middle of the flange joint a Drill a hole 5 6 mm on one side of the flange only and weld within the hole b Do not weld on the edge of the flange joint BVQBP6008 1mm Maximum tolerance BVQBP6006 Good BVQBP6009 No good ...

Page 72: ...t and welding point selection Cutting if necessary should not be done in a reinforcement area Select an area which will result in the least amount of deformation after welding 3 Cutting rough area for replacement part Cutting should be done according to the following steps to make removal easy a Use care when cutting an area close to a pipe or wiring harness b Cut an area leaving 30 50 mm of toler...

Page 73: ...hole in the middle of spot welded area with a punch remove welded area using a spot cutter and remove using a chisel b Removing brazed area Remove using a torch and wire brush and chisel c Removing arc welded area Remove plug welded area using a disk grinder and chisel BVQBP6014 BVQBP6016 BFDBP6015 ...

Page 74: ...is greater than 3 mm drill a hole using a 7 mm diameter drill NOTE Do not spot weld where thickness is greater than 3 mm PREPARATION FOR INSTALLATION 1 Spot weld finish Use a disk grinder or similar tool to finish spot weld mark Do not grind more than is necessary to smooth surface 2 Panel preparation Repair any bent or uneven areas with a hammer to improve the installation process 3 Cutting a rou...

Page 75: ...g should be done only on areas that were originally brazed at the factory 3 Caution when spot welding a Do a test welding on a piece of material of the same type and thickness as the part to be welded and proceed if test weld is good b Before spot welding check if welding debris oil or paint is present on the area where surfaces meet Clean or sand as necessary BVQBP6024 3mm Spot welding initial nu...

Page 76: ...5 Finishing after welding a Grind any areas that were plug welded or butt welded using a disk grinder Grind carefully to avoid removing too much material This degrades the strength of the weld b Finish areas that have been brazed by applying body filler then smooth the area with a flexible file and sander 6 Applying anti rust agent and body sealer After coating the surface with anti rust agent app...

Page 77: ...BP 12 BODY PANEL REPAIR PROCEDURE FENDERAPRONPANEL WELDING POINTS MIG plug welding MIG butt welding MIG lap welding MIG plug welding MIG butt welding MIG lap welding BFDBP6102 BFDBP6104 290mm ...

Page 78: ...separate fender apron inner panel assembly from fender apron upper panel assembly and front side member assembly When spotwelded portions are not apparent remove paint with a rotary wire brush 2 Remove the fender apron inner panel assembly On the right side remove engine mounting support assembly before removing the fender apron inner panel assembly 3 Drill out all the spotwelds to separate fender...

Page 79: ...from front fender apron upper inner panel end on the fender apron upper panel assembly as shown in the illustration 6 Cut the fender apron upper inner panel along the cutline 7 Remove the fender apron upper inner panel 8 Prepare all surfaces to be welded 9 After removing apply the welding primer BFDBP6105 BFDBP6106 290mm BFDBP6106A BFDBP6106B BFDBP6106C ...

Page 80: ...t end to improve weld surface 2 Fit and clamp the fender apron upper inner panel in place 3 Measure each measurement point Refer to the BODY DIMENSIONS and correct the installation position 4 MIG butt weld all seams 5 Clean and prepare all welds and remove all residue 6 After removing apply the welding primer BFDBP6106D BFDBP6106E BFDBP6106F BFDBP6106G BFDBP6106H BFDBP6105A ...

Page 81: ...er outer panel in place 9 Measure each measurement point Refer to the BODY DIMENSIONS and correct the installation position 10 MIG plug weld all holes 11 Clean and prepare all welds and remove all residue 12 Drill 8mm holes in the new fender apron inner panel assembly for MIG plug welding BEDBP6107 BEDBP6108 BFDBP6104B BFDBP6104C BFDBP6104D BFDBP6104E ...

Page 82: ...ior of the each panel 17 Apply an anti corrosion agent as required Refer to the BODY CORROSION PROTECTION 18 Prepare the exterior surfaces for priming using wax and grease remover 19 Apply metal conditioner and water rinse 20 Apply conversion coating and water rinse 21 Apply the two part epoxy primer 22 Apply the correct seam sealer to all joints carefully Refer to the BODY SEALING LOCATIONS BFDBP...

Page 83: ...BP 18 BODY PANEL REPAIR PROCEDURE FRONT SIDE MEMBER WELDING POINTS MIG plug welding MIG butt welding MIG lap welding MIG plug welding MIG butt welding MIG lap welding BFDBP6203 BFDBP6202F 260mm 143mm ...

Page 84: ...repair for the front left side member The procedure may also be applied to the front right side member NOTE BEDBP6101 REMOVAL 1 Before cutting the front side member remove the front crash member assembly 2 Measure and mark the vertical cutlines on front side member from tooling hole edge as shown in the illustration 3 Drill out all the spotwelds to separate front side member BEDBP6201 BEDBP6202 14...

Page 85: ...emoving apply the welding primer INSTALLATION 1 Transcribe the front side member inner and outer cutlines to the new front side member cut to length and chamfer butt end to improve weld surface 2 Fit and clamp the front side member in place 3 Measure each measurement point Refer to the BODY DIMENSIONS and correct the installation position BEDBP6204 BEDBP6204A BFDBP6203B BEDBP6206 BFDBP6205 ...

Page 86: ...t as required Refer to the BODY CORROSION PROTECTION 8 Prepare the exterior surfaces for priming using wax and grease remover 9 Apply metal conditioner and water rinse BFDBP6203C BEDBP6203D 10 Apply conversion coating and water rinse 11 Apply the two part epoxy primer 12 Apply the correct seam sealer to all joints carefully Refer to the BODY SEALING LOCATIONS 13 Install the front crash member asse...

Page 87: ...BP 22 BODY PANEL REPAIR PROCEDURE FRONTPILLAR 120mm BFDBP6307 WELDING POINTS A B A B 150mm B 100mm 90mm Laser welding MIG plug welding MIG butt welding MIG lap welding ...

Page 88: ...owl side upper outer panel 3 Before cutting the front pillar be sure to support roof panel 4 Measure and mark the each cutline on the front pillar outer panel 150mm and 270mm from the roof panel corner as indicated in the illustration 5 Cut the front pillar outer panel along the cutlines When cutting the front pillar outer panel take care not to cut through mating flanges or front pillar outer rei...

Page 89: ...uter panel section 8 Measure and mark the cutlines on front side sill outer panel as indicated in the illustration 9 Cut the front side sill outer panel along the cutlines When cutting the front side sill outer panel take care not to cut through mating flanges or the side sill outer reinforcement BEDBP6307A 100mm 90mm NOTE BEDBP6307B BFDBP6305B BFDBP6306 ...

Page 90: ...rk the cutline on side sill outer reinforcement as indicated in the illustration 13 Cut the side sill outer reinforcement along the cutline When cutting side sill outer reinforcement take care not to cut through mating flanges BEDBP6307C NOTE BFDBP6308 BFDBP6308A 130mm BFDBP6308B BFDBP6309 14 To remove the front pillar outer panel drill out all spotwelds and laser welds BFDBP6306A ...

Page 91: ...EL REPAIR PROCEDURE 16 To remove the front pillar inner panel drill out and grind away all spotwelds and lap welds BEDBP6313 BEDBP6313A BEDBP6314 15 Remove the front pillar outer panel BFDBP6304 BFDBP6311 BFDBP6312B ...

Page 92: ...e front pillar inner panel 18 Clean cut portions with a disc grinder 19 After removing apply the welding primer BEDBP6316 BEDBP6318 BEDBP6316A BEDBP6316B INSTALLATION 1 Drill 8mm holes in the front pillar inner panel for MIG plug welding BEDBP6319 ...

Page 93: ...0mm overlap to each end and cut to length 8 Drill 8mm holes along front pillar outer panel flanges for attachment to other panels 4 MIG plug weld all holes and MIG lap weld seams BEDBP6315A BEDBP6315B BEDBP6315C BEDBP6320 2 Fit and clamp the new front pillar inner panel in place for welding 3 Measure each measurement point Refer to the BODY DIMENSIONS and correct the installation position BEDBP631...

Page 94: ... installation position 11 MIG plug weld all holes 12 Clean and prepare all welds and remove all residue BEDBP6309A BEDBP6309B BEDBP6309C 13 After removing apply the welding primer 14 Reattach the cut away front pillar outer panel section then MIG plug weld all holes and MIG butt weld seams 15 Clean all welds with a disc grinder BEDBP6309D BEDBP6321A BEDBP6321B ...

Page 95: ... sealer to all joints carefully Refer to the BODY SEALING LOCATIONS 28 Reprime over the seam sealer to complete the repair 16 After removing apply the welding primer 17 Apply the two part epoxy primer to the interior of the front pillar 18 Before welding the cowl side upper outer panel apply the two part epoxy primer and anti corrosion agent to the interior of the fender apron panel 19 Install the...

Page 96: ...ration BEDBP6401 WELDING POINTS MIG plug welding MIG butt welding MIG lap welding 70mm 50mm 50mm BEDBP6401A 50mm 2 Measure and mark the horizontal cutline on center pillar outer panel 70mm from the door hinge mounting hole 3 Measure and mark the vertical cutline on rear side sill outer panel 50mm from the rear door step trim mounting hole as indicated in the illustration BEDBP6401B 70mm 50mm ...

Page 97: ...he welding primer 4 Cut the side sill outer panel along the cutlines When cutting the side sill outer panel be careful not to cut mating flanges 5 Drill out all spotwelds attaching the side sill outer panel 6 Remove the side sill outer panel NOTE BEDBP6401C BEDBP6401D BEDBP6402A BEDBP6402B BEDBP6402C ...

Page 98: ...ter rinse 13 Apply the two part epoxy primer 14 Apply the correct seam sealer to all joints Refer to the BODY SEALING LOCATIONS 15 Reprime over the seam sealer INSTALLATION 1 Transcribe the cutlines to the new side sill outer panel adding 30mm overlap to each end and cut to length 2 Using service panel for replacement of side sill outer panel drill 8mm holes in overlap areas and along upper and lo...

Page 99: ...BP 34 BODY PANEL REPAIR PROCEDURE CENTER PILLAR BFDBP6508 WELDING POINTS A 100mm 100mm 35mm 100mm 35mm C B A B C 100mm Laser welding MIG plug welding MIG butt welding MIG lap welding ...

Page 100: ...lar outer panel as indicated in the illustration 3 Cut center pillar outer panel along the cutlines When cutting center pillar outer panel take care not to cut through mating flanges or center pillar outer reinforcement 4 Drill out all spotwelds and laser welds attaching the center pillar outer panel BEDBP6501 NOTE BFDBP6502 100mm 100mm BFDBP6502A BFDBP6502B ...

Page 101: ...icated in the illustration 7 Cut the center pillar outer reinforcement along the cutlines When cutting center pillar outer reinforcement take care not to cut through mating flanges or rear door hinge mounting upper reinforcement 8 Drill out all spotwelds attaching the center pillar outer reinforcement NOTE BEDBP6503A 40mm 130mm BEDBP6503B BEDBP6503C BFDBP6503 ...

Page 102: ...d in the illustration 11 Cut the rear door hinge mounting upper reinforcement along the cutline When cutting rear door hinge mounting upper reinforcement take care not to cut through mating flanges 12 Measure and mark the vertical cutlines on front side sill outer panel 35mm and 135mm from the front door step trim mounting hole NOTE BFDBP6504 BFDBP6504A 150mm BFDBP6504B BFDBP6505 35mm 100mm ...

Page 103: ...rough mating flanges or side sill outer reinforcement 14 Drill out all spotwelds attaching the front side sill outer panel section 15 Remove the front side sill outer panel section 16 Measure and mark the vertical cutlines on front side sill outer reinforcement as indicated in the illustration NOTE BEDBP6506 BFDBP6505 35mm 100mm BEDBP6505A BFDBP6506A 60mm 50mm ...

Page 104: ...n the illustration 21 Cut the front side sill inner reinforcement along the cutline 17 Cut the front side sill outer reinforcement cutlines When cutting front side sill outer reinforcement take care not to cut through mating flanges 18 Drill out all spotwelds attaching the front side sill outer reinforcement section NOTE BEDBP6506B BFDBP6507 BFDBP6507A 85mm BEDBP6506C BFDBP6507B ...

Page 105: ...utlines When cutting rear side sill outer panel take care not to cut through mating flanges or side sill outer reinforcement 24 Drill out all spotwelds attaching the rear side sill outer panel section 25 Remove the rear side sill outer panel 26 Measure and mark the cutline on side sill outer reinforcement as indicated in the illustration NOTE BEDBP6508B BEDBP6508C BFDBP6508A 100mm 55mm BFDBP6509 B...

Page 106: ...er reinforcement take care not to cut through mating flanges 28 Drill out all spotwelds attaching the center pillar outer panel BFDBP6509B BFDBP6510 BFDBP6509C NOTE 29 Remove the center pillar outer panel 30 To remove the center pillar inner panel drill out and grind away all spotwelds and lap welds BEDBP6511 BEDBP6512 BEDBP6513 ...

Page 107: ...ces to be welded 33 After removing apply the welding primer BEDBP6514 BEDBP6514A BEDBP6514B INSTALLATION 1 Fit and clamp the new center pillar inner panel in place for welding 2 Measure each measurement point Refer to the BODY DIMENSIONS and correct the installation position BEDBP6516 BEDBP6511A ...

Page 108: ...cut to length 7 Drill 8mm holes in overlap areas and along center pillar outer panel flanges 8 Fit and clamp the new center pillar outer panel in place for welding 9 Measure each measurement point Refer to the BODY DIMENSIONS and correct the installation position 10 Check the fit of the front and rear doors 11 Reinstall center pillar outer panel 12 Apply body filler to the outer center pillar seam...

Page 109: ...then MIG plug weld all holes and MIG butt weld seams 17 Clean all welds with a disc grinder 13 MIG plug weld all holes and MIG butt weld seams 14 Clean and prepare all welds and remove all residue 15 After removing apply the welding primer BEDBP6510B BEDBP6510C BEDBP6510D BEDBP6501A BEDBP6501B ...

Page 110: ...erior of the center pillar Refer to the CORROSION PROTECTION 20 Prepare exterior surfaces for priming using wax and grease remover 21 Apply metal conditioner and water rinse 22 Apply conversion coating and water rinse 23 Apply the two part epoxy primer 24 Apply the correct seam sealer to all joints carefully Refer to the BODY SEALING LOCATIONS BEDBP6513C BEDBP6513D ...

Page 111: ...BP 46 BODY PANEL REPAIR PROCEDURE QUARTER PANEL BFDBP6601 WELDING POINTS 5 0 m m 5 0 m m 50mm Laser welding MIG plug welding MIG butt welding MIG lap welding ...

Page 112: ...rter outer panel along the cutlines and remove the quarter outer panel as illustration When cutting the quarter outer panel be careful not to cut quarter inner panel NOTE 3 Drill out all attaching spotwelds and laser welds on the quarter outer panel including the seam around the door lip opening BFDBP6603 5 0 m m 5 0 m m BFDBP6602 50mm BFDBP6601A BEDBP6606 BFDBP6604 BEDBP6605 ...

Page 113: ... 1 Transcribe the cutlines to the new quarter outer panel adding 30 mm overlap each end 2 Drill 8 mm holes in overlap areas and along upper and lower flanges of the new quarter outer panel for MIG plug welding 4 Remove the quarter outer panel 5 Clean cut portions with a disc grinder BFDBP6607 BFDBP6607A BFDBP6607B BFDBP6608 ...

Page 114: ...y metal conditioner and water rinse 11 Apply conversion coating and water rinse 12 Apply the two part epoxy primer 3 Apply body filler to the welded seam Sand and finish Apply the two part epoxy primer to the interior of the quarter outer panel 4 Fit and clamp the quarter outer panel in place 5 Measure each measurement point Refer to the BODY DIMENSIONS and correct the installation position 6 MIG ...

Page 115: ...t seam sealers to all joints 14 Reprime over the seam sealer to complete the repair 15 In order to improve corrosion resistance if necessary apply an under body anti corrosion agent to the wheel well Refer to the CORROSION PROTECTION BFDBP6604A BFDBP6601F ...

Page 116: ...BODY PANEL REPAIR PROCEDURE BP 51 LOWER QUARTER PANEL BFDBP6601G WELDING POINTS 2 7 0 m m 50mm Laser welding MIG plug welding MIG butt welding MIG lap welding ...

Page 117: ...tlines and remove the quarter outer panel as illustration When cutting the quarter outer panel be careful not to cut quarter inner panel NOTE 3 Drill out all attaching spotwelds and laser weld on the quarter outer panel including the seam around the door lip opening 4 Remove the quarter outer panel 5 Clean cut portions with a disc grinder BFDBP6718 2 7 0 m m 50mm BEDBP6606 BFDBP6601H BFDBP6601I BF...

Page 118: ...wer flanges of the new quarter outer panel for MIG plug welding BFDBP6720B 3 Apply body filler to the welded seam Sand and finish Apply the two part epoxy primer to the interior of the quarter outer panel 4 Fit and clamp the quarter outer panel in place 5 Measure each measurement point Refer to the BODY DIMENSIONS and correct the installation position 6 MIG plug weld all holes and MIG butt weld se...

Page 119: ...gent to the welded parts and interior of the quarter outer panel Refer to the CORROSION PROTECTION 9 Prepare exterior surfaces for priming using wax and grease remover 10 Apply metal conditioner and water rinse 11 Apply conversion coating and water rinse 12 Apply the two part epoxy primer BFDBP6717C BFDBP6717D ...

Page 120: ...BODY PANEL REPAIR PROCEDURE BP 55 BACK COMPLETE PANEL AND REAR FLOOR SIDE MEMBER BFDBP6705 WELDING POINTS 130mm MIG plug welding MIG butt welding MIG lap welding ...

Page 121: ...he following procedure applys when only one rear floor side member needs to be replaced If both side members are damaged and need to be replaced then the procedure of rear floor side members and rear floor section should be followed Refer to the body dimension charts and measure the vehicle to determine straightening and alignment requirements The body must be returned to its original dimensions b...

Page 122: ...ar floor side member as indicated in the illustration 6 Cut rear floor side member along the cutline 7 Drill out all spotwelds and MIG lap welds attaching the rear floor side member to rear floor panel 8 Remove the rear floor side member 9 Clean cut portions with a disc grinder BFDBP6704 BFDBP6705A 130mm BFDBP6705B BFDBP6706 BFDBP6707 BEDBP6707A ...

Page 123: ...overlap to the rear end 2 Drill 8 mm holes in the new rear floor side member for MIG plug welding 3 Fit and clamp the rear floor side member in place 4 Measure each measurement point Refer to the BODY DIMENSIONS and correct the installation position 5 MIG plug weld all holes and MIG lap weld seams 6 Clean and prepare all welds remove all residue BEDBP6707B BFDBP6708 BFDBP6705C BFDBP6706A BFDBP6706...

Page 124: ...ete panel assembly in place 9 Measure each measurement point Refer to the BODY DIMENSIONS and correct the installation position BFDBP6706C BFDBP6709 BFDBP6702B 10 MIG plug weld all holes 11 Clean and prepare all welds remove all residue 12 After removing apply the welding primer BFDBP6702C BFDBP6702D BFDBP6701A ...

Page 125: ...PROTECTION 19 Prepare exterior surfaces for priming using wax and grease remover 20 Apply metal conditioner and water rinse 21 Apply conversion coating and water rinse 22 Apply the two part epoxy primer 13 Fit and clamp the new rear combination lamp housing panel assembly in place 14 Measure each measurement point Refer to the BODY DIMENSIONS and correct the installation position 15 MIG plug weld ...

Page 126: ... the seam sealer to complete the repair 25 After completing body repairs carefully apply Under coating to the Under body Refer to the CORROSION PROTECTION 26 In order to improve corrosion resistance if necessary apply an Under body anti corrosion agent to the panel whichisrepairedorreplaced RefertotheCORROSION PROTECTION BFDBP6705D BFDBP6705E ...

Page 127: ... PANEL REPAIR PROCEDURE FRONT AND REAR DOOR OUTER PANELS WELDING POINTS BFDBP6711 BFDBP6712 FRONT DOOR REAR DOOR MIG plug welding MIG butt welding MIG lap welding MIG plug welding MIG butt welding MIG lap welding ...

Page 128: ...ing location remove the outer panel 3 Dress rusty part with a sander and prepare surface to be hemmed INSTALLATION 1 Apply adhesive or equivalent to outer panel hem 2 Apply mastic sealer or equivalent to the door upper member and door reinforcement beam as shown in the figure PRO 1831 PRO 1771 BFDBP6713 BFDBP6714 ...

Page 129: ... 50 mm intervals on the inside 5 Clean and prepare all welds remove all residue 6 Apply the two part epoxy primer to the interior of the door panel 7 Apply an anti corrosion agent to the welded parts and lower inside of the door panel Refer to the CORROSION PROTECTION 8 Prepare exterior surfaces for priming using wax and grease remover 9 Apply metal conditioner and water rinse 10 Apply conversion ...

Page 130: ...BODY PANEL REPAIR PROCEDURE BP 65 12 Apply the correct seam sealer to whole panel edge 13 Reprime over the seam sealer to complete the repair BFDBP6716 ...

Page 131: ...Body Sealing Locations BS EXTERIOR BS 2 INTERIOR BS 5 UNDER BODY BS 8 HOOD BS 9 DOOR BS 10 TAIL GATE BS 13 ...

Page 132: ...BS 2 BODY SEALING LOCATIONS EXTERIOR BFDBS6006 G K K A C B D E F J J H H I I N N L L M M ...

Page 133: ...BODY SEALING LOCATIONS BS 3 BFDBS6205 BFDBS6402 BFDBS6203 BFDBS6201 BFDBS6202 BFDBS6204 A B C D E F RH SIDE F LH SIDE G BFDBS6206 BFDBS6101 ...

Page 134: ...310 BFDBS6310 BFDBS6308 H H I I J J L L N N M M K K BFDBS6305 Front inner lower pillar Quarter inner lower panel Side sill inner rear panel Outer inner lower panel Roof panel Side outer panel Side outer panel Wheel house inner front extension Front side member outer ...

Page 135: ...BODY SEALING LOCATIONS BS 5 INTERIOR BEDBS6306 BFDBS6001 BEDBS6302 BEDBS6301 A B C D BEDBS6303 L L M M C A B I K D G F E H J ...

Page 136: ...BS 6 BODY SEALING LOCATIONS BEDBS6307 BEDBS6311 BEDBS6309 BEDBS6310 BEDBS6308 E F G H I J K BEDBS6305 BEDBS6304 ...

Page 137: ...wer panel Dash panel Dash lower center reinforcement Dash lower center reinforcement Center floor panel Center floor reinforcement Rear floor front cross member reinforcement Rear floor front cross member Rear floor front panel Rear floor front extension L L M M ...

Page 138: ...BS 8 BODY SEALING LOCATIONS UNDER BODY BFDBS6502 BFDBS6002 BFDBS6501 A B A B ...

Page 139: ...BODY SEALING LOCATIONS BS 9 BEDBS6020 BFDBS6016 BEDBS6018 BEDBS6017 BEDBS6019 X Y 1 5 m m 5 mm 2 1 A A B B Y X 1 5 m m 5 m m 2 1 A A B B HOOD ...

Page 140: ...BS 10 BODY SEALING LOCATIONS DOOR BFDBS6029 BFDBS6025 BFDBS6028 C C C C H2 G1 D2 A A B B F2 H1 F1 G2 E E D1 E E ...

Page 141: ...DBS6030 BEDBS6031 BEDBS6029 A A B B V C C T D1 D2 E BEDBS6027 BEDBS6026 V 94 5 mm _ T V Rear door front frame Rear door rear frame Front door rear frame Front door inner panel Front door outer panel Front door frame assembly Front door frame assembly 1 5 mm 5 m m ...

Page 142: ...frame assembly Front door frame assembly Front door outer panel Rear door outer panel Rear door frame assembly Front door inner panel Front door outer panel Rear door frame assembly Rear door inner panel Rear door frame assembly Rear door inner panel Rear door outer panel Rear door frame assembly Rear door outer panel ...

Page 143: ...BODY SEALING LOCATIONS BS 13 BEDBS6024 BFDBS6021 BEDBS6022 Z BEDBS6023 Z A A B B 2 5 m m 5mm A A B B TAIL GATE ...

Page 144: ...OSITION PRIMER CP 2 ATTACHMENT OF ANTIVIBRATION PADS CP 3 ANTIVIBRATION PADS LOCATION SECTION CP 4 UNDER BODY SIDE BODY COAT CP 7 CAVITY WAX INJECTION CP 10 SIDE BODY CP 10 HOOD CP 11 TAIL GATE CP 12 FRONT DOOR REAR DOOR CP 13 UNDER BODY ANTI CORROSION AGENT CP 14 ...

Page 145: ...der to improve the adhesion of the paint coat on the steel panel and also to improve the corrosion resistance the entire body is coated with a film of Zinc phosphate and a cationic electrodeposition primer BMCCP6020 Cationic electrodeposition primer Zinc phosphate film Body steel panel ...

Page 146: ...anels be sure to wear gloves BMCCP6041 BMCCP6042 ATTACHMENT OF ANTIVIBRATION PADS Antivibration pads are attached to the upper surface of the floor and at the interior side of the dash panel in order to absorb vibrations and shut out exhaust gas heat If these antivibration pads are peeled off in the course of replacement or repair of a welded panel cut and attach replacement material in the shape ...

Page 147: ...RATION PADS LOCATION SECTION F F H H BEDCP6202 5 Door Wagon G G C C D D E E H H A A B B I I 84123 1H000 84127 1H000 84125 2L000 84181 1H000 84171 1H000 84115 2L000 84181 2L200 84171 2L200 84193 2L000 84117 1H000 84113 1H000 84193 2L000 ...

Page 148: ...CORROSION PROTECTION CP 5 BFDCP6207 BFDCP6205 BFDCP6206 BFDCP6204 BFDCP6203 B B C C A A D D E E Dash panel Dash panel Center floor panel Center floor side member Center floor panel 24mm 25mm 82mm ...

Page 149: ...TECTION BFDCP6210 BFDCP6211 BFDCP6209 BFDCP6208 Front seat mounting member Spare tire mounting bracket Rear floor rear panel Rear floor side member Rear floor front panel Rear floor front panel F F G G H H I I 22mm 33mm ...

Page 150: ...tone chipping and vibration resistance under body coat is applied to the under sides of the floor and wheel house Therefore when such panel is replaced or repaired apply under body coat to that part BFDCP6002 C C B B E E A A D D F F X Y Under body coating Thickness 1 0 mm 1 5 mm 2 0mm ...

Page 151: ...ousing lower panel Front side inner member Side outer rear extension Side frame mounting rear support Side frame mounting rear reinforcement Fender apron upper outer panel Shock absorber housing cover Front side outer member Tie down front reinforcement Center floor side member Side sill inner panel Side outer panel Side frame mounting rear bracket ...

Page 152: ...08 E E Y F F X G G Rear floor rear panel Rear floor center cross member 5Door 20mm 50mm 50mm Rear suspension mounting bracket Wheel house inner panel Outer inner uper panel Side outer panel Rear floor rear panel Rear floor center cross member Back panel Wagon 20mm 50mm 50mm ...

Page 153: ... the vehicle such as the side member the side sill and the inside of other panels which have a hollow construction When replacing these parts be sure to apply cavity wax to the appropriate areas of the new parts BFDCP6213 BFDCP6212 A A 40mm Wax injection hole Side sill inner panel Side outer panel Side sill inner front extension Side sill outer reinforcement 25 16 A A ...

Page 154: ...DCP6118 BFDCP6116 BFDCP6117 B B C C HOOD Wax injection hole Wax injection hole Wax injection hole Wax injection hole Hood hinge assembly Cowl side upper panel Wax injection hole 100mm 200mm 100mm 200mm 150mm 150mm B B C C 30mm HOOD ...

Page 155: ...CP 12 CORROSION PROTECTION TAIL GATE BFDCP6121 BFDCP6119 BFDCP6120 D D E E 150mm 3 0 m m 30mm 5mm 5mm E E E E D D ...

Page 156: ...CORROSION PROTECTION CP 13 FRONT DOOR REAR DOOR BFDCP6122 BFDCP6123 F F 130mm 3 0 m m 3 0 m m F F F F 130mm Wax injection hole Wax injection hole Wax injection hole ...

Page 157: ...rrosion resistance Therefore when such panel is replaced or repaired apply under body anti corrosion agent to that part NOTE Do not apply the under body anti corrosion agent to come in contact with tires muffler and exhaust pipe BFDCP6115 BFDCP6114 A A A A 25mm 80mm Side sill inner panel Side outer panel Side sill outer front reinforcement ...

Page 158: ...fication Tools BT MODIFICATION TOOLS BT 2 CUT AND DISASSEMBLY TOOLS BT 3 ASSEMBLY TOOLS BT 4 MEASUREMENT TOOLS BT 4 WELDING MACHINE BT 5 BUFFING AND GRINDING TOOLS BT 6 HANDHELD TOOLS BT 8 REPAIR TOOLS SET BT 9 ...

Page 159: ...me straightener Port power Body puller Modify twisted or bent body Push out stretch pull in damaged area Stretch damaged area BODY MODIFICATION TOOLS MODIFICATION TOOLS A3EB3501 A3EB3502 A3EB3503 A3EB3504 A3EB3505 Name Used for Figure ...

Page 160: ...a panel Cut and disassemble spot welded area CUT AND DISASSEMBLY TOOLS Name Used for Figure Hand saw and metal scissors Cut or bend a panel cut and disassemble spot welded area Fix a spot cutter or drill to cut or disassembly spot welding area to finish a hole A3EB3506 A3EB3507 A3EB3508 A3EB3509 A3EB3510 A3EB3511 ...

Page 161: ...sh a hole for plug welding Finish contact area of flange Name Used for Figure Finish contact area of flange and finish a hole for plug welding MEASUREMENT TOOLS Centering gauge Tracking gauge Measure distortion of body and frame Measure body and frame Name Used for Figure A3EB3512 A3EB3513 A3EB3514 A3EB3515 A3EB3516 A3EB3517 ...

Page 162: ...ine Spot welding machine Stud welding machine Cut a panel Weld a panel Weld a panel A3EB3518 A3EB3519 A3EB3520 A3EB3521 Name Used for Figure WELDING MACHINE Carbon arc welding machine Stretch a panel weld a stud bolt to fix front window mold clip ...

Page 163: ...er Double action sander Orbital sander short Buff Buff Buff paints Buff paints or smooth finishing BUFFING AND GRINDING TOOLS Name Used for Figure Grind rough area of puttee assembled area A3EB3522 A3EB3523 A3EB3524 A3EB3525 A3EB3526 A3EB3527 Grind rough area of puttee assembled area ...

Page 164: ...lexible file Surform tool Hand file Used for puttee grinding of wide area Buff rough area of puttee area Grind body puttee pulley finish puttee Name Used for Figure A3EB3528 A3EB3529 A3EB3506 A3EB3530 A3EB3531 Grind touch up area uneven area of a panel ...

Page 165: ...in hammer Spoon Cut and disassemble a panel Used when greater force is required Used when smaller force is required HANDHELD TOOLS Name Used for Figure Punch a hole in the middle of a spot welding area A3EB3532 A3EB3533 A3EB3534 A3EB3535 A3EB3536 A3EB3537 Used for an area where not reached by hand ...

Page 166: ...A3EB3538 A3EB3539 Remove paints rust slag on welded area which are hard to recognize Window tool set Repair window collar Repair plastic parts Name Used for Figure A3EB3540 A3EB3541 Bend rough body line damaged or sheet metal etc REPAIR TOOLS SET Repair tool set for plastics ...

Page 167: ...Plastic Parts PP POLYPROPYLENE PP BUMPER REPAIRABILITY PP 2 BUMPER REPAIR PROCEDURE PP 3 REPAIR METHOD FOR PP BUMPER PP 4 ...

Page 168: ... considerations bumpers with more damage may be repaired but replacing the bumper is encouraged 1 If a hole on a bumper is less than 2 in 50 mm 2 If a crack on a bumper is less than 100 mm 4 in 3 If a crack on bumper sectionis A is less than 100 mm 4 in less than half of the bumper height A3EB3601 A3EB3602 Bumper height Crack on section A A3EB3603 ...

Page 169: ...for polypropylene over damaged area Apply solvent over damaged area Spray primer surface over bumper and let dry Sand surface of bumper with sandpaper Clean and degrease with TCE de oil material Wipe the surface of bumper with a tack cloth Paint bumper with a paint of the same color and let dry Surface of bumper is not visible Surface of bumper is visible Replace damaged bumper with a new bumper A...

Page 170: ...rea 45 using a knife and then sand the angle smooth Hole Section A A Section D D Section B B Section C C Crack Scar 4 2 1 D D D D 3 1 2 3 4 Upper layer coating Primer layer Primer surface layer Polypropylene layer VQPP002 C C C C B B B B A A A A Surface of polypropylene A A B B C C Angle of 45 is required for accumulation of polypropylene welding rod VQPP003 Cut with a knife Section Section D D Cu...

Page 171: ...g rod over melts like jelly the welding strength will deteriorate Use the heat gun 10 20 mm 0 4 0 8 in away from the repair area to be welded Welding rod should not move until the welded area is cooled Heat gun Apply on surface Surface of polypropylene Section view after melt Melt the surface using a heat gun VQPP004 Remove oil Section A A Apply aluminum tape on the rear side of the damaged area V...

Page 172: ... material and hardener so that no bubbles are made Work immediately after mixing filler material because the filler material hardens quickly in about 5 minutes Dry it at 20 C 68 F for about 30 minutes before sanding Filler material consists of two types of epoxy When the filler material hardens you will have a desirable finish with flexibility like polypropylene Use only filler material designed f...

Page 173: ...sible Forced drying may create air bubbles on the top layer VQPP011 Use the primer within 16 hours after it is mixed Polypropylene primer Primer hardener VQPP012 7 Sand the damaged area with sandpaper using 180 240 grit paper NOTE The surface will not be even if excessive force is applied during sanding If there is fuzz in the damaged area heat it a little bit with a heater gun and melt it 8 Degre...

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