Hyundai i30 (2007) manual

General Information Body Construction Body Dimensions Body Panel Repair Procedure Body Sealing Locations Corrosion Protection Body Modification T ools Plastic Parts Bod y Repair Manual FOREWORD This Body Repair Manual provides detailed repair procedures for repair of commonly damaged structural panels on the 2008 i30 / ELANTRA NEOS(FD). To aid in t[...]

IN THIS MANUAL Proper service methods and repair procedures are essential for safe, reliable operation of all motor vehicles as well as personal safety of the operator. The service procedures and descriptions in this manual provide general directions for a service and repair. Procedure, techniques, tools, and parts for service including the skill o[...]

General Inf ormation GI GENERAL GUIDE LINES AND PRECA UTIONS .............................................. BD - 2 FUND AMENT AL PROCEDURES VEHICLE PROTECTION .................................. GI - 3 SAFETY F A CT ORS .......................................... GI - 3 SRS AIR BAG ................................................... GI - 4 WELDING ..[...]

GI-2 GENERAL INFORMA TION GENERAL GUIDE LINES AND PRECA UTIONS The i30 / ELANTRA NEOS is a completely new vehicle design. During its development, close attention has been given to saf ety , stability , weight and corrosion protection. T ypical of unit body design, the i30 / ELANTRA NEOS is designed so that the front and rear compar tments will abso[...]

GENERAL INFORMA TION GI-3 FUND AMENT AL PR OCEDURES VEHICLE PRO TECTION 1. Cover the seats before performing any procedure to keep them from getting dir ty . 2. Cover all glasses, seats and mats with a heat resistant cover when welding. 3. Protect moldings, garnishes and ornaments. BVQGI6001 SAFETY F A CT ORS 1. Disconnect the negative(-) battery c[...]

GI-4 GENERAL INFORMA TION SRS AIR-BA G The i30 / ELANTRA NEOS is equipped with a Supplemental Restraint System AIR-BAG to provide the vehicle's driver and/ or the front passenger with additional protection than that offered by the seat-belt system alone, in case of a frontal impact of sufficient sev erity . When handling airbag components (rem[...]

GENERAL INFORMA TION GI-5 WELDING All repairs in this manual require the use of a Metal-Iner t Gas (MIG) welder , Gas (o xyacetylene) welding must not be used. Both high strength steel and mild steel can be welded using the MIG welder . The I-CAR recommendations f or welding should be follo wed. The shielding gas should be 75% Argon and 25% CO 2 . [...]

GI-6 GENERAL INFORMA TION ELECTR ONIC P AR TS V ehicles toda y include a great man y electronic par ts and components, and these are in general very susceptible to adverse effects caused by overcurrent, reverse current, electromagnetic waves, high temperature, high humidity impacts, etc. In par ticular such electronic components can be damaged if t[...]

GENERAL INFORMA TION GI-7 FOR BEST RESUL TS REMO V AL Measuring dimensions before beginning Measure the dimensions of the damaged area according to the body dimension drawings before removing and repairing. Adjust dimensions with body frame adjuster if deformed. Selecting cutting area Select a cutting area that is easily accessible and that is pron[...]

GI-8 GENERAL INFORMA TION Removing Use caution when removing body molding and trim from the area to be worked. Apply masking tape where needed to prevent damage to the par t being remov ed or to the v ehicle body . Bef ore star ting repairs , check if pipes , hoses or electrical components are present near damaged area. BVQGI6006 Wire har ness Repa[...]

GENERAL INFORMA TION GI-9 Machining holes for plug welding Drill a hole of approximately 5~6 mm (0.2~0.24 in) in diameter in those areas which are not suitable for spot welding. BVQGI6008 PREP ARA TION OF INST ALLA TION Applying spot sealer Remov e paint from the surf ace of ne w par ts and body to be spot welded, and apply spot sealer f or r ustpr[...]

GI-10 GENERAL INFORMA TION INST ALLA TION Measuring dimensions before welding When installing a new par t, assemb le it according to the body dimensions giv en in Section BD , and star t welding after checking the gaps with nearb y par ts. Caution when welding The number of welding points should be determined based on the criteria below: Caution wh[...]

GENERAL INFORMA TION G I-11 CORROSION PR O TECTION AND SEALING Proper corrosion protection and sealing is an impor tant par t of any repair . When re vie wing these repair procedures, it is impor tant to recognize the need f or corrosion restoration to pro vide f or long term strength of the repaired member . A two part epoxy primer was applied to [...]

GI-12 GENERAL INFORMA TION VEHICLE LIFT (2-SUPPORT TYPE) AND SAFETY ST AND POSITIONS 1. Place the lift bloc ks under the suppor t points as shown in the illustr ation 2. Raise the hoist a f ew inches and roc k the v ehicle to be sure it is firmly suppor ted. 3. Raise the hoist to full height to inspect the lift points f or secure suppor t. LIFT BLO[...]

BC Bod y Construction FRONT SIDE MEMBER ............................... BC - 2 FENDER APR ON P ANEL ........................... BC - 6 SIDE BOD Y P ANEL ...................................... BC -10 D ASH P ANEL .................................................. BC -13 CENTER FLOOR P ANEL ........................... BC -17 REAR FLOOR P ANEL .......[...]

BC-2 BODY CONSTRUCTION FRONT SIDE MEMBER BFDBC6101 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 F ront crash member assemb ly F ront side member outer front e xtension assemb ly T ransmission mounting reinf orcement assemb ly F ront side member inner reinf orcement F ront side inner member assemb ly Crash member rear brac k et assembly Crash member brac k e[...]

BODY CONSTRUCTION BC-3 < Cross-Sectional Views > BFDBC6105 [ SIDE VIEW RH ] [ SIDE VIEW LH ] [ T OP VIEW RH ] [ T OP VIEW LH ] A A B B E E F F C C D D Z Y[...]

BC-4 BODY CONSTRUCTION BENBC6110 BFDBC6111 BFDBC6109 BFDBC6108 BFDBC6107 BFDBC6106 BFDBC6105A F ront side inner member assembly F ront side member outer front extension assembly F ront side outer member assembly F ront side member outer front extension assembly A - A B - B D - D F - F C - C Y E - E F ront side outer member assembly F ront side inne[...]

BODY CONSTRUCTION BC-5 BFDBC6112 Z[...]

BC-6 BODY CONSTRUCTION FENDER APR ON P ANEL BFDBC6113 1 2 3 4 5 6 7 F ender apron inner front reinforcement assemb ly F ender apron inner panel assembly Shock absorber housing complete panel assemb ly F ender apron upper outer F ender apron upper rear gusset F ender apron upper inner panel assembly Shock absorber housing reinf orcement P ART NAME N[...]

BODY CONSTRUCTION BC-7 < Cross-Sectional Views > BFDBC6115 [ T OP VIEW RH ] [ SIDE VIEW RH ] B B C C A A[...]

BC-8 BODY CONSTRUCTION < Cross-Sectional Views > BFDBC6117 [ T OP VIEW LH ] [ SIDE VIEW LH ][...]

BODY CONSTRUCTION BC-9 BFDBC6120 BFDBC6119 BFDBC6118 Shock absorber housing complete F ront side complete member assembly Shock absorber housing complete A - A B - B C - C Fender apron upper outer panel assemlby Fender apron inner front reinforcement assembly Fender apron inner front reinforcement assembly F ront side complete member assembly Fende[...]

BC-10 BODY CONSTRUCTION SIDE BOD Y P ANEL BFDBC6121 1 2 3 4 5 Side outer complete panel assembly Side inner complete panel assembly Quar ter inner & wheel house complete panel assemb ly P ART NAME No. Center inner complete panel assembly F ront inner complete panel assemb ly P ART NAME No. 2 3 4 5 1[...]

BODY CONSTRUCTION B C-11 BFDBC6124 BFDBC6122 BFDBC6126 BFDBC6125 BFDBC6123 B - B D - D A - A C - C Side outer complete panel assembly 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 i[...]

BC-12 BODY CONSTRUCTION BFDBC6132 BFDBC6134 BFDBC6133 BFDBC6130 BFDBC6129 BFDBC6131 BFDBC6128 BFDBC6127 Side outer complete panel assembly Side outer complete panel assembly Side outer complete panel assembly Side outer complete panel assembly Side outer complete panel assembly Side outer complete panel assembly Side outer complete panel assembly S[...]

BODY CONSTRUCTION B C-13 D ASH P ANEL BFDBC6135 1 2 3 4 5 6 7 Dash low er member assembly Dash cross center member assembly Dash cross side member assembly Dash cross side member assembly P ART NAME No. Dash panel reinf orcement assembly Dash panel assembly Dust cov er panel P ART NAME No. 2 3 4 5 6 7 1[...]

BC-14 BODY CONSTRUCTION < Cross-Sectional Views > BFDBC6138 J J C C D D A A G G B B K K E E[...]

BODY CONSTRUCTION B C-15 BFDBC6141 BFDBC6140 BFDBC6142 BFDBC6139 A - A B - B D - D C - C Dash cross center member assembly Dash panel assemby Dash cross center member assembly Dust cov er panel Dash panel assembly Dash panel reinforcement assemb ly Dash cross center member assembly Dash cross center member assembly Dash lower member assembly Dash p[...]

BC-16 BODY CONSTRUCTION BFDBC6145 BFDBC6143 BFDBC6146 BFDBC6144 Dash panel assembly Dash 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 [...]

BODY CONSTRUCTION B C-17 CENTER FLOOR P ANEL BFDBC6147 1 2 3 4 5 6 7 Center floor side member Center floor panel Side sill inner panel assembly (LH) F ront seat mounting member assemb ly (LH) P ART NAME No. Center floor reinf orcement assembly F ront seat mounting member assemb ly (RH) Side sil inner panel assembly (RH) P ART NAME No. 3 2 4 5 6 7 1[...]

BC-18 BODY CONSTRUCTION BFDBC6149 [ T OP VIEW] [ SIDE VIEW ] F F A A B B C C D D E E[...]

BODY CONSTRUCTION B C-19 BFDBC6152 BFDBC6151 BFDBC6153A BFDBC6154 BFDBC6153 BFDBC6150 Center floor reinforcement assemb ly Center floor reinforcement assemb ly Center floor side member Rear seat outer mounting brack et Side sill inner panel assembly Center floor panel F ront seat mounting member assembly Seat rear inner mounting brack et Seat rear [...]

BC-20 BODY CONSTRUCTION REAR FLOOR P ANEL BFDBC6155 1 2 3 4 5 6 7 8 9 P ART NAME No. Rear floor front complete panel assembly Rear floor e xteansion 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 pan[...]

BODY CONSTRUCTION B C-21 BFDBC6156 < Cross-Sectional Views > A A[...]

BC-22 BODY CONSTRUCTION BFDBC6160 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 brack et assembly < Cross-Sectional Views > [ REAR VIEW ] [ SIDE VIEW][...]

BODY CONSTRUCTION B C-23 BFDBC6162 12 Back panel assemb ly P ART NAME No. Rear transv erse member assembly P ART NAME No. 1 2 B A CK COMPLETE P ANEL[...]

BC-24 BODY CONSTRUCTION < Cross-Sectional Views > BFDBC6164 [ T OP VIEW] [ REAR VIEW ] A A[...]

BODY CONSTRUCTION B C-25 BFDBC6165 A - A T ail gate blanking cov er T ransverse member tirm Latch T ail gate str ik er plate Rear bumper beam Back panel Rear bumper co ver T ransverse member T ail gate str ik er suppor t[...]

BC-26 BODY CONSTRUCTION BFDBC6166 1 2 3 4 5 6 Roof center No .2 rail Sun roof reinf orcement ring assembly Roof center No .4 rail P ART NAME No. Roof center No .3 rail Roor center No .2 rail Roof panel P ART NAME No. 2 3 4 5 6 1 R OOF P ANEL[...]

BODY CONSTRUCTION B C-27 < Cross-Sectional Views > BFDBC6168 [ ROOF ] [ SUN ROOF ] C C E E A A B B Y Z[...]

BC-28 BODY CONSTRUCTION BFDBC6173 BFDBC6174 BFDBC6174A BFDBC6172 BFDBC6171 BFDBC6170 BFDBC6169 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 r[...]

BODY CONSTRUCTION B C-29 < Cross-Sectional Views > BFDBC6197 C C A A B B HOOD[...]

BC-30 BODY CONSTRUCTION BFDBC6200 BFDBC6199 BFDBC6198 A - A B - B C - C Radiator grille Hood panle assembly Hood panle assembly Fender panel assemb ly Hood panle assembly Head lamp Hood latch assembly + _ 5 0.5 mm + _ 3 0.5 m m + _ 5 0.5 mm[...]

BODY CONSTRUCTION B C-31 BFDBC6177 BFDBC6175 BFDBC6178 BFDBC6178 BFDBC6176 B - B D - D A - A C - C < Cross-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 F ront door panel assembly Fender panel F ront door panel assembly F ront door panel assembly F ront door panel assembly[...]

BC-32 BODY CONSTRUCTION BFDBC6185 BFDBC6187 BFDBC6186 BFDBC6183 BFDBC6182 BFDBC6184 BFDBC6181 BFDBC6180 E - E F - F H - H L - L N - N G - G K - K M - M + _ 3.8 0.5 m m + _ 4.5 0.5 mm + _ 4.5 0.5 m m + _ 3.8 0.5 mm + _ 3.8 0.5 mm + _ 3.8 0.5 m m + _ 3.8 0.5 m m + _ 4.5 0.5 mm Fender panel Rear door panel assembly Rear door panel assembly Side outer [...]

BODY CONSTRUCTION B C-33 < Cross-Sectional Views > BFDBC6190 D D B B A A E E C C T AIL GA TE[...]

BC-34 BODY CONSTRUCTION BFDBC6185 BFDBC6182 BFDBC6184 BFDBC6181 BFDBC6180 A - A B - B D - D C - C E - E + _ 5 0.5 mm 4 mm 2 mm 3.5 mm 5 mm + _ 4 0 .5 m m 0.5 mm T ail gate outer panel T ail gate inner panel Headlining High mounted stop lamp Rear glass assemby T ail gate panel assembly[...]

Bod y Dimensions BD GENERAL ......................................................... BD - 2 MEASUREMENT METHOD ....................... BD - 2 PROJECTED DIMENSIONS ............................ BD - 2 ACTUAL-MEASUREMENT DIMENSIONS ...... BD - 2 MEASUREMENT POINT .................................. BD - 2 FRONT BOD Y ..................................[...]

BD-2 BODY DIMENSIONS A CTU AL-MEASUREMENT DIMENSIONS 1. These dimensions indicate the actual linear distance between measurement points, and are the reference dimensions for use if a tracking gauge is used for measurement. 2. Measure by first adjusting both probes to the same length (A=A') CAUTION Check the probes and gauge itself to make sure[...]

BODY DIMENSIONS BD-3 FRONT BOD Y * These dimensions indicated in this figure are actual-measurement dimensions . P oint symbol Length(mm) P oint symbol Length(mm) P oint 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&apos[...]

BD-4 BODY DIMENSIONS F ront end module mounting hole (ø9) Cowl top co ver mounting hole (ø7) F ront end module mounting hole (ø9) Hood hinge mounting hole (ø9) F ront pillar corner T ooling hole (ø9) F ront suspension mounting hole (ø11) Roof front cor ner T ransmission mounting brac k et (ø11) T ransmission mounting brac k et (ø11) Engine [...]

BODY DIMENSIONS BD-5 SIDE BOD Y BFDBD6201 * These dimensions indicated in this figure are actual-measurement dimensions . P oint symbol Length(mm) P oint symbol Length(mm) P oint symbol Length(mm) P oint 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[...]

BD-6 BODY DIMENSIONS T ooling hole (ø10) F ront door hinge upper mounting hole (ø9) Rear door hinge upper mounting hole (ø13) T ooling hole (ø20) F ront door hinge lo wer mounting hole (ø9) Rear door hinge low er mounting hole (ø13) T ooling hole (ø7) F ender mounting hole (ø6) Quar ter fix ed glass mounting hole (ø11) Rear door s witch mo[...]

BODY DIMENSIONS BD-7 INTERIOR A * These dimensions indicated in this figure are actual-measurement dimensions . P oint symbol Length(mm) P oint symbol Length(mm) P oint symbol Length(mm) P oint symbol Length(mm) P oint 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[...]

BD-8 BODY DIMENSIONS T rim mounting passage hole (ø10) Cowl side trim mounting hole (ø6.6) Rear door check er mounting hole (ø13) Cowl cross bar mounting hole (ø9) Seat belt height adjust upper mounting hole (ø12) F ront seat belt retractor mounting hole (ø12) F ront door chec ker mounting hole (ø9) Seat belt height adjust low er mounting ho[...]

BODY DIMENSIONS BD-9 Pillar trim mounting hole (ø8.5) T ooling and drain hole (ø10) Roof rear cor ner Side trim mounting hole (ø6.6) Fuel pump wire mounting hole (ø7) Luggage side trim mounting hole (ø8) Roof front cor ner BFDBD6130 M,M' BFDBD6128 O ,O' N,N' BFDBD6129 BFDBD6129A P P' Q BFDBD6131 R,R' BFDBD6132 S,S&apos[...]

BD-10 BODY DIMENSIONS INTERIOR B * These dimensions indicated in this figure are actual-measurement dimensions . P oint 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'[...]

BODY DIMENSIONS BD-11 T rim mounting passage hole (ø10) F ront seat belt retractor mounting hole (ø12) Pillar trim 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' BFD[...]

BD-12 BODY DIMENSIONS REAR BOD Y * These dimensions indicated in this figure are actual-measurement dimensions . P oint symbol Length(mm) P oint 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 BFDBD6[...]

BODY DIMENSIONS BD-13 T ail gate hinge mounting hole (ø12) Side outer rear cor ner T ail gate str ik er mounting hole (ø11) Roof rear cor ner 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 B[...]

BD-14 BODY DIMENSIONS UNDER BOD Y (PROJECTED DIMENSIONS) * These dimensions indicated in this figure are projected dimensions . P oint symbol Length(mm) P oint symbol Length(mm) P oint 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'[...]

BODY DIMENSIONS BD-15 T ooling hole (ø25) Subframe mounting bolt T ooling and paint drain hole (ø20) Subframe mounting pipe (ø25) Subframe mounting bolt Rear suspension mounting hole (ø21) T ooling hole (ø25) T ooling hole (ø11) Cross member mounting hole (ø19) Spring mounting hole (ø20) T ooling hole ( ø 25) BFDBD6136 BFDBD6136A BEDBD6503[...]

BD-16 BODY DIMENSIONS UNDER BOD Y (A CTU AL-MEASUREMENT DIMENSIONS) * These dimensions indicated in this figure are actual-measurement dimensions . P oint symbol Length(mm) P oint 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 [...]

BODY DIMENSIONS BD-17 T ooling hole (ø25) T ooling and paint drain hole (ø20) T ooling hole (ø25) T ooling hole (ø25) Rear suspension mounting hole (ø21) T ooling 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&[...]

Bod y P anel Repair Pr ocedure BP B A CK COMPLETE P ANEL AND REAR FLOOR SIDE MEMBER .............................. BP - 55 REMO V AL ........................................................ BP - 56 INST ALLA TION ................................................. BP - 58 FRONT AND REAR DOOR OUTER P ANELS .............................................[...]

BP-2 BO D Y PANEL REP AIR PR OCEDURE REPLA CING BOD Y P ANELS CODES FOR REMO VING AND INST ALLING BOD Y P ANELS BVQBP6001A Location f or cut and assembly Rough cutting location 20~30 mm (0.8~1.2 in.) 20~30 mm (0.8~1.2 in.)[...]

BOD Y PANEL REP AIR PROCEDURE BP-3 NO TES WHEN WELDING BOD Y REMO VING SPO T WELDED AREA Most body par ts are spot welded. In order to remov e the damaged area, it is best to remo ve the spot w elded 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 we[...]

BP-4 BO D Y PANEL REP AIR PR OCEDURE BVQBP6003 Center punch the middle(nugget) of the spot weld. Otherwise, Spot welded area can be remov ed from the body frame . Spot welded area cannot be remov ed from the body frame. This par t will not be cut. This par t will be cut.[...]

BOD Y PANEL REP AIR PROCEDURE BP-5 SPO T WELDING 1. Commercial spot welding machines do not perform as well as the machines used in the manufacturing process. When spot w elding, increase the number of spot welds by 30% (1.3 times the original number of welds). 2. When spot welding, weld in the middle of the joint. • Spot welding on the edge of t[...]

BP-6 BO D Y PANEL REP AIR PR OCEDURE CARBON ARC WELDING In areas where spot welding is not suitable, do plug welding using a carbon are welding machine. 1. Clamp the par ts to be welded together tightly . Do not e xceed 1 mm of space between par ts . A tolerance greater than 1 mm will reduce the strength of the welded area. 2. Weld in the middle of[...]

BOD Y PANEL REP AIR PROCEDURE BP-7 REPLA CING BOD Y P ANEL REMO V AL 1. Body measurement a ) Before removing, measure the damaged area according to the dimensions supplied in Body Dimension, section BD . If def ormation is present, use a frame straightener to adjust. b ) When removing a panel, apply clamps to prevent damage of each par t, and suppo[...]

BP-8 BO D Y PANEL REP AIR PR OCEDURE 5 . Determine a cutting method a ) Cutting a spot welded area Make a 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 are[...]

BOD Y PANEL REP AIR PROCEDURE BP-9 4 . Preparation for spot welding Remove paint on spot welded area and on the area o verlapped by the new part using a belt sander or similar tool. 5 . Drilling a hole for plug welding If the thickness of the part to be welded is less than 3 mm, drill a 5~6 mm diameter hole. If the thickness of the par t to be weld[...]

BP-10 BOD Y PANEL REP AIR PR OCEDURE INST ALLA TION 1 . Checking welding and fitting in advance a ) When installing a ne w par t, measure the dimensions of each par t according to the body dimensions given in Section BD , and set par t to the reference dimensions. b ) Prior to final welding, check the fit of all related parts. 2. Selecting number o[...]

BOD Y PANEL REP AIR PR OCEDURE BP-11 c) The tip of the spot welding machine should be maintained to a minimum tolerance of 3 mm. Also let area cool after 5 or 6 welds to minimize problems caused by excessive heat. 4 . Cutting and welding an removed area T o align a roof panel and a center pillar together for butt welding, temporarily fasten a steel[...]

BP-12 BOD Y PANEL REP AIR PR OCEDURE FENDER APR ON P ANEL WELDING POINTS MIG plug welding MIG butt welding MIG lap welding MIG plug welding MIG butt welding MIG lap welding BFDBP6102 BFDBP6104 290mm[...]

BOD Y PANEL REP AIR PR OCEDURE BP-13 REMO V AL Before repairing, remove Engine and Suspension Components. Refer to the body dimension charts and measure the vehicle to determine straightening and alignment requirements. The body must be returned to its original dimension before begining the repair procedure. 1 . Drill out all the spotwelds to separ[...]

BP-14 BOD Y PANEL REP AIR PR OCEDURE 4 . Remove the fender apron upper outer panel. 5 . Measure and mark the cutline on the fender apron upper inner panel 290mm 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[...]

BOD Y PANEL REP AIR PR OCEDURE BP-15 INST ALLA TION 1 . T ranscribe the fender apron upper inner panel cutline to the new fender apron upper inner panel, cut to length and chamfer butt 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 BOD Y DIMENSIONS) and cor[...]

BP-16 BOD Y PANEL REP AIR PR OCEDURE 7 . Drill 8mm holes in the new fender apron upper outer panel for MIG plug welding. 8 . Fit and clamp the fender apron upper outer panel in place. 9 . Measure each measurement point (Ref er to the BOD Y DIMENSIONS) and correct the installation position. 1 0 . MIG plug weld all holes. 1 1 . Clean and prepare all [...]

BOD Y PANEL REP AIR PR OCEDURE BP-17 1 3 . Fit and clamp the fender apron inner panel assembly in place. 1 4 . MIG plug weld all holes. 1 5 . Clean and prepare all welds, and remove all residue. BFDBP6102A 1 6 . Apply the two par t epoxy primer to the interior of the each panel. 1 7 . Apply an anti-corrosion agent as required. (Refer to the BOD Y C[...]

BP-18 BOD Y PANEL REP AIR PR OCEDURE 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[...]

BOD Y PANEL REP AIR PR OCEDURE BP-19 This procedure is to be used only for repair of minor damage to the front side member and when it is impossible to straighten the damaged front side member . The following procedure illustrates a repair for the front left side member . The procedure may also be applied to the front right side member. NOT E BEDBP[...]

BP-20 BOD Y PANEL REP AIR PR OCEDURE 4 . Cut the front side member inner and outer panel along the cutlines. 5 . Remov e the front side member . 6 . Prepare all surfaces to be welded. BEDBP6202A 7 . After removing, apply the welding primer . INST ALLA TION 1 . T ranscribe the front side member inner and outer cutlines to the new front side member ,[...]

BOD Y PANEL REP AIR PR OCEDURE BP-21 4 . MIG plug weld all holes and MIG butt weld seams. 5 . Clean and prepare all welds, and remove all residue. 6 . Apply the two par t epoxy primer to the inter ior of the each panel. 7 . Apply an anti-corrosion agent as required. (Refer to the BOD Y CORROSION PRO TECTION) 8 . Prepare the exterior surfaces for pr[...]

BP-22 BOD Y PANEL REP AIR PR OCEDURE FRONT PILLAR 120mm BFDBP6307 WELDING POINTS A B A B 150mm B 100mm 90mm Laser welding MIG plug welding MIG butt welding MIG lap welding[...]

BOD Y PANEL REP AIR PR OCEDURE BP-23 REMO V AL 1 . T o remove the front pillar , dr ill out and g rind aw ay all spotwelds and plug welds attaching the cowl side upper outer panel. If the cowl side upper outer panel is reusable, be careful not to damage it while removing. 2 . Remove the cowl side upper outer panel. 3 . B efore cutting the front pil[...]

BP-24 BOD Y PANEL REP AIR PR OCEDURE 6 . Drill out all the spotwelds and laser welds attaching the front pillar outer panel section. 7 . Remove the front pillar outer 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 cutt[...]

BOD Y PANEL REP AIR PR OCEDURE BP-25 1 0 . Drill out all the spotwelds attaching the front side sill outer panel section. 1 1 . Remove the front side sill outer panel section. 1 2 . Measure and mark the cutline on side sill outer reinforcement as indicated in the illustration. 1 3 . Cut the side sill outer reinforcement along the cutline. When cutt[...]

BP-26 BOD Y PANEL REP AIR PR OCEDURE 1 6 . T o remov e the front pillar inner panel, drill out and g rind away all spotwelds and lap welds. BEDBP6313 BEDBP6313A BEDBP6314 1 5 . Remove the front pillar outer panel. BFDBP6304 BFDBP6311 BFDBP6312B[...]

BOD Y PANEL REP AIR PR OCEDURE BP-27 1 7 . Remove the front pillar inner panel. 1 8 . Clean cut por tions with a disc gr inder . 19. After remo ving, apply the welding primer . BEDBP6316 BEDBP6318 BEDBP6316A BEDBP6316B INST ALLA TION 1 . Drill 8mm holes in the front pillar inner panel for MIG plug welding. BEDBP6319[...]

BP-28 BOD Y PANEL REP AIR PR OCEDURE 5. Clean and prepare all welds, and remove all residue. 6 . After removing, apply the welding primer . 7 . T ranscribe the cutlines to the ne w front pillar outer panel, adding 30mm overlap to each end and cut to length. 8 . Drill 8mm holes along front pillar outer panel flanges for attachment to other panels. 4[...]

BOD Y PANEL REP AIR PR OCEDURE BP-29 9 . Install the front pillar outer panel in place. 1 0 . Measure each measurement point (Refer to the BOD Y DIMENSIONS) and correct the installation position. 1 1 . MIG plug weld all holes. 1 2 . Clean and prepare all welds, and remove all residue. BEDBP6309A BEDBP6309B BEDBP6309C 1 3 . After removing, apply the[...]

BP-30 BOD Y PANEL REP AIR PR OCEDURE 2 2 . Apply an anti-corrosion agent to the welded par ts and inside of front pillar (Refer to the CORROSION PRO TECTION). 2 3 . Prepare exterior surfaces for priming, using wax and grease remov er . 2 4 . Apply metal conditioner and water rinse. 2 5 . Apply conversion coating and water rinse. 2 6 . Apply the two[...]

BOD Y PANEL REP AIR PR OCEDURE BP-31 SIDE SILL P ANEL REMO V AL 1 . Measure and mark the horizontal cutline on front pillar outer panel 50mm from the door hinge mounting hole as indicated in the illustration. BEDBP6401 WELDING POINTS MIG plug welding MIG butt welding MIG lap welding 70mm 50mm 50mm BEDBP6401A 50mm 2 . Measure and mark the horizontal[...]

BP-32 BOD Y PANEL REP AIR PR OCEDURE 7 . Clean cut por tions with a disc grinder . 8 . After removing, apply the 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 si[...]

BOD Y PANEL REP AIR PR OCEDURE BP-33 6 . Clean and prepare all welds and remove all residue. 7 . Apply body filler to the side sill outer seams. 8 . Apply the two-par t epo xy primer to the inter ior of the side sill. 9 . Apply an anti-corrosion agent to welded par ts and interior of the side sill (Refer to the CORROSION PR O TECTION). 1 0 . Prepar[...]

BP-34 BO D Y PANEL REP AIR 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[...]

BOD Y PANEL REP AIR PR OCEDURE BP-35 REMO V AL 1 . Bef ore cutting center pillar , be sure to suppor t roof panel. 2 . Measure and mark the horizontal cutlines on center pillar 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 mati[...]

BP-36 BOD Y PANEL REP AIR PROCEDURE 5 . Remove the center pillar outer panel. 6 . Measure and mark the horizontal cutlines on center pillar outer reinforcement as indicated 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 flange[...]

BOD Y PANEL REP AIR PR OCEDURE BP-37 9 . Remove the center pillar outer reinforcement section. 1 0 . Measure and mark the horizontal cutline on rear door hinge mounting upper reinforcement as indicated in the illustration. 1 1 . Cut the rear door hinge mounting upper reinforcement along the cutline. When cutting rear door hinge mounting upper reinf[...]

BP-38 BOD Y PANEL REP AIR PROCEDURE 1 3 . 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 side sill outer reinforcement. 1 4 . Drill out all spotwelds attaching the front side sill outer panel section. 1 5 . Remove the front side sill outer panel se[...]

BOD Y PANEL REP AIR PR OCEDURE BP-39 1 9 . Remove the front side sill outer reinforcement section. 2 0 . Measure and mar k the v ertical cutline on side sill inner reinforcement as indicated in the illustration. 2 1 . Cut the front side sill inner reinforcement along the cutline. 1 7 . Cut the front side sill outer reinforcement cutlines. When cutt[...]

BP-40 BOD Y PANEL REP AIR PROCEDURE 2 2 . Measure and mar k the v er tical cutlines on rear side sill outer panel 55mm and 155mm from the rear door step trim mounting hole. 2 3 . Cut the rear side sill outer panel along the cutlines. When cutting rear side sill outer panel, take care not to cut through mating flanges or side sill outer reinforcemen[...]

BOD Y PANEL REP AIR PR OCEDURE BP-41 27. Cut the rear side sill outer reinforcement along the cutline. When cutting rear side sill outer reinforcement, take care not to cut through mating flanges. 2 8 . Drill out all spotwelds attaching the center pillar outer panel. BFDBP6509B BFDBP6510 BFDBP6509C NOT E 2 9 . Remove the center pillar outer panel. [...]

BP-42 BOD Y PANEL REP AIR PROCEDURE 3 1 . Remove the center pillar inner panel. 3 2 . Prepare all surfaces to be welded. 3 3 . After removing, apply the welding primer . BEDBP6514 BEDBP6514A BEDBP6514B INST ALLA TION 1 . Fit and clamp the new center pillar inner panel in place for welding. 2 . Measure each measurement point (Ref er to the BOD Y DIM[...]

BOD Y PANEL REP AIR PR OCEDURE BP-43 3 . MIG plug weld all holes and MIG lap weld seams. 4 . Clean and prepare all welds, and remove all residue. 5 . After removing, apply the w elding pr imer . 6 . T ranscribe the cutlines to the new side outer panel, adding 30mm overlap to each end and cut to length. 7 . Drill 8mm holes in overlap areas and along[...]

BP-44 BOD Y PANEL REP AIR PROCEDURE 1 6 . Reattach the cut away center pillar outer panel section, then MIG plug weld all holes and MIG butt weld seams. 1 7 . Clean all welds with a disc grinder . 1 3 . MIG plug weld all holes and MIG butt weld seams. 1 4 . Clean and prepare all welds, and remove all residue. 1 5 . After removing, apply the welding[...]

BOD Y PANEL REP AIR PR OCEDURE BP-45 1 8 . Apply the two-par t epo xy primer to the interior of the center pillar . 1 9 . Apply an anti-corrosion agent to the welded par ts and interior of the center pillar (Refer to the CORROSION PRO TECTION). 2 0 . Prepare exterior surfaces for priming, using wax and grease remov er . 2 1 . Apply metal conditione[...]

BP-46 BOD Y PANEL REP AIR PROCEDURE QU ARTER P ANEL BFDBP6601 WELDING POINTS 50mm 50mm 50mm Laser welding MIG plug welding MIG butt welding MIG lap welding[...]

BOD Y PANEL REP AIR PR OCEDURE BP-47 REMO V AL 1 . Depending on the extent of damage, measure and mark cutlines on the quar ter outer panel as indicated in the illustration. 2 . Cut the quar ter outer panel along the cutlines and remov e the quarter outer panel as illustration. When cutting the quarter outer panel, be careful not to cut quarter inn[...]

BP-48 BOD Y PANEL REP AIR PROCEDURE 6. After removing, apply the welding primer . 7. Prepare all surfaces to be welded. INST ALLA TION 1 . T ranscribe the cutlines to the new quar ter outer panel, adding 30 mm overlap each end. 2 . Drill 8 mm holes in overlap areas and along upper and low er flanges of the ne w quar ter outer panel for MIG plug wel[...]

BOD Y PANEL REP AIR PR OCEDURE BP-49 7 . Clean and prepare all welds, remove all residue. 8 . Apply an anti-corrosion agent to the welded par ts and interior of the quar ter outer panel (Ref er to the CORROSION PR O TECTION). 9 . Prepare exterior surfaces for priming, using wax and grease remov er . 1 0 . Apply metal conditioner and water rinse. 11[...]

BP-50 BOD Y PANEL REP AIR PROCEDURE 1 3 . Apply the correct seam sealers to all joints. 1 4 . Reprime ov er the seam sealer to complete the repair . 1 5 . In order to improv e corrosion resistance, if necessary , apply an under body anti-corrosion agent to the wheel well (Ref er to the CORR OSION PR O TECTION). BFDBP6604A BFDBP6601F[...]

BOD Y PANEL REP AIR PR OCEDURE BP-51 LO WER QU AR TER P ANEL BFDBP6601G WELDING POINTS 270mm 50mm Laser welding MIG plug welding MIG butt welding MIG lap welding[...]

BP-52 BOD Y PANEL REP AIR PROCEDURE REMO V AL 1 . Depending on the extent of damage, measure and mark cutlines on the quar ter outer panel as indicated in the illustration. 2 . Cut the quarter outer panel along the cutlines and remov e the quar ter outer panel as illustr ation. When cutting the quarter outer panel, be careful not to cut quarter inn[...]

BOD Y PANEL REP AIR PR OCEDURE BP-53 6. After removing, apply the we lding primer . INST ALLA TION 1 . T ranscribe the cutlines to the new quar ter outer panel, adding 30 mm overlap each end. 2 . Drill 8 mm holes in overlap areas and along upper and low er flanges of the ne w quar ter outer panel for MIG plug welding. BFDBP6720B 3 . Apply body fill[...]

BP-54 BOD Y PANEL REP AIR PROCEDURE 7 . Clean and prepare all welds, remove all residue. 8 . Apply an anti-corrosion agent to the welded par ts and interior of the quar ter outer panel (Refer to the CORROSION PR O TECTION). 9 . Prepare exterior surfaces for priming, using wax and grease remov er . 1 0 . Apply metal conditioner and water rinse. 11 .[...]

BOD Y PANEL REP AIR PR OCEDURE BP-55 B A CK COMPLETE P ANEL AND REAR FLOOR SIDE MEMBER BFDBP6705 WELDING POINTS 130mm MIG plug welding MIG butt welding MIG lap welding[...]

BP-56 BOD Y PANEL REP AIR PROCEDURE REMO V AL Because the rear floor side members are designed to absorb energy during a rear collision, care must be used when deciding to use this repair method. This repair is recommended only for moderate damage to the vehicle, where distortions do not extend forward of the luggage compartment region. If the dama[...]

BOD Y PANEL REP AIR PR OCEDURE BP-57 4 . Remov e the back complete panel assemb ly . 5 . Depending on the extent of damage, measure and mark cutline on the rear 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 [...]

BP-58 BOD Y PANEL REP AIR PROCEDURE 1 0 . After removing, apply the welding primer . 1 1 . Prepare all surfaces to be welded. INST ALLA TION 1 . T ranscribe the cutline to the new rear floor side member , adding 30 mm 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 floo[...]

BOD Y PANEL REP AIR PR OCEDURE BP-59 7 . After removing, apply the welding primer . 8 . Fit and clamp the new back complete panel assembly in place. 9 . Measure each measurement point (Ref er to the BOD Y DIMENSIONS) and correct the installation position. BFDBP6706C BFDBP6709 BFDBP6702B 10 . MIG plug weld all holes. 1 1 . Clean and prepare all weld[...]

BP-60 BOD Y PANEL REP AIR PROCEDURE 1 6 . Clean and prepare all welds, remove all residue. 1 7 . Apply the two-par t epo xy primer to the interior of the rear floor side member . 1 8 . Apply an anti-corrosion to the interior of the rear floor side member . (Ref er to the CORROSION PR O TECTION) 1 9 . Prepare exterior surfaces for priming, using wax[...]

BOD Y PANEL REP AIR PR OCEDURE BP-61 2 3 . Apply the correct seam sealer to all joints (Refer to the BOD Y SEALING LOCA TIONS). BFDBP6701E 2 4 Reprime over the seam sealer to complete the repair 2 5 After completing body repairs, carefully apply Under coating to the Under body (Refer to the CORROSION PRO TECTION). 2 6 In order to improv e corrosion[...]

BP-62 BOD Y PANEL REP AIR PROCEDURE FR ONT AND REAR DOOR OUTER P ANELS 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[...]

BOD Y PANEL REP AIR PR OCEDURE BP-63 REMO V AL 1 . Cut door outer panel hem with a sander . 2 . After grinding off the hemming location, remove the outer panel. 3 . Dress rusty par t with a sander and prepare surf ace to be hemmed. INST ALLA TION 1 . Apply adhesive or equivalent to outer panel hem. 2 . Apply mastic sealer or equivalent to the door [...]

BP-64 BOD Y PANEL REP AIR PROCEDURE 3 . Bend the flange hem with a hammer and dolly , then fasten tightly with a hemming tool. Hemming work should be done in three steps as illustration. If a hemming tool cannot be used, hem with a hammer and dolly . NOT E 4. After completing the hemming work, make MIG spot welds at 50 mm intervals on the inside. 5[...]

BOD Y PANEL REP AIR PR OCEDURE BP-65 12 . Apply the correct seam sealer to whole panel edge. 13 . Reprime ov er the seam sealer to complete the repair . BFDBP6716[...]

Bod y Sealing Locations BS EXTERIOR ........................................................ BS - 2 INTERIOR ......................................................... BS - 5 UNDER BOD Y ................................................. BS - 8 HOOD .............................................................. BS - 9 DOOR ...........................[...]

BS -2 BOD Y SEALING LOCA TIONS EXTERIOR BFDBS6006 G K K A C B D E F J J H H I I N N L L M M[...]

BOD Y SEALING LOCA TIONS B S-3 BFDBS6205 BFDBS6402 BFDBS6203 BFDBS6201 BFDBS6202 BFDBS6204 A B C D E F (RH SIDE) F (LH SIDE) G BFDBS6206 BFDBS6101[...]

BS -4 BOD Y SEALING LOCA TIONS BFDBS6307 BEDBS6311 BEDBS6309 BEDBS6310 BFDBS6310 BFDBS6308 H - H I - I J - J L - L N - N M - M K - K BFDBS6305 F ront inner lower pillar Quar ter inner lo wer panel Side sill inner rear panel Outer inner lower panel Roof panel Side outer panel Side outer panel Wheel house inner front extension F ront side member oute[...]

BOD Y SEALING LOCA TIONS B S-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[...]

BS -6 BOD Y SEALING LOCA TIONS BEDBS6307 BEDBS6311 BEDBS6309 BEDBS6310 BEDBS6308 E F G H I J K BEDBS6305 BEDBS6304[...]

BOD Y SEALING LOCA TIONS B S-7 BFDBS6004 BFDBS6003 Cowl inner low er panel Dash panel Dash lower center reinf orcement Dash lower center reinf orcement 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[...]

BS -8 BOD Y SEALING LOCA TIONS UNDER BOD Y BFDBS6502 BFDBS6002 BFDBS6501 A B A B[...]

BOD Y SEALING LOCA TIONS B S-9 BEDBS6020 BFDBS6016 BEDBS6018 BEDBS6017 BEDBS6019 X Y 1.5 m m 5 mm + 2 - 1 A - A B - B Y X 1.5 mm 5 mm +2 -1 A A B B HOOD[...]

BS-10 BOD Y SEALING LOCA TIONS DOOR BFDBS6029 BFDBS6025 BFDBS6028 C C C C H2 G1 D2 A A B B F2 H1 F1 G2 E E D1 E E[...]

BOD Y SEALING LOCA TIONS BS-11 BEDBS6028 BEDBS6033 BEDBS6032 BEDBS6030 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 F ront door rear frame F ront door inner panel F ront door outer panel F ront door frame assembly F ront door frame assembly 1.5 m m 5 mm[...]

BS-12 BOD Y SEALING LOCA TIONS BEDBS6036 BEDBS6038 BEDBS6039 BEDBS6037 F2 BEDBS6035 BEDBS6034 G1 H1 F1 H2 F2 F ront door frame assembly F ront door frame assemb ly F ront door outer panel Rear door outer panel Rear door frame assembly F ront door inner panel F ront door outer panel Rear door frame assembly Rear door inner panel Rear door frame asse[...]

BOD Y SEALING LOCA TIONS BS-13 BEDBS6024 BFDBS6021 BEDBS6022 Z BEDBS6023 Z A - A B - B 2.5 mm 5mm A A B B T AIL GA TE[...]

Corr osion pr otection CP ZINC-PHOSPHA TE CO A T & CA TIONIC ELECTRODEPOSITION PRIMER ........... CP - 2 A TT A CHMENT OF ANTIVIBRA TION P ADS .............................................................. CP - 3 ANTIVIBRA TION P ADS-LOCA TION & SECTION ...................................................... CP - 4 UNDER BOD Y & SIDE BOD[...]

CP -2 CORROSION PR O TECTION ZINC-PHOSPHA TE CO A T & CA TIONIC ELECTR ODEPOSITION PRIMER In order 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 prim[...]

CORROSION PR O TECTION CP -3 1 . Heat the "antivibration pad" with a blow drier to soften it. 2 . Align the antivibration pad layer in the position where it is to be installed, and then press it down with a roller or a block of wood so that it adheres well. NOT E An infrared lamp can also be used to heat both the antivibration pad layer a[...]

CP -4 CORROSION PR O TECTION ANTIVIBRA TION P ADS-LOCA TION & SECTION F F H H BEDCP6202 [ 5 Door ] [W agon ] 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[...]

CORROSION PR O TECTION 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[...]

CP -6 CORROSION PR O TECTION BFDCP6210 BFDCP6211 BFDCP6209 BFDCP6208 F ront seat mounting member Spare tire mounting brack et 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[...]

CORROSION PR O TECTION CP -7 UNDER BOD Y & SIDE BOD Y CO A T In order to provide corrosion, stone 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 par t. BFDCP6002 C C B B E E A A D D F F X Y Under bod[...]

CP -8 CORROSION PR O TECTION BFDCP6105 BFDCP6103 BFDCP6107 BFDCP6106 BFDCP6104 B - B D - D A - A C - C G G [ W agon ] Fender apron upper inner panel Shock absorber housing lower panel F ront side inner member Side outer rear extension Side frame mounting rear suppor t Side frame mounting rear reinforcement Fender apron upper outer panel Shock absor[...]

CORROSION PR O TECTION CP -9 BFDCP6111 BFDCP6110 BFDCP6112 BFDCP6109 BFDCP6108 E - E Y F - F X G - G Rear floor rear panel Rear floor center cross member [ 5Door ] 20mm 50mm 50mm Rear suspension mounting brack et Wheel house inner panel Outer inner uper panel Side outer panel Rear floor rear panel Rear floor center cross member Back panel [ W agon [...]

CP-10 COR R OSION PR O TECTION SIDE BOD Y CA VITY W AX INJECTION In order to provide greater corrosion resistance, cavity wax injection has been performed for the lower areas of the vehicle, such as the side member , the side sill and the inside of other panels which ha v e a hollow construction. When replacing these par ts, be sure to apply ca vit[...]

CORROSION PR O TECTION CP-11 BFDCP6118 BFDCP6116 BFDCP6117 B - B C - C [ HOOD ] W ax injection hole W ax injection hole W ax injection hole W ax injection hole Hood hinge assembly Cowl side upper panel W ax injection hole 100mm 200mm 100mm 200mm 150mm 150mm B B C C 30mm HOOD[...]

CP-12 COR R OSION PR O TECTION T AIL GA TE BFDCP6121 BFDCP6119 BFDCP6120 D - D E - E 150mm 30mm 30mm 5mm 5m m E E E E D D[...]

CORROSION PR O TECTION CP-13 FRONT DOOR & REAR DOOR BFDCP6122 BFDCP6123 F - F 130mm 30mm 30mm F F F F 130mm W ax injection hole W ax injection hole W ax injection hole[...]

CP-14 COR R OSION PR O TECTION UNDER BOD Y ANTI-CORROSION A GENT The undersides of the floor and wheel house are undercoated to provide greater corrosion resistance . Theref ore, when such panel is replaced or repaired, apply under body anti-corrosion agent to that par t. NOT E Do not apply the under body anti-corrosion agent to come in contact wit[...]

Bod y Modification T ools BT MODIFICA TION T OOLS .............................. BT - 2 CUT AND DISASSEMBL Y T OOLS ......... BT - 3 ASSEMBL Y T OOLS ....................................... BT - 4 MEASUREMENT T OOLS ............................ BT - 4 WELDING MA CHINE .................................... BT - 5 BUFFING AND GRINDING T OOLS ........ [...]

BT-2 BO D Y MODIFICA TION TOOLS Frame straightener Port power Body puller Modify twisted or bent body Push out, stretch, pull in damaged area Stretch damaged area BOD Y MODIFICA TION T OOLS MODIFICA TION T OOLS A3EB3501 A3EB3502 A3EB3503 A3EB3504 A3EB3505 N am e Used for Figure[...]

BOD Y MODIFICA TION TOOLS BT-3 Air saw Air chisel Rotary cutter Air drill Spot cutter Cut a panel Cut a panel Cut a panel Cut and disassemble spot welded area CUT AND DISASSEMBL Y T OOLS N am e 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 [...]

BT-4 BO D Y MODIFICA TION TOOLS ASSEMBL Y T OOLS 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 N am e Used for Figure Finish contact area of flange and finish a hole for plug welding MEASUREMENT T OOLS Centering gauge T racking gauge Measure distor tion of bo[...]

BOD Y MODIFICA TION TOOLS BT-5 Gas welding machine Spot welding machine Stud welding machine Cut a panel Weld a panel Weld a panel A3EB3518 A3EB3519 A3EB3520 A3EB3521 N am e Used for Figure WELDING MA CHINE Carbon arc welding machine Stretch a panel, weld a stud bolt to fix front window mold clip[...]

BT-6 BO D Y MODIFICA TION TOOLS Disk grinder Disk sander Belt sander Small sized grinder Double action sander Orbital sander(short) Buff Buff Buff paints Buff paints or smooth finishing BUFFING AND GRINDING T OOLS N am e Used for Figure Grind rough area of puttee assembled area A3EB3522 A3EB3523 A3EB3524 A3EB3525 A3EB3526 A3EB3527 Grind rough area [...]

BOD Y MODIFICA TION TOOLS BT-7 Orbital sander(long) Flexible file Surform tool Hand file Used for puttee grinding of wide area Buff rough area of puttee area Gr ind body puttee , pulley , finish puttee N am e Used for Figure A3EB3528 A3EB3529 A3EB3506 A3EB3530 A3EB3531 Grind touch up area, uneven area of a panel[...]

BT-8 BO D Y MODIFICA TION TOOLS Body hammer and dolly Center punch Plane chisel Weight hammer Bowl pin hammer Spoon - Cut and disassemble a panel Used when greater force is required Used when smaller force is required HANDHELD T OOLS N am e Used for Figure Punch a hole in the middle of a spot welding area A3EB3532 A3EB3533 A3EB3534 A3EB3535 A3EB353[...]

BOD Y MODIFICA TION TOOLS BT-9 Body chisel Wire brush N am e Used for Figure A3EB3538 A3EB3539 Remove paints, rust, slag on welded area which are hard to recognize Window tool set Repair window collar Repair plastic parts N am e Used for Figure A3EB3540 A3EB3541 Bend rough body line damaged or sheet metal etc. REP AIR T OOLS SET Repair tool set for[...]

Plastic P ar ts PP POL YPR OPYLENE(PP) BUMPER REP AIRABILITY ............................................. PP - 2 BUMPER REP AIR PROCEDURE ................... PP - 3 REP AIR METHOD FOR PP BUMPER ............. PP - 4[...]

PP-2 PLASTIC PARTS POL YPROPYLENE(PP) BUMPER REP AIRABILITY The three types of damaged bumpers shown below can be repaired. Because of cost and quality 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 [...]

PLASTIC PARTS PP-3 BUMPER REP AIR PROCEDURE Remov e paint. Sand damaged area smooth. Apply aluminum tape on the rear side of bumper . W eld damaged area. Sand damaged area with a rough sandpaper . Clean and degrease damaged area(use TCE de-oil mater ial). Apply primer for polyprop ylene o ver damaged area. Apply solvent o v er damaged area. Spra y [...]

PP-4 PLASTIC PARTS REP AIR METHOD FOR PP BUMPER Damage to the bumper that reaches the surface of the polyporpylene cannot be fixed just by painting. Use the repair methods shown below to repair damage that reaches the surface of the polypropylene. 1. Rough cut the damaged area 45 using a knife and then sand the angle smooth. Hole Section A-A' [...]

PLASTIC PARTS PP-5 2. Welding damaged area a ) T o repair crack ed area, melt the area using a heat gun and attachment. b ) T o repair a hole , remov e oil from the damaged area and apply aluminum tape to the rear side of the damaged area. 3. Melt polypropylene welding rod using a heat gun and fill in the cracked area. NOT E • Heat and melt the a[...]

PP-6 PLASTIC PARTS 4. Grind polypropylene surf ace carefully . It melts easily due to the heat gener ated by friction. If melted, remove that area. Also , grind the area where solvent is to be applied. 5. Apply polypropylene primer evenly with a brush over an area wider than the area to be repaired. Dry it at 20 C (68 F) for more than 10 minutes. 6[...]

PLASTIC PARTS PP-7 7. Sand the damaged area with sandpaper using #180~#240 grit paper . NOT E • 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. Degrease the painted surface. 9. Mix polypropylene primer and hardener at a rati[...]