body panel replacement

7/23/2019 Body Panel Replacement

1/70

RE

RE-1

BODY PANELREPLACEMENT

PageRADIATOR UPPER SUPPORT (ASSY) RE-2. . . . . . . . . . . . . . . . . .

RADIATOR SIDE SUPPORT (ASSY) RE-4. . . . . . . . . . . . . . . . . . . .

RADIATOR SUPPORT UPPER BRACE (ASSY) RE-6. . . . . . . . . . .

FRONT CROSSMEMBER (ASSY) RE-8. . . . . . . . . . . . . . . . . . . . . .

RADIATOR SUPPORT (ASSY) RE-10. . . . . . . . . . . . . . . . . . . . . . . . .

FRONT FENDER FRONT APRON (ASSY) RE-12. . . . . . . . . . . . . . .

FRONT APRON TO COWL SIDE UPPER

MEMBER (ASSY) RE-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT FENDER APRON (ASSY) RE-16. . . . . . . . . . . . . . . . . . . . . .

FRONT PANEL UPPER RENFORCEMENTBRACE (ASSY) RE-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT SIDE MEMBER (CUT-P) RE-20. . . . . . . . . . . . . . . . . . . . . . . .

FRONT SIDE MEMBER (ASSY) RE-22. . . . . . . . . . . . . . . . . . . . . . . .

FRONT BODY PILLAR (CUT) RE-24. . . . . . . . . . . . . . . . . . . . . . . . . .

CENTER BODY PILLAR (CUT) RE-29. . . . . . . . . . . . . . . . . . . . . . . . .

FRONT DOOR OUTER PANEL (ASSY) RE-32. . . . . . . . . . . . . . . . . .

REAR DOOR OUTER PANEL (ASSY) RE-34. . . . . . . . . . . . . . . . . . .

ROCKER OUTER PANEL (ASSY) RE-36. . . . . . . . . . . . . . . . . . . . . . .

QUARTER PANEL (CUT) RE-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

QUARTER PANEL (CUT-P) RE-42. . . . . . . . . . . . . . . . . . . . . . . . . . . .

QUARTER WHEEL HOUSING OUTER PANEL (ASSY):

Right Side RE-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Left Side RE-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BODY LOWER BACK PANEL (ASSY) RE-48. . . . . . . . . . . . . . . . . . .

BACK DOOR OPENING TROUGH, REAR

BODY REAR SIDE CORNER PANEL (ASSY) RE-50. . . . . . . . . .

ROOF SIDE INNER REAR PANEL (ASSY) RE-52. . . . . . . . . . . . . . .

ROOF SIDE INNER LOWEL PANEL, ROOF SIDE

INNER FRONT PANEL (ASSY) RE-54. . . . . . . . . . . . . . . . . . . . . .

REAR FLOOR CENTER CROSSMEMBER (ASSY) RE-56. . . . . . . .

REAR FLOOR PAN (ASSY) RE-58. . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR FLOOR SIDE PANEL (ASSY) RE-60. . . . . . . . . . . . . . . . . . . . .

REAR FLOOR SIDE REAR MEMBER (ASSY) RE-62. . . . . . . . . . . .

REAR FLOOR NO.2 CROSSMEMBER (ASSY) RE-64. . . . . . . . . . .

ROOF PANEL (ASSY) RE-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


2/70

RADIATOR UPPER SUPPORT (ASSY)

REMOVAL

5

2

1

1

BODY PANEL REPLACEMENTRE-2


3/70

1. Temporarily install the new parts and mea-sure each part in accordance with the body di-mension diagram.

HINT: First install the hood lock support.

5

2 1

1

BODY PANEL REPLACEMENT RE-3

INSTALLATION


4/70

RADIATOR SIDE SUPPORT (ASSY)

REMOVAL (With the radiator upper support removed.)

1. Replace the radiator side support, radiatorside lower support and radiator support tofront fender bracket at the same time.

Radiator Side Support

RH:LH:

6 5

Radiator Support toFront Fender Bracket

Radiator SideLower Support

2

2

4



5/70


HINT: First install the radiator upper support.

RH:LH:

8

7 3

2

3

6

4

3[RH Side]

Radiator Support toFront Fender Bracket

[LH Side]

Radiator Supportto Front FenderBracket


INSTALLATION


6/70

RADIATOR SUPPORT UPPER BRACE (ASSY)

REMOVAL (With the radiator upper support removed.)

2

4



7/70


HINT: First install the radiator upper support.

3

4


INSTALLATION


8/70

FRONT CROSSMEMBER (ASSY)

REMOVAL

1

2

1

3

3

2

4

2

2



9/70


HINT: First install the hood lock support.

1

2

1

3

3

4

2

2

2


INSTALLATION


10/70

RADIATOR SUPPORT (ASSY)

REMOVAL

5

5

3

4

2

2

RH:LH:

10

9

3



11/70


5

5 3

3

4

2

2

RH:LH:

13

12


INSTALLATION


12/70

FRONT FENDER FRONT APRON (ASSY)

REMOVAL (With the radiator side support removed.)

7

7 6

4 1



13/70


10

7 6

4 1


INSTALLATION


14/70

FRONT APRON TO COWL SIDE UPPERMEMBER (ASSY)

REMOVAL (With the front fender front apron, front panelupper reinforcement brace removed.)

3

3 3

1

1

10

5



15/70


2. Temporarily install the front fender and hoodand check the fit.

4

3

4

1

1

10

5


INSTALLATION


16/70

FRONT FENDER APRON (ASSY)

REMOVAL (With the radiator side support, front panelupper reinforcement brace removed.)

3

3

4

6

6

8

4 13



17/70


2. Measurements must be accurate with thebody dimension diagram, as this affects the

front wheel alignment.

3. Temporarily install the front fender and hood,and check the fit.

3

6

4

6

6

8

4 13


INSTALLATION


18/70

FRONT PANEL UPPER RENFORCEMENTBRACE (ASSY)

REMOVAL

10

2 6Cut withdisc Sander, etc.



19/70

7 1

6

3 6 Tack Weld

(30 mm each)

Tack Weld(25 mm)


INSTALLATION

mm in.

2530

0.981.18


20/70

FRONT SIDE MEMBER (CUT-P)

REMOVAL (With the radiator support upper brace, frontcrossmember, front fender front apron removed.)

1. After removing the battery carrier support (LHonly), cut and join the parts at the locations asshown above.

2. Shift each cut and join location of the frontside member plate, front side member andfront side member reinforcement.

RH:LH:

2

3

60 mm

Cut and Join Location(Front Side Member)

80 mm

Front SideMemberExtension

RH:LH:

6

4

2 9

1 9

9Cut and Join Location(Front Side Member Plate)

RH:LH:

9

6

[LH Only]

Battery CarrierSupport

RH: 120 mmLH: 100 mm

Cut and JoinLocation

Front Side MemberReinforcement

RH:LH:

6

5


mm in.

6080

100120

2.363.153.944.72


21/70


Butt Weld

RH:LH:

7

5

Front Side Member Plate

7

1

8

9

RH:LH:

3

4

RH:LH:

9

6

RH:LH:

6

5

Front SuspensionMember MountingBracket

Front BumperMountingReinforcement

Butt Weld

Butt Weld

RH:LH: 6 4

RH:LH:

6

5

2

9 1

2

9

[LH Only]


INSTALLATION


22/70

FRONT SIDE MEMBER (ASSY)

REMOVAL (With the radiator support upper brace, frontcrossmember, front fender front apron removed.)

1. Leave the floor side member No.1 reinforce-ment to the vehicle. Remove the front sidemember.

2. Replace the front side member extension atthe same time.

12

5 5

8

11

Floor Side MemberNo.1 Reinforcement

6

1

4

8 3

3

3



23/70


HINT: Make sure each measurement is correct, asthis parts affects the front wheel alignment.

12

3

RH:LH:

6

4

Front SideMember Extension 1 RH:

LH: 6

5

5 5

8

11

6

1

4

8

3

3

3


INSTALLATION


24/70

FRONT BODY PILLAR (CUT)

REMOVAL (With the front panel upper reinforcementbrace removed.)

1. Cut and join the parts at the locations asshown above.

2. Shift the each cut and join locations of the out-er pillar and inner pillar.

3. Shift the each cut and join locations of the out-er panel and rocker panel No.1 reinforcement.

3

2

2 1

1

7

18

Cut and Join Location(Cut Location forSupply Parts)


[Cut and Join Location]

80 mm


40 mm

Rocker Panel No.1Reinforcement


mm in.

4080

1.573.15


25/70

4. Remove the remaining foamed material fromthe vehicles side.

1

2

2

4

2

Cut with discSander, etc.



26/70

1. Cut the new parts for the outer pillar and rock-er panel No.1 reinforcement at the locationsshown above.

HINT: After butt welding the rocker panel No.1 re-inforcement attach it to the lower area of the outer

pillar.

2. Before temporarily installing the new parts,weld the outer pillar, reinforcement, inner pil-lar and rocker panel No.1 reinforcement withstandard points.

3. Temporarily install the new parts and mea-

sure each part in accordance with the body di-mension diagram.

Outer Piller

Cut Location

80 mm

270 mmRocker Panel No.1 Reinforcement

Cut Location

Outer Piller

Inner Piller

Rocker Panel No.1Reinforcement Reinforcement

16

13

3

22

3

10

5

7

6

2

2

4

2

2

2 4


INSTALLATION

mm in.

80270

3.1510.63


27/70

4. Before welding the new parts, check the fit ofthe front door, front fender and windshieldglass.

5. Apply framed material to the pillar section.

Tack Weld(45 mm)

Butt Weld

A

A

A A[Foamed MaterialApplication Areas]

Butt Weld

B B[Foamed MaterialApplication Areas]

Butt Weld

B

B

Butt Weld

7

4 12

8

12

15

1

1

2

3

2

1


mm in.

45 1.77


28/70


MEMO


29/70

CENTER BODY PILLAR (CUT)

REMOVAL


HINT:1) Shift the each cut and join locations of the out-

er piller, inner piller and reinforcement.

2) Shift the each cut and join locations of the out-er piller and rocker panel No.1 reinforcement.

Cut and JoinLocation(Cut Locationfor SupplyParts)

410 mm


Cut and Join Location

Cut and JoinLocation(Cut Location forSupply Parts)


80 mm

Rocker Panel No.1 Reinforcement


50 mm


2

2

2

2 1

13

2

11


mm in.

5080

410

1.973.15

16.14


30/70

1. Cut the new parts for the rocker panel No.1 re-inforcement at the location shown above.

2. Before temporarily installing the new parts.Weld the rocker panel No.1 reinforcement,rocker panel No.3 reinforcement, inner pillar

and center body pillar reinforcement withstandard points.


4. Before welding the new parts, check the fit ofthe front door and rear door.


580 mmCut Location



Center BodyPillarReinforcement

Inner PillarButt Weld

Butt Weld

4 4

28 26

11

6

3

12


INSTALLATION

mm in.

580 22.83


31/70

5. After welding the inner pillar, center body pil-lar reinforcement and rocker panel No.1 rein-forcement to the vehicle install the outer pil-lar.

6. Apply framd material to the pillar section.


40 Butt Weld

41

1

1

A A

Butt WeldButt WeldButt Weld

21 2

3

3

11



32/70

FRONT DOOR OUTER PANEL (ASSY)

REMOVAL

1. Before removing the outer panel, make theinstallation position with a tape.

2. After grinding off the hemming location, re-move the outer panel.

Hemming Location

Disc Sander

Braze

InstallationPosition

Braze

Positioning Tape



33/70

1. Before temporarily installing the new parts,apply body sealer to the reinforcement, sideimpact protection beam and back side of thenew parts.

HINT:1) Apply just enough sealer for the reinforce-

ment and side impact beam to touch the new

panel. Apply sealer evenly around the flangearea, about 10 mm (0.39 in.) from the edge, asshown.

2) For other sealing points, refer to section AR.

2. Bend the flange hem about 30with a hem-mer and dolly, then fasten tightly with a hem-ming tool.

HINT:1) Perform hemming in three steps, being care-

ful not to warp the panel.

2) If a hemming tool cannot be used, hem witha hammer and dolly.

Body Sealer

about 10 mm

Do not close thedrain hole.

Cloth Tape

30

Hemming Tool

Braze

Body Sealer

PositioningTape

Braze

Body Sealer

4

4

4

4


INSTALLATION

mm in.

10 0.39


34/70

REAR DOOR OUTER PANEL (ASSY)

REMOVAL

1. Before removing the outer panel, make theinstallation position with a tape.

2. After grinding off the hemming location, re-move the outer panel.

Hemming Location

Disc Sander

PositioningTape

InstallationPosition

Braze

Braze



35/70

1. Bofore temporarily installing the new parts,apply body sealer to the reinforcement, sideimpact protection beam and back side of thenew parts.

HINT:1) Apply just enough sealer for the reinforce-

ment and side impact beam to touch the new

panel. Apply sealer evenly around the flangearea, about 10 mm (0.39 in.) from the edge, asshown.


2. Bend the flange hem about 30with a hem-mer and dolly, then fasten tightly with a hem-ming tool.

HINT:1) Perform hemming in three steps, being care-

ful not to warp the panel.

2) If a hemming tool cannot be used, hem witha hammer and dolly.

Body Sealer

about 10 mm

Do not close thedrain hole.

Cloth Tape

30

Hemming Tool

PositioningTape

Body Sealer

Braze

Braze

Body Sealer

4

4

4

4


INSTALLATION

mm in.

10 0.39


36/70

ROCKER OUTER PANEL (ASSY)

REMOVAL


HINT: Take care not to damage the internal rein-forcement of the center body pillar.

2. Remove the remaining foamed material fromthe vehicles side.

70 mm





[Cut and Join Location][Cut and Join Location]

16

24

2

9


mm in.

70 2.76


37/70

1. Temporarily install the new parts and checkthe fit of the front door and rear door.

2. After installing the new parts, apply foamedmaterials.


Butt Weld

A A

Butt Weld

Butt Weld

21

12

2

32


INSTALLATION


38/70

QUARTER PANEL (CUT)

REMOVAL


2. Replace the fuel filler opening lid at the sametime as the quarter panel.


Fuel FillerOpening Lid

22

27

21

10

Cut and Join Location(Cut Location for Supply Parts)


140 mm

145 mm


9



mm in.

140145

5.515.71


39/70

2. Bend a part of the body lower back panel andremoved the quarter panel.

2

7

2

2

2

5



40/70

1. Before temporarily installing the new parts,apply body sealer to the wheel arch.

HINT:1) Apply body sealer about 5 mm (0.20 in.) from

the flange, avoiding any oozing.

2) Apply sealer evenly, about 3 4 mm (0.12 0.16 in.) in diameter.


2. Temporarily install the new parts and checkthe fit of the rear door, back door and rearcombination light.


Body Sealer

about 5 mm


Butt Weld

Butt Weld

A

A

B

B

Body Sealer

Butt Weld

B B[Foamed MaterialApplication Areas]

36

13

28 12

22


INSTALATION

mm in.

5 0.20


41/70

4. Attach the fuel filler opening lid by rivets tothe quarter panel.

HINT:1) Use water proof rivets.

2) Refer to the introduction when installation re-

ivets.

Fuel Filler

Opening Lid

Waterproof Rivet

2

7

2

2

2

5



42/70

QUARTER PANEL (CUT-P)

REMOVAL

1. Cut and join the part at the location as shownabove.

2. Bend a part of the body lower back panel andremoved the quarter panel.


5

9

7

2

2

5

2



43/70

1. Before temporarily installing the new parts,apply body sealer to the wheel arch.

HINT:1) Apply body sealer about 5 mm (0.20 in.) from

the flange, avoiding any oozing.

2) Apply sealer evenly, about 3 4 mm (0.12 0.16 in.) in diameter.


2. Temporarily install the new parts and checkthe fit of the back door and rear combinationlight.

Body Sealer

about 5 mm

Butt Weld

Body Sealer

7

11

7

2

2

2

5


INSTALLATION

mm in.

5 0.20


44/70

QUARTER WHEEL HOUSING OUTER PANEL(ASSY): Right Side

REMOVAL (With the quarter panel removed.)

1. Cut the roof side outer panel at the locationshown in the above figure and remove thequarter wheel housing outer panel.


130 mm

Roof SideOuter Panel

4

2

1

6

4

2

7

2

18

10

18 8

1

1

5

2


mm in.

130 5.12


45/70

1. Determine the position of the new parts by theassembly marks of the inner and outer panels.

2. Before welding the new parts, temporarilyinstall the quarter panel and check the fit.


Butt Weld


A

A

AssemblyMark

4 1

4

2

4 4 4

2

24

6

2

2

1

1

8 24

5

7


INSTALLATION


46/70

QUARTER WHEEL HOUSING OUTER PANEL(ASSY): Left Side


1. Cut the roof side outer panel at the locationshown in the above figure and remove thequarter wheel housing outer panel.


130 mm

Roof SideOuter Panel

1 4

2

4

2

6

7 3

2

2

18

1

1 12

5

5

8


mm in.

130 5.12


47/70

1. Determine the position of the new parts by theassembly marks of the inner and outer panels.

2. Before welding the new parts, temporarilyinstall the quearter panel and check the fit.


Butt Weld


A

A

AssemblyMark

4 2

1

4

5

2 6

4

4

3

8

16

24

2

2

1

5

1


INSTALLATION


48/70

BODY LOWER BACK PANEL (ASSY)

REMOVAL

2

1

2

5 19

3 5

2

3

10 2



49/70

1. Temporarily install the new parts and checkthe fit of the back door.

2

1

2 2

5 5

10

25

4

4

3


INSTALLATION


50/70

BACK DOOR OPENING TROUGH, REAR BODYREAR SIDE CORNER PANEL (ASSY)


1. Replace the back door opening trough andrear body rear side corner panel at the sametime.

Back DoorOpening Trough

Rear Body RearSide Corner Panel

4

2

10

1

1 2

2



51/70

1. Before welding the new parts, temporarilyinstall the quarter panel and check the fit.

4

2

2

1

2

1

13

1


INSTALLATION


52/70

ROOF SIDE INNER REAR PANEL (ASSY)

REMOVAL (With the back door opening trough, rear bodyrear side corner panel removed.)

1. Cut the quarter panel upper rear extension atthe location shown in the above figure and re-move the roof side inner rear panel.

100 mm


Quarter Panel UpperRear Extension

4

2

10

1 1

1

1

10

1 4

1


mm in.

100 3.94


53/70

Butt Weld

6 2

1

1

1

1

13

1 6

1

13


INSTALLATION


54/70

ROOF SIDE INNER LOWER PANEL, ROOF SIDEINNER FRONT PANEL (ASSY)

REMOVAL (With the roof side inner rear panel, bodylower back panel removed.)

1. Replace the roof side inner lower panel, roofside inner front panel and quarter inner panelbracket (LH only) at the same time.

1

4

3 4

1

6

Quarter InnerPanel Bracket(LH only)

Roof Side InnerLower Panel

Roof Side InnerFront Panel



55/70

[LH Only]

1

4

3

5

6

8

2


INSTALLATION


56/70

REAR FLOOR CENTER CROSSMEMBER (ASSY)

REMOVAL

[LH Side]

[RH Side]

6 4

6 3

6 15 6

15



57/70

[LH Side]

[RH Side]

4 6

6 3

15

6 6

15


INSTALLATION


58/70

REAR FLOOR PAN (ASSY)

REMOVAL (With the body lower back panel, rear floorcenter crossmember removed.)

5

28

12 11 15 4

15

12

1 1

RH:LH:

3

2

1



59/70

1. Attach the weld bolt to the center of the bear-ing surface.

Tack Weld(Weld Bolt)

2

3

1

8

28

5

12

1

4

12 11 15 4

15

1RH:LH:

3

2


INSTALLATION


60/70

REAR FLOOR SIDE PANEL (ASSY)

REMOVAL(With the rear floor pan removed.)

7

3

6 4

4



61/70

7

3

6 4

4


INSTALLATION


62/70

REAR FLOOR SIDE REAR MEMBER (ASSY)

REMOVAL (With the body lower back panel removed.)

9

9

RH Only:

RH Only:

4

4

12



63/70

1. When temporarily installing the new parts,determine the installation position by the as-sembly mark, Then, measure each part in ac-cordance with the body dimension diagram.

9

9

RH Only:

RH Only:

4

4

12

Assembly Mark


INSTALLATION


64/70

REAR FLOOR NO.2 CROSSMEMBER (ASSY)

REMOVAL

3 7

4

15

7



65/70

3 4

7

7

15


INSTALLATION


66/70

ROOF PANEL (ASSY): w/o Moon Roof

REMOVAL

39

39

28

12

20

1

Braze



67/70

1. Before temporarily installing the new parts,apply body sealer to the windshied headerpanel, roof panel reinforcement and backdoor opening frame.

HINT:

1) Apply just enough sealer for new parts tomake contact.



Body Sealer

A

A


Braze

51

8

16

16

8

12

3

3

1

51


INSTALLATION


68/70

ROOF PANEL (ASSY): w/ Moon Roof

REMOVAL

[If reusing the roof panel reinforcement]

Hemming Location

Disc Sander

Braze

36

12

28

12

20

1

36



69/70

1. Before temporarily installing the new parts,apply body sealer to the windshield headerpanel, roof panel reinforcement and backdoor opening frame.

HINT:1) Apply just enough sealer for the new parts to

make contact.2) For other sealing points, refer to section AR.2. After installing the new parts, apply foamed

materials.

3. Bend the flange hem with a wooden hammerand dolly.

HINT: Perform hemming three steps, being care-ful not to warp the panel.

Cloth Tape

Wooden Hammer

Body Sealer

A

A


Braze

47

8

16

8

16

47

1

12

3 16

3


INSTALLATION


70/70

MEMO

body panel replacement

Documents