Page 425 of 1807
mm in.
20
600.79
2.36
3. Before welding the new parts, check the fit
of the front door, front fender and windshield
glass.
4. A 60mm (2.36in.) wide access hole should
be made in the rocker outer panel. After butt
welding the rocker panel reinforcement reat-
tach the rocker outer panel by welding.
INSTALLATION (Cont'd)
Tack Weld (20mm)
Butt Weld
Butt Weld
Butt Weld
(Rocker Panel
Reinforcement) Butt Weld
(Pillar Outer
Panel)
60 mm
5. After installing the new parts, apply foamed
material.
HINT: For the formed material application areas,
refer to page AP-4.
BODY PANEL REPLACEMENTRE-25
Page 426 of 1807
FRONT CROSSMEMBER (ASSY)
REMOVAL
BODY PANEL REPLACEMENTRE-4
Page 427 of 1807
INSTALLATION
1. Temporarily install the new parts and measure
each part in accordance with the body dimen-
sion diagram.
BODY PANEL REPLACEMENTRE-5
Page 428 of 1807
FRONT DOOR OUTER PANEL (ASSY)
REMOVAL
Hemming Location
Disc Sander
1. After grinding off the hemming location,
remove the outer panel.
BODY PANEL REPLACEMENTRE-30
Page 429 of 1807
mm in.
100.39
1. Before temporarily installing the new parts,
apply body sealer to the reinforcement, side
impact protection beam and back side of the
new 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 flange
area, about 10 mm (0.39 in.) from the edge,
as shown.
2) For other sealing points, refer to section AR.
INSTALLATION
Body sealer
Body sealer
about 10mm
Do not close the
drain hole.
Body sealer
Cloth Tape
Hemming Tool
2. Bend the flange hem about 30° with a ham-
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 with
a hammer and dolly.
BODY PANEL REPLACEMENTRE-31
Page 430 of 1807
FRONT FENDER FRONT APRON (ASSY)
REMOVAL (With the radiator upper support removed.)
Apron Fender
Side Extension
Fender Side Apron
1. Replace the fender side apron and apron
fender side extension at the same time.
BODY PANEL REPLACEMENTRE-6
Page 431 of 1807
INSTALLATION
1. Temporarily install the new parts and mea-
sure each part in accordance with the body
dimension diagram.
BODY PANEL REPLACEMENTRE-7
Page 432 of 1807
mm in.
50
701.97
2.76
FRONT SIDE MEMBER (CUT-P)
REMOVAL (With the radiator upper support and
front crossmember removed.)
70 mm
Cut and Join Location
(Inner Member and
Reinforcement)
50 mm
Cut and Join Location
(Outer Plate)
1. Cut and join the parts at the location shown
above.
HINT: Shift the cut and join location of the outer
plate, inner member and reinforcement.
BODY PANEL REPLACEMENTRE-13