Page 649 of 4770
mmin.
10
15
25
1000.39
0.59
0.98
3.94 Butt Weld
Butt Weld
100 mm
Butt Weld
Butt Weld
(Rocker panel No. 5
Reinforcement.)
Butt Weld
Tack Weld
(10 mm ~ 15 mm each)
Butt Weld
(Center Body
Pillar Lower
Reinforcement)
25 mm
Butt Weld
(Outer Pillar)
Butt Weld
[Foamed Material
Application Areas]
4. Before welding the new parts, check the fit of
the front door, front fender and windshield
glass.
5. Cut the upper part of the outer pillar 100 mm
(3.94 in.) from its cut and join location and af-
ter butt welding the reinforcement, attach the
outer pillar.6. Cut the center body pillar lower reinforce-
ment 25 mm (0.98 in.) from its previous cut
and joining location.
Butt weld the rocker panel No. 5 reinforce-
ment and butt weld the center body pillar
lower reinforcement.
7. Apply foamed material to the pillar section.
BODY PANEL REPLACEMENTRE-27
Page 650 of 4770
Page 651 of 4770
mm in.
20
50
70
85
260
3800.79
1.97
2.76
3.35
11.42
14.96
CENTER BODY PILLAR (CUT)
REMOVAL
Cut and Join Location
(Cut Location for
Supply Parts)
Cut and Join
Location
260 mm
380 mm
Cut and Join location
Cut and Join
Location
[Cut and Join Location]
50 mm
[Cut and Join Location]
[Cut and Join Location]
20 mm
70
mm85 mm
Center Body Pillar Lower Reinforcement
Center Body Pillar Lower Reinforcement
1. Cut and join the parts at the locations shown
above.
HINT:
1) Sift the each cut and join locations of the cen-
ter outer pillar, reinforcement and inner pillar.
2) Sift the each cut and join locations of the rock-
er outer and center body pillar lower reinforce-
ment.
BODY PANEL REPLACEMENTRE-29
Page 652 of 4770
mm in.
60
702.36
2.76
INSTALLATION
Center Body Pillar Reinforcement
Center Pillar
Reinforcement
60 mm
70 mm
Cut Location
Butt Weld
Center Body Pillar
Reinforcement
Butt Weld
Butt Weld
Inner Pillar
1. Cut the new parts for the center body pillar re-
inforcement at the locations shown above.
2. Before temporarily installing the new parts,
weld the inner pillar, center pillar reinforcement
and center body pillar reinforcement with stan-
dard points.3. Temporarily install the new parts and mea-
sure each part in accordance with the body
dimension diagram.
4. Before welding the new parts, check the fit of
the front door and rear door.
BODY PANEL REPLACEMENTRE-30
Page 653 of 4770
Butt Weld
[Foamed Material
Application Areas]
[Foamed Material
Application Areas]
Butt Weld
Butt Weld
Butt Weld
5. After welding the inner pillar, reinforcement
and center body pillar reinforcement to the
vehicle install the outer pillar.6. Apply framed material to the pillar section.
BODY PANEL REPLACEMENTRE-31
Page 654 of 4770
FRONT DOOR OUTER PANEL (CUT)
REMOVAL
Cut and Join
Location
Cut and Join
Location
Hemming Location
Disc Sander
2. After grinding off the hemming location, re-
move the outer panel. 1. Cut and join the parts at the location shown
above.
BODY PANEL REPLACEMENTRE-32
Page 655 of 4770
mm in.
100.39
INSTALLATION
Body Sealer
Butt
Weld
Body Sealer
about 10 mm
Butt
WeldDo not close the
drain hole.
Body Sealer
Cloth Tape
30°
Hemming Tool
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.
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-33
Page 656 of 4770
REAR DOOR OUTER PANEL (CUT)
REMOVAL
Cut and Join
Location
Cut and Join
Location
Hemming Location
Disc Sander
2. After grinding off the hemming location, re-
move the outer panel. 1. Cut and join the parts at the location shown
above.
BODY PANEL REPLACEMENTRE-34