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BODY REPAIR BL-259
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Revision: 2006 December 2006 FX35/FX45
The spot weld on HSS panels is harder than that of an ordi-
nary steel panel.
Therefore, when cutting spot welds on a HSS panel, use a
low speed high torque drill (1,000 to 1,200 rpm) to increase
drill bit durability and facilitate the operation.
2. Precautions in spot welding HSS This work should be performed under standard working condi-
tions. Always note the following when spot welding HSS:
The electrode tip diameter must be sized properly according
to the metal thickness.
The panel surfaces must fit flush to each other, leaving no
gaps.
Follow the specifications for the proper welding pitch.
Unit:mm
PIIA0145E
PIIA0146E
PIIA0147E
Thickness (t) Minimum pitch (l)
0.6 (0.024)
0.8 (0.031)
1.0 (0.039)
1.2 (0.047)
1.6 (0.063)
1.8 (0.071) 10 (0.39) or over
12 (0.47) or over
18 (0.71) or over
20 (0.79) or over
27 (1.06) or over
31 (1.22) or over
PIIA0148E
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BL-260
BODY REPAIR
Revision: 2006 December 2006 FX35/FX45
Replacement OperationsNIS001QE
DESCRIPTION
This section is prepared for technicians who have attained a high level of skill and experience in repairing col-
lision-damaged vehicles and also use modern service tools and equipment. Persons unfamiliar with body
repair techniques should not attempt to repair collision-damaged vehicles by using this section.
Technicians are also encouraged to read Body Repair Manual (Fundamentals) in order to ensure that the orig-
inal functions and quality of the vehicle can be maintained. The Body Repair Manual (Fundamentals) contains
additional information, including cautions and warning, that are not including in this manual. Technicians
should refer to both manuals to ensure proper repairs.
Please note that these information are prepared for worldwide usage, and as such, certain procedures might
not apply in some regions or countries.
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BODY REPAIR BL-261
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The symbols used in this section for cutting and welding / brazing operations are shown below.
PIIA0149E
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BL-262
BODY REPAIR
Revision: 2006 December 2006 FX35/FX45
Front pillar butt joint can be determined anywhere within shaded
area as shown in the figure. The best location for the butt joint is
at position A due to the construction of the vehicle. Refer to the
front pillar section.
Determine cutting position and record distance from the locating
indent. Use this distance when cutting the service part. Cut outer
front pillar over 60 mm above inner front pillar cut position.
Prepare a cutting jig to make outer pillar easier to cut. Also, this
will permit service part to be accurately cut at joint position.
An example of cutting operation using a cutting jig is as follows.
1. Mark cutting lines. A: Cut position of outer pillar
B: Cut position of inner pillar
2. Align cutting line with notch on jig. Clamp jig to pillar.
3. Cut outer pillar along groove of jig. (At position A)
4. Remove jig and cut remaining portions.
5. Cut inner pillar at position B in same manner.
PIIA0150E
PIIA0151E
PIIA0152E
PIIA0153E
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BODY REPAIR BL-263
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Revision: 2006 December 2006 FX35/FX45
HOODLEDGE
SIIA2270E
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BL-264
BODY REPAIR
Revision: 2006 December 2006 FX35/FX45
Change parts Hoodledge assembly (LH) Hoodledge reinforcement (LH)
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BODY REPAIR BL-265
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Revision: 2006 December 2006 FX35/FX45
FRONT SIDE MEMBER
Work after hoodledge has been removed.
SIIA2271E
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BL-266
BODY REPAIR
Revision: 2006 December 2006 FX35/FX45
SIIA2272E
Change parts Front side member (LH) Front side member closing plate (LH) Front side member outrigger assembly (LH)