ed12_eng_[from_]

General Information

Body Construction

Body Dimensions

Body Panel Repair Procedure

Body Sealing Locations

Corrosion Protection

Body Modification Tools

Plastic Parts

Body Shop ManualFOREWORD

This Body Shop Manual illustrates body structures andservice procedures for the CEE'D.

This manual illustrates the replacement of major bodypanels, plastic parts, body dimensions, sealing treatmentetc., in a systematic manner which is necessary for effectiveand lasting body repairs.You are encouraged to become familiar with this manualand understand each section in order to perform properrepair procedures. Keep this manual in a convenientlocation so that it is readily available.

All information in this manual including specifications,data and illustrations is made based on the vehicles built atthe time the manual was printed.

Information regarding the removal/replacement ofcomponents not specifically covered in this manual can befound in the CEE'D Service Manual. Information regardingelectrical harness routing/ connections, etc. can be foundin the CEE'D Electrical Troubleshooting Manual.

The descriptions and specifications contained in this manualwere in effect at the time this manual was approved forprinting. Kia Motors Corporation reserves the right todiscontinue models at any time, or change specificationsor design without notice and without incurring obligation.

Kia Motors CorporationSEOUL, KOREA

All rights reserved. No part of this publication may be reproduced, stored in any retrieval system or transmitted inany form or by any means without the prior written permission of Kia Motors Corporation.

CONTENTS

Title Group

GI

BC

BD

BP

BS

CP

BT

PP

Copyright c 2006, Kia Motors CorporationPrinted in Korea, November 2006Pub. No. : A1HB-EG6NA (English)

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 shop manual provide general directions for a service and repair.

Procedure, techniques, tools, and parts for service including the skill of the technician vary.It is impossible to provide advice or caution as to each case in this manual.Accordingly, anyone who intends to use a replacement part, service procedure, or tool, which is not recommended by the vehicle manufacturer, must first assure thoroughly that neither their personal safety nor the safe operation of the vehicle will be first jeopardized by the replacement part, service procedure, or tool they select.

The following list contains some general WARNINGS that you should follow while working on a vehicle.

Always wear safety glasses for eye protection.Use safety stands whenever a procedure requires you to be under the vehicle.Make sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure.Set the parking brake when working on the vehicle. If you have an automatic transaxle, set in park unless instructed otherwise for a specific operationPlace supporters against the front and rear surfaces of the tires to help prevent the vehicle from movingOperate the engine only in a well-ventilated area to avoid the danger of carbon monoxide poisoning.Keep yourself and your clothing away from moving parts when the engine is running, especially the drive belts.To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler.Do not smoke while working on a vehicle.To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle.When it is necessary to work under the hood, keep hands and other objects clear of the radiator fan blades! Your vehicle may be equipped with a cooling fan that may turn on, even though the ignition switch is in the OFF position. For this reason care should be taken to ensure that the radiator fan electric motor is completely disconnected when working under the hood and the engine is not running.

Remind you to be especially careful in those areas where carelessness can cause personal injury.To prevent you from making errors that could damage the vehicle as well as personal injury.

Gives you added information that will help you complete a particular procedure.

WARNING :

CAUTION :

NOTE :

IMPORTANT SAFETY NOTICE

GeneralInformation

GI

FUNDAMENTAL PROCEDURESVEHICLE PROTECTION.................................. GI - 2A WORD ABOUT SAFETY ...............................GI - 2WELDING PROCEDURES .............................. GI - 3BODY FRAME STRAIGHTENER ..................... GI - 3ELECTRICAL PROCEDURES ........................ GI - 3

FOR BEST RESULTSDISASSEMBLY.................................................GI - 4PREPARATION OF ASSEMBLY ....................... GI - 6ASSEMBLY.......................................................GI - 7RUSTPROOF TREATMENT AFTERASSEMBLY.......................................................GI - 8

VEHICLE LIFT (2-SUPPORT TYPE) ANDSAFETY STAND POSITIONS ...................GI - 9

JACK SUPPORT POSITIONS .................. GI - 10

GI-2 GENERAL INFORMATION

FUNDAMENTAL PROCEDURES

VEHICLE PROTECTION

1. Cover the seats before performing any procedure tokeep them from getting dirty.

2. Cover all glasses, seats and mats with a heat resistantcover when welding.

3. Protect moldings, garnishes and ornaments.

BVQGI6001

A WORD ABOUT SAFETY

1. Wear the appropriate safety equipment that isnecessary for the procedure being performed.

2. When welding or performing other procedures thatrequire the use of an open flame near the fuel tank,disconnect and remove the tank and fuel pipe, andcap the pipe to prevent fuel leakage.

BVQGI6002

Safety glasses

Ear protectors

GlovesFace shield

Mask

Safety shoes

BVQGI6003

GENERAL INFORMATION GI-3

WELDING PROCEDURES

Observe the following tips when welding.1. Wear appropriate eye protection.

2. Carefully follow the manufacturers operatinginstructions for the welding machine you are using.

3. Do not weld, smoke or allow open flames aroundvolatile chemicals, cleaners or solvents or in any areawhere they have just been used.

BODY FRAME STRAIGHTENER

When using a frame straightener, do not enter the areawhere the body is being straightened by the chain.

ELECTRICAL PROCEDURES

1. Disconnect the negative battery terminal.

2. Do not pull on wires when disconnecting electricalconnectors. Be careful to hold the connector itself whendisconnecting it.

3. Insert the connector until it "licks" when connectingthe connector.

4. Handle all electrical components with care.

BVQGI6004


FOR BEST RESULTS

DISASSEMBLY

Measuring dimensions before beginningMeasure the dimensions of the damaged area according to the body dimension drawings before disassembling and repairing.Adjust dimensions with body frame adjuster if deformed.

Selecting cutting areaSelect a cutting area that is easily accessible and that is prone to the least amount of distortion when welding.Select an area that would allow the new part to overlap repair area by 1.2~2.0 in (30~50 mm).

Protecting body from damageSecure the body with clamps and jacks to prevent damage to the body when working on it.

BEDGI6005


Disassembling related partsUse caution when removing body molding and trim fromthe area to be worked.Apply masking tape where needed to prevent damage tothe part being removed or to the vehicle body.Before starting repairs, check if pipes, hoses or electricalcomponents are present near damaged area.

BVQGI6006

Wire harness

Repair work area Cutting area


Machining holes for plug weldingDrill a hole of approximately 0.2~0.24 in (5~6 mm) indiameter in those areas which are not suitable for spotwelding.

BVQGI6008

PREPARATION OF ASSEMBLY

Applying spot sealerRemove paint from the surface of new parts and body to be spot welded, and apply spot sealer for rustproofing.

Selecting a welding methodIf the thickness of the area to be welded with the panels overlapped is greater than 0.1 in (3 mm), do plug welding using acarbon arc welding machine.

Protecting body from damageSecure the body with clamps and jacks to prevent damage to the body when working on it.

Adjusting a new partThe new part should be cut larger than the repair area,overlapping the repair area by 1.2~2.0 in (30~50 mm).

BVQGI6009

1.2~2.0 in(30~50 mm)

Overlap

1.2~2.0 in(30~50 mm)

Overlap

body side to modify

new part to modify

BEDGI6007

Thicker than0.1 in (3mm)


ASSEMBLY

Measuring dimensions before weldingWhen assembling a new part, assemble it according to the body dimensions given in Section 31, and start welding afterchecking the gaps with nearby parts.

Caution when weldingThe number of welding points should be determined based on the criteria below:

Caution when spot weldingThe tip of the spot welding machine should be maintained to a minimum of 0.1 in (3 mm) because it greatly affects weldingstrength. When possible, spot welding should be done between the existing spot welded points.Before and after spot welding, weld a test piece(test pin) of the same material as the body panel, and check the weldingstrength.

0.1 in(3 mm)

0.1 in(3 mm)

Centerdiameter

Good Existing welded spots

New welded spots

Using a hammer and a chisel Using a test piece(test pin)

Nugget diameterto be 4/5 of chipdiameter

No good

BVQGI6011

BEDGI6010

Spot welding Plug welding

Old part Repair part

Pitch:2.0 in (50 mm)

Increase the number ofspot welds by 30%.

Pitch: Same number of welds as original part.

Pitch:1.4 in (35 mm) Repair part

more than0.1 in (3 mm)


RUSTPROOF TREATMENT AFTER ASSEMBLY

Body sealingApply body sealer where necessary.

Applying rustproof materialApply rustproofing material(wax, oil, etc.) behind welded area.

Applying undercoatApply undercoat on the body where necessary.

BEDGI6012


VEHICLE LIFT (2-SUPPORT TYPE) AND SAFETY STAND POSITIONS

1. Place the lift blocks under the support points as shown in the illustration

2. Raise the hoist a few inches and rock the vehicle to be sure it is firmly supported.

3. Raise the hoist to full height to inspect the lift points for secure support.

BEDGI6013

Lift Block

[Rear][Front]

Lift Block


JACK SUPPORT POSITIONS

BEDGI6014

BC

BodyConstruction

FENDER APRON PANEL ........................... BC - 2

FRONT SIDE MEMBER ...............................BC - 5

DASH PANEL ..................................................BC - 8

CENTER FLOOR PANEL ........................... BC -12

REAR FLOOR PANEL ................................. BC -15

ROOF PANEL ..................................................BC -16

SIDE BODY ...................................................... BC -17

FRONT AND REAR BODY ........................ BC -20

SIDE BODY ...................................................... BC -22

BC-2 BODY CONSTRUCTION

FENDER APRON PANEL

BEDBC6001

1

2

3

4

Fender apron upper outer panel assembly

Fender apron upper inner panel assembly

Fender apron front upper reinforcement assembly

Fender apron inner panel assembly

PART NAMENo.

5

6

7

Shock absober housing cover assembly

Shock absorber housing reinforcement

Shock absorber housing panel assembly

PART NAMENo.

1

2

34

5

6

7

BODY CONSTRUCTION BC-3

< Cross-Sectional Views >

BEDBC6003

[ RH TOP VIEW ]

[ RH SIDE VIEW ]

B

B

A

A

C

C


BEDBC6006

BEDBC6005BEDBC6004


Fender apron upper outer panel assemlby

Shock absorber housing cover assembly

A - A B - B

C - C


Front side complete member assembly


Fender apron front upper reinforcement assembly

Fender apronfront upperreinforcementassembly


Shock absorberhousing panel

assembly


Front side complete member assembly



Shock absorber housing panel assembly


Front sidecomplete memberassembly


FRONT SIDE MEMBER

BEDBC6101

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Front crash member assembly

Crash member rear bracket assembly

Crash member bracket assembly

Front side member outer front extension assembly

Engine mounting support assembly

Front side outer member assembly

Front side member inner reinforcement assembly

Front side inner member assembly

PART NAMENo.

Transmission mounting reinforcement assembly

Front side member inner reinforcement

Front side member rear lower extension assembly

Side sill inner front extension

Front side inner rear reinforcement assembly

Front side rear lower member assembly

Subframe rear mounting bracket assembly

PART NAMENo.

1

2 3 4

7

8

9

10

11

12

13

14

15

6

5



BEDBC6104

[ RH SIDE VIEW ]

[ RH TOP VIEW ]

[ LH SIDE VIEW ]

A

A

C C

B B

E

E

D

D

F

F


BEDBC6108

BEDBC6110

BEDBC6109BEDBC6107

BEDBC6106BEDBC6105


Front side member outer front extension assembly

Front side outer member assembly

A - A B - B

C - C D - D

E - E

F - F

Engine mounting support assembly

Front side member inner reinforcement

assembly

Front side inner member asembly

Front side rear lower member assembly

Crash member bracket assembly

Crash member rear bracket assemblyFront crashmember assembly


Front side memberouter front

extension assembly

Washer assembly bolt


Subframe rear mounting bracket assembly

Front side member rear lower extension assembly

Side sill innerfront extension


Front side rear lowermember assembly

Front side member inner reinforcement assembly

Front side inner member assembly Front side outer

member assembly


DASH PANEL

BEDBC6201

1

2

3

4

Dash cross side member assembly

Dash cross center member assembly

Dash lower member assembly

Foot rest bracket

PART NAMENo.

5

6

7

Dash panel reinforcement assembly

Dash panel assembly

Dust cover panel

PART NAMENo.

1

1

2

3

4

5

6

7



BEDBC6203

[ TOP VIEW ]

[ REAR VIEW ]

A

A

C

C

E

E

D

D

B

B

F

F

H

G

H

G


BUNBC6207BUNBC6206

BUNBC6205BUNBC6204

Dash cross side member assembly

A - A B - B

C - C D - D


Dash panelassembly

Dust cover panelFoot rest cover

Dash panel assembly

Foot rest bracket


Dash panel reinforcement assembly Dash panel reinforcement assembly

Dash panel assembly


Dash panel centerdeadening sheet

Dash panel center deadening sheet

Dash panel assembly

Dash lower member assemblyDash lower member assembly


BEDBC6211

BEDBC6210BEDBC6208

BEDBC6209

Dash cross center member

assembly

Dash panelassembly



E - E F - F

G - G

H - H

Dash panel assembly

Dash lowermember assembly

Dash cross centermember assembly

Dash panelassembly



Dash panelassembly


Dash panel assemblyDash lower

member assembly

Dash cross centermember assembly


CENTER FLOOR PANEL

BEDBC6301

1

2

3

4

Center floor side member

Muffler hanger mounting bracket assembly

Center floor panel

Side sill inner panel assembly

PART NAMENo.

5

6

7

Front seat rear mounting member assembly

Front seat mounting member assembly

Center floor reinforcement assembly

PART NAMENo.

1

1

2

3

4

4

5

5

6

6

7



BEDBC6303

[ TOP VIEW ]

[ SIDE VIEW ]

E

E

AA

F F

C

C

D

D

B

B


BEDBC6307

BEDBC6308 BEDBC6309

BEDBC6306BEDBC6305

BEDBC6304



A - A

B - B C - C

D - D

E - E F - F

Center floor panel


Center floor panel


Center floor panel

Center floor panel



Center floor panel



Side sillinner panelassembly

Front seat mounting member assembly

Center floor panel

Front seat mountingmember assembly



REAR FLOOR PANEL

BEDBC6401

1

2

3

Rear floor front extension assembly

Rear floor front panel assembly

Rear seat belt anchor bracket assembly

PART NAMENo.

4

5

6

Rear floor center cross upper member assembly

Rear floor rear panel assembly

Rear floor side panel

PART NAMENo.

1

2

3

3

4

5

6

6


ROOF PANEL

BEDBC6501

1

2

3

4

Roof panel

Roof center No.1 rail

Sunroof reinforcement ring assembly

Roof center No.2 rail assembly

PART NAMENo.

5

6

7

Roof center No.3A rail



PART NAMENo.

1

2

3

4

5

6

7


SIDE BODY

BEDBC6601

1

2

3

Quarter outer rear complete extension assembly

Side outer reinforcement assembly

Side outer panel

PART NAMENo.

4

5

Rear door striker retainer assembly

Fender rear mounting bracket

PART NAMENo.

1

2

3

4

5


BEDBC6604

BEDBC6605 BEDBC6606

BEDBC6602

B - BA - A

C - C D - D

Center floor panel

Side outer panelSide outer

reinforcementassembly

Side sillinner panel

Front inner lower pillar

Side outer panel

Side outer reinforcement

assembly


assembly

Side outer panel

Fender rear mounting bracket


assembly

Side outer panel

BEDBC6603

A

A

G

G

L

L

F

F

B

B

E E

D D

C C

I I

J J

KK

H H

[SIDE VIEW ]


BEDBC6612

BEDBC6614BEDBC6613

BEDBC6610BEDBC6609

BEDBC6611

BEDBC6608BEDBC6607

Side outer panel


assembly

E - E F - F

G - G H - H

J - J

L - L

I - I

K - K

Side outer panel

Side outerreinforcement

assembly

Front innerupper pillar

Side outer panel

Center inner pillar

Side outer panel


assembly


Side outer reinforcementassembly

Side outer panel


Side outer panel

Quarter inner upper panel

Quarter outer rear complete extension

assembly

Side outer panel

Side outer panel

Center inner pillar




BEDBC6702

[ TOP VIEW ]

[ REAR VIEW ]

B B

A A D D

C

C

G

G

F

F

E

E

FRONT AND REAR BODY


BEDBC6709BEDBC6708

BEDBC6706BEDBC6705

BEDBC6707

BEDBC6704BEDBC6703

Hood panel assembly

A - A B - B

C - C D - D

G - GE - E

F - F

Hood panel assembly

Front bumper cover

Roof panel assemblyHood panel assembly

Head lamp

Tail gate panel assembly

Rear lampTail gate panel assembly



Side outer panel assembly

+_5.8 0.5 mm

+_5.

0 0

.5 m

m

+_4.0 0.5 mm

+_5.

0 0

.5 m

m

5 m

m

3.5 mm

+_4 0.5 mm


SIDE BODY

BEDBC6803

BEDBC6804 BEDBC6805

BEDBC6801

B - BA - A

C - C D - D

Side outer panel

Front door panel assembly


Side outer panel

Side outer panel

Rear doorpanel assembly

Rear door panel assembly

BEDBC6802

[SIDE VIEW ]

G

G

L

L

C

C

M

M

D

D

E E

B

B

N

N

A

A

F F K K

J J

I I

H H

+_5 0.5 m

m

+_5 0.5 mm

+_5 0.5 mm

+_4 0.5 mm


BEDBC6811

BEDBC6813BEDBC6812

BEDBC6809BEDBC6808

BEDBC6810

BEDBC6807BEDBC6806






Rear doorpanel assembly



Fender panel

E - E F - F

G - G H - H

J - J

L - L

I - I

K - K

Fender panel



Rear door panel assembly Rear door panel assembly

+_3.5 0.5 mm

+_3.5 0.5 mm

+_5

0.5

mm

+_4 0.5 mm

+_3.5 0.5 mm

+_3.5 0.5 mm

+_3.5 0.5 mm+_

5

0.5

mm


BEDBC6815BEDBC6814


Frender panel

Hood panel assembly

M - M N - N

+_2.7 0.5 mm+_3.5 0.5 mm

BodyDimensions

BD

GENERAL ......................................................... BD - 2

MEASUREMENT METHOD .......................BD - 2PROJECTED DIMENSIONS ............................BD - 2ACTUAL-MEASUREMENT DIMENSIONS ......BD - 3MEASUREMENT POINT ..................................BD - 3

FRONT BODY .................................................BD - 4

SIDE BODY ......................................................BD - 6

INTERIOR A .....................................................BD - 8

INTERIOR B .....................................................BD - 11

REAR BODY ....................................................BD - 13

UNDER BODY(PROFECTED DIMENSIONS) ..................BD - 15

UNDER BODY(ACTUAL-MEASUREMENTDIMENSIONS) .................................................BD - 18

BD-2 BODY DIMENSIONS

GENERAL1. Basically, all measurements in this manual are taken

with a tracking gauge.

2. When a measuring tape is used, check to be sure thereis no elongation, twisting or bending.

3. For measuring dimensions, both projected dimensionand actual-measurement dimension are used in thismanual.

MEASUREMENT METHOD

PROJECTED DIMENSIONS

1. These are the dimensions measured when themeasurement points are projected into the referenceplane, and are the reference dimensions used for bodyalterations.

2. If the length of the tracking gauge probes areadjustable, make the measurement by lengthening oneprobe by the amount equivalent to the difference inheight of the two surfaces.

BMCBD6001Projected Dimension

Height

BODY DIMENSIONS BD-3

ACTUAL-MEASUREMENT DIMENSIONS

1. These dimensions indicate the actual linear distancebetween measurement points, and are the referencedimensions for use if a tracking gauge is used formeasurement.

2. Measure by first adjusting both probes to the samelength (A=A')

CAUTIONCheck the probes and gauge itself to make surethere is no free play.

MEASUREMENT POINT

1. Measurements should be taken at the hole center.

BMCBD6003

Hole Center

BMCBD6002

Actually-Measured Dimension

A

A'


FRONT BODY

* These dimensions indicated in this figure are actual-measurement dimensions.

Point symbol

Length(mm)

Point symbol

Length(mm)

Point 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'

H-J

D-F'

H-J'

1432.0

1437.4

1120.0

646.9

714.8

583.0

1611.3

1455.9

994.7

1303.9

1119.2

987.8

1520.7

1074.0

1653.1

1024.0

1181.0

483.3

1446.9

1150.3

BEBD6101

I

A

B

C D

E

F

H

G

J

I'

A'

B'

C'D'

E'

F'

H'

G'

J'


Front end module mounting hole (ø9)

Cowl top cover mounting hole (ø7)

Front end module mounting hole (ø9)

Hood hinge mounting hole (ø12)

Front pillar coroner

Tooling hole (ø9)

Front suspension mounting hole (ø11)

Roof front corner

Transmission mounting bracket hole (ø18)

Transmission mounting bracket hole (ø18)

Engine mounting bracket hole (ø13) Engin mounting bracket hole (ø13)

BEDBD6102

A,A'

BEDBD6103B

B,B'

BEDBD6104

C,C'

BEDBD6105

DD'

BEDBD6103E

E,E'

BEDBD6106

F,F'

BEDBD6107G

G,G'BEDBD6107H

H,H'

BEDBD6108I

I'

BEDBD6108J

J'

BEDBD6109I

I

BEDBD6109J

J


SIDE BODY

BEDBD6201

I

A B

C D

E

F

H

G

L

J

K


Point symbol

Length(mm)

Point symbol

Length(mm)

Point symbol

Length(mm)

Point symbol

Length(mm)

A-B

C-F

G-H

K-L

A-C

D-E

G-J

B-C

D-G

G-K

B-D

D-H

H-J

B-E

E-F

H-K

B-F

E-G

I-J

C-D

E-H

J-K

C-E

F-H

J-L

155.3

839.5

331.8

662.4

616.5

345.0

978.2

511.5

1116.1

869.1

1014.2

1107.0

1154.4

953.7

306.6

953.5

977.9

1175.3

246.8

591.8

1065.4

335.3

661.5

1122.3

719.7


Tooling hole (ø10)

Front door hinge upper mountinghole (ø13)

Rear door hinge upper mountinghole (ø13)

Tooling hole (ø20)

Front door hinge lower mountinghole (ø13)

Rear door hinge lower mounting hole (ø13)

Tooling hole (ø9)

Fender mounting hole (ø12)

Quarter fixed glass mounting notch (ø8 notch)

Quarter fixed glass mounting hole (ø6)

Rear door switch mounting hole (ø9)

Rear bumper mounting hole (8.5X8.5)

BEDBD6202A

A

BEDBD6202B

B

BEDBD6203

C

BEDBD6204

D

BEDBD6205E

E

BEDBD6205F

F

BEDBD6206G

G

BEDBD6206H

H

BEDBD6207I

I

BEDBD6207J

J

BEDBD6208

K

BEDBD6209

L


INTERIOR A


Point symbol

Length(mm)

Point symbol

Length(mm)

Point symbol

Length(mm)

Point symbol

Length(mm)

A-A'

E-P

J-Q

R-R'

A-P

E-Q

K-K'

R-S

B-B'

F-F'

L-L'

R-S'

B-P

G-G'

M-M'

S-S'

C-C'

H-H'

M-Q

D-D'

I-I'

N-N'

D-P

I-Q

O-O'

E-E'

J-J'

O-Q

1201.0

1149.2

1061.1

1119.2

1136.5

1085.8

1526.6

1651.6

1405.8

1353.4

1420.4

1977.0

1138.9

1494.4

1128.1

1055.0

1490.1

1393.4

1355.8

1422.0

1164.0

1146.2

1031.6

1167.6

974.8

1219.9

1232.4

1441.9

BEDBD6301

I

A

B

CD

E

F

H

G

L

JK

M

N

O

P

Q

R S

I'A'

B'

C'

D'

E'

F'

H'

G' L'

J'K'

M'

N'

O'

R'S'


Trim mounting passage hole (ø9)

Cowl side trim mounting hole (ø8.4)

Rear door checker mounting hole (ø13)

Cowl cross bar mounting hole (ø9)

Seat belt height adjust uppermounting hole (ø16)

Center pillar trim mounting hole (ø8.4)

Front door checker mounting hole (ø13)

Seat belt height adjust lowermounting hole (ø16)

Pillar trim mounting hole (ø6.6)

Seat striker passage hole (ø10) Rear door striker mounting hole (ø13) Wheel house trim mounting hole (ø8.4)

BEDBD6302

A,A'

BEDBD6303

B,B'

BEDBD6304

C,C'

BEDBD6305

D,D'

BEDBD6306E

E,E'

BEDBD6306F

F,F'

BEDBD6307

G,G'

BEDBD6308

H,H'

BEDBD6309I

I,I'

BEDBD6310J

J,J'

BEDBD6311

K,K'

BEDBD6310L

L,L'



Tooling and drain hole (ø10)

Side outer rear corner

Side trim mounting hole (ø6.6)

Fuel pump wire mounting hole (ø7)

Luggage side trim mounting hole (ø8.4)

Roof front corner

BEDBD6309M

M,M'

N,N'

BEDBD6312N

O,O'

BEDBD6312O

BEDBD6313P

P

BEDBD6313Q

Q

BEDBD6106R

R,R'

BEDBD6402S

S,S'


INTERIOR B


Point symbol

Length(mm)

A-D A-D' E-H E-H' I-L M-O'I-L' M-O

1000.6 1645.9 880.0 1572.9 854.7 1544.0 621.4 1219.0

BEDBD6301A

IA

D

E

HL

M

O

I'A'

D'

E'

H'

L'

M'

O'


Trim mounting passage hole (ø9)

Center pillar trim mounting hole (ø8.4)

Pillar trim mounting hole (ø8.4) Luggage side trim mounting hole (ø8.4)

Cowl side trim mounting hole (ø8.4)


Seat belt height adjust uppermounting hole (ø16)

Wheel house trim mounting hole (ø8.4)

BEDBD6302

A,A'

BEDBD6305

D,D'

BEDBD6306E

E,E'

BEDBD6308

H,H'

BEDBD6310L

L,L'

BEDBD6309I

I,I'

BEDBD6309M

M,M'

O,O'

BEDBD6312O


REAR BODY


Point symbol

Length(mm)

Point symbol

Length(mm)

Point symbol

Length(mm)

A-A'

C-H

G-G'

B-B'

D-D'

B-E

E-E'

B-E'

E-G

B-H

E-G'

C-C'

F-F'

C-D

F-G

C-D'

F-G'

625.0

978.1

1110.0

1055.0

1469.1

746.4

1576.6

1486.9

416.4

1045.3

1383.3

1112.4

954.0

484.8

286.0

1367.2

1068.1

BEDBD6401

A

B

C

D

E

F

H

G

A'

B'

C'

D'

E'

F'

H'

G'


Tail gate hinge mounting hole (ø12)

Rear combination lamp mounting hole (ø8)

Rear bumper mounting hole (ø16)

Tail gate striker mounting hole (ø13)



Gas lifter mounting passage hole (ø9)

Rear bumper mounting hole (8.5X8.5)

BEDBD6402A

A,A'

BEDBD6402B

B,B'

BEDBD6402C

C,C'

BEDBD6403D

D,D'

BEDBD6403EE,E'

BEDBD6403F

F,F'

BEDBD6404

G,G'

BEDBD6405

H' H


UNDER BODY (PROJECTED DIMENSIONS)

* These dimensions indicated in this figure are projected dimensions.

Point symbol

Length(mm)

Point symbol

Length(mm)

Point symbol

Length(mm)

Point symbol

Length(mm)

Point symbol

Length(mm)

Point symbol

Length(mm)

A-A'

I-I'

C-D

K-L

F-0

N-0

B-B'

J-J'

D-E

L-M

G-0

C-C'

K-K'

E-F

M-N

H-0

D-D'

L-L'

F-G

A-0

I-0

E-E'

M-M'

G-H

B-0

J-0

F-F'

N-N'

H-I

C-0

K-0

G-G'

A-B

I-J

D-0

L-0

H-H'

B-C

J-K

E-0

M-0

1004.0

1328.0

645.0

115.2

-72.6

178.0

1012.0

1100.0

53.0

34.8

-79.7

1000.0

993.0

65.0

339.0

-81.0

630.0

1061.0

377.0

173.8

99.0

590.0

839.0

935.0

77.6

98.4

832.0

998.0

363.0

184.0

130.7

824.0

140.0

0

-86.0

115.4

848.0

155.0

420.0

4.8

156.2

BEDBD6201A

IA B C D E F HG L M NJ K

0

IA

B

C

D EF HG LJ K

MN

I'

A'

B'

C'

D'E'

F' H'G'L'

J'K'

M'

N'


Tooling hole (ø25)

Subframe mounting bolt

Subframe mounting hole (ø25)


Tooling hole (ø20)

Tooling hole (ø25)

Tooling hole (ø10)

Tooling and paint drain hole (ø20)

Trailing arm mounting hole (ø16) Rear suspension mounting hole (ø19) Cross member mounting hole (ø18)

BEDBD6202A

A

BEDBD6202B

B

BEDBD6502C

C,C'

BEDBD6504D

D,D'

BEDBD6503

D,D'BEDBD6504F

E,E'

BEDBD6504E

F,F'

BEDBD6504G

G,G'

BEDBD6505H

H,H'

BEDBD6505I

I,I'

BEDBD6505J

J,J'

BEDBD6506K

K,K'

Passage stay mounting hole (ø15)


Spring mounting hole (ø20) Cross member mounting hole (ø18) Tooling hole (ø20)

BEDBD6506L

L,L'

BEDBD6506M

M,M'

BEDBD6506N

N,N'


UNDER BODY (ACTUAL-MEASUREMENT DIMENSIONS)


Point symbol

Length(mm)

Point symbol

Length(mm)

Point symbol

Length(mm)

B-C'

F'-J

J'-L

B'-D

G'-H

J'-M

B'-G

H-K'

J'-N

C-F'

H-L'

D'-G

H-M'

F-G'

H-N'

F-H'

H'-J

F-N'

J'-K

1029.3

1941.1

1205.9

1153.7

1254.2

1126.1

1591.7

1226.9

1390.3

1219.5

1325.3

879.5

1279.9

909.8

1592.8

1557.9

1054.8

2752.6

1128.1

B C

D

F HG LJ

KM

N

B' C'

D'

F' H'G'L'J'

K' M'N'

BEDBD6501A


Subframe mounting hole (ø25)


Tooling hole (ø25)

Passage stay mounting hole (ø15)

Rear suspension mounting hole (ø19)


Tooling hole (ø20)

Cross member mounting hole (ø18)

Spring mounting hole (ø20) Cross member mounting hole (ø18) Tooling hole (ø20)

Tooling and paint drain hole (ø20)

BEDBD6502B

B,B'

BEDBD6502C

C,C'

BEDBD6504D

D,D'

BEDBD6503

D,D'

BEDBD6504F

F,F'

BEDBD6504G

G,G'

BEDBD6505H

H,H'

BEDBD6505J

J,J'

BEDBD6506KK,K'

BEDBD6506L

L,L'

BEDBD6506M

M,M'

BEDBD6506N

N,N'

Body Panel RepairProcedure

BP

FRONT AND REAR DOOR OUTERPANELS .............................................................BP - 63

REMOVAL ........................................................BP - 64INSTALLATION.................................................BP - 64

REPLACING BODY PANELSCODES FOR REMOVING ANDINSTALLING BODY PANELS ........................... BP - 2

NOTES WHEN WELDING BODYREMOVING SPOT WELDED AREA ................BP - 3INSTALLING A NEW BODY FRAME ................BP - 5DETERMINING A WELDING METHOD ...........BP - 5SPOT WELDING ..............................................BP - 5CARBON ARC WELDING ...............................BP - 6REPLACING BODY PANEL

REMOVAL ................................................... BP - 7PREPARATION FOR INSTALLATION ........BP - 9INSTALLATION ...........................................BP - 10

FENDER APRON PANELASSEMBLY .......................................................BP - 12


FRONT SIDE MEMBER ...............................BP - 19REMOVAL ........................................................BP - 20INSTALLATION.................................................BP - 22

FRONT PILLAR ..............................................BP - 24REMOVAL ........................................................BP - 25INSTALLATION.................................................BP - 30

SIDE SILL PANEL ..........................................BP - 34REMOVAL ........................................................BP - 34INSTALLATION.................................................BP - 36

CENTER PILLAR ...........................................BP - 37REMOVAL ........................................................BP - 38INSTALLATION.................................................BP - 46

QUARTER PANEL .........................................BP - 50REMOVAL ........................................................BP - 51INSTALLATION.................................................BP - 53

BACK COMPLETE PANEL ASSEMBLY ANDREAR FLOOR SIDE MEMBER ................BP - 55


BP-2 BODY PANEL REPAIR PROCEDURE

REPLACING BODY PANELS

CODES FOR REMOVING AND INSTALLING BODY PANELS

BVQBP6001

Location for cut and assemblyRough cutting location

0.8~1.2 in.(20~30 mm)

0.8~1.2 in.(20~30 mm)

BODY PANEL REPAIR PROCEDURE BP-3

NOTES WHEN WELDING BODY

REMOVING SPOT WELDED AREA

Most body parts are spot welded. In order to remove the damaged area, it is best to remove the spot welded area from thebody 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 weld to insure the entire spot weld will be removed.

BVQBP6002

1. Spot cutter 1. Drill(candle type edge) 1. Drill(taper edge)

2. 2. 2.

3. 3. 3.

Correct Correct Not correct


BVQBP6003

Center punch the middle(nugget) of the spot weld. Otherwise,

Spot welded area can be removed from the body frame. Spot welded area cannot be removed from the body

frame.

This part will not be cut. This part will be cut.


INSTALLING A NEW BODY FRAME

The efficiency of the transmission and load distribution are determined by many complicated factors such as thickness ofplate, shape and size of a cross section, damage of parts, variance of joints, welding method, and/or welding locations.Therefore, a new part should be fitted to the body frame using the proper procedures to avoid reducing the strength of thebody.

DETERMINING A WELDING METHOD

It is extremely important that appropriate welding methods, which don't reduce the original strength and durability of the bodybe used when making repairs, Try to use either spot welding or carbon arc(plug) welding, Do not braze any body componentsother than the ones brazed at the factory. Do not use an oxy-acetylene torch for welding.

SPOT WELDING

1. Commercial spot welding machines do not perform aswell as the machines used in the manufacturingprocess. When spot welding, increase the number ofspot welds by 30% (1.3 times the original number ofwelds).

2. When spot welding, weld in the middle of the joint.

• Spot welding on the edge of the joint will reduce weldingstrength.

BVQBP6005

BVQBP6006

Good

BVQBP6007

No good

BVQBP6004

Welding Symbol Details

Spot welding

Oxygen-acetylene welding

Carbon arc welding(Plug welding)

Not used

Use when spot welding cannot be done or spot welding is not necessary.

The most reliable welding method(provides high efficiency and quality of assembled part.)


CARBON ARC WELDING

In areas where spot welding is not suitable, do plug weldingusing a carbon are welding machine.

1. Clamp the parts to be welded together tightly. Do notexceed 1 mm of space between parts. A tolerancegreater than 1 mm will reduce the strength of thewelded area.

2. Weld in the middle of the flange joint.a) Drill a hole 5~6 mm on one side of the flange

only, and weld within the hole.

b) Do not weld on the edge of the flange joint.

BVQBP6008

1mm

Maximumtolerance

BVQBP6006

Good

BVQBP6009

No good


REPLACING BODY PANEL

REMOVAL

1. Body measurementa) Before removing, measure the damaged area

according to the dimensions supplied in BodyDimension, section 31. If deformation is present,use a frame straightener to adjust.

b) When removing a panel, apply clamps to preventdamage of each part, and support the lower endof the frame to prevent deformation during theprocedure.

2. Cut and welding point selectionCutting, if necessary, should not be done in areinforcement area. Select an area which will result inthe least amount of deformation after welding.

3. Cutting rough area for replacement partCutting should be done according to the following stepsto make removal easy:a) Use care when cutting an area close to a pipe or

wiring harness.b) Cut an area leaving 30~50 mm of tolerance.

4. Removing paint from an area to be spot weldedUsing a torch and wire brush, remove paint completelybefore beginning welding.

BVQBP6010

Tracking gauge

BVQBP6011

Reinforcement

Reinforcement

Cut area

BVQBP6012

BVQBP6013


5. Determine a cutting methoda) Cutting a spot welded area

Make a hole in the middle of spot welded areawith a punch, remove welded area using a spotcutter and remove using a chisel.

b) Removing brazed areaRemove using a torch and wire brush, and chisel.

c) Removing arc welded areaRemove plug welded area using a disk grinderand chisel.

BVQBP6014

BVQBP6015

BVQBP6016


4. Preparation for spot weldingRemove paint on spot welded area and on the areaoverlapped by the new part using a belt sander orsimilar tool.

5. Drilling a hole for plug weldingIf the thickness of the part to be welded is less than 3mm, drill a 5~6 mm diameter hole. If the thickness ofthe part to be welded is greater than 3 mm, drill a holeusing a 7 mm diameter drill.

NOTEDo not spot weld where thickness is greater than3 mm.

PREPARATION FOR INSTALLATION

1. Spot weld finishUse a disk grinder or similar tool to finish spot weldmark, Do not grind more than is necessary to smoothsurface.

2. Panel preparationRepair any bent or uneven areas with a hammer toimprove the installation process.

3. Cutting a rough area for a new partWhen rough cutting an area for a new part, leave atolerance of 30~50 mm.

BVQBP6017

BVQBP6018

BVQBP6019

BVQBP6020

BVQBP6021


INSTALLATION

1. Checking welding and fitting in advancea) When installing a new part, measure the

dimensions of each part according to the bodydimensions given in Section 31, and set part tothe reference dimensions.

b) Prior to final welding, check the fit of all relatedparts.

2. Selecting number of welding pointsSpot welding : Multiply the original number of

factory welds by 1.3 timesPlug welding : Same number as original number

of factory welds

NOTE

• Plug welding should be done using a carbon arcwelding machine.

• Brazing should be done only on areas that wereoriginally brazed at the factory.

3. Caution when spot weldinga) Do a test welding on a piece of material of the

same type and thickness as the part to be weldedand proceed if test weld is good.

b) Before spot welding, check if welding debris, oilor paint is present on the area where surfacesmeet.Clean or sand as necessary.

BVQBP6022

BVQBP6023

BVQBP6024

3mm

Spot welding:initial number of welds x1.3

Plug welding-used whenspot welding is notfeasible or material isthicker than 3 mm

Welding points-same number as original number of factory welds.

Initial weldingpitch:50 mm

Welding after repairpitch:35 mm

BVQBP6025

Centerdiameter

3 mm

Using a test pieceUsing a hammerand a chisel

Nuggetdiameter:4/5 of tip


c) The tip of the spot welding machine should bemaintained to a minimum tolerance of 3 mm. Alsolet area cool after 5 or 6 welds to minimizeproblems caused by excessive heat.

4. Cutting and welding an removed areaTo align a roof panel and a center pillar together forbutt welding, temporarily fasten a steel flange to theroof panel and then apply the new center pillar panel.Remove the flange when final welding is done.

5. Finishing after weldinga) Grind any areas that were plug welded or butt

welded using a disk grinder. Grind carefully to avoidremoving too much material. This degrades thestrength of the weld.

b) Finish areas that have been brazed by applyingbody filler then smooth the area with a flexible fileand sander.

6. Applying anti-rust agent and body sealerAfter coating the surface with anti-rust agent, applybody sealer where necessary.

NOTE

Apply body sealer before assembly.

7. Anti-rust treatmentApply anti-rust agent to inside of doors and sills byspraying through access holes provided.

BVQBP6026

3mm(0.2 in)

BVQBP6027

BVQBP6028

BVQBP6029

BVQBP6030

BVQBP6031


FENDER APRON PANEL ASSEMBLY

WELDING POINTS

MIG plug weldingMIG butt weldingMIG lap welding


BEDBP6102

BEDBP6104

290mm


REMOVAL

Before repairing, remove Engine and SuspensionComponents.Refer to the body dimension charts and measure thevehicle to determine straightening and alignmentrequirements. The body must be returned to its originaldimension before begining the repair procedure.

1. Drill out all the spotwelds(29) to separate fender aproninner panel assembly from fender apron upper panelassembly and front side member assembly.

When spotwelded portions are not apparent, removepaint with a rotary wire brush.

2. Remove the fender apron inner panel assembly.

On the right side, remove engine mounting supportassembly before removing the fender apron inner panelassembly.

3 Drill out all the spotwelds(27)to separate fender apronupper outer panel from fender apron upper inner panelassembly.

NOTE

NOTE

BEDBP6101

BEDBP6102

BEDBP6103

NOTE

BEDBP6109

BEDBP6104A


4. Remove the fender apron upper outer panel.

5. Measure and mark the cutline on the fender apron upperinner panel 290mm from front fender apron upper innerpanel end on the fender apron upper panel assemblyas shown in the illustration.

6. Cut the fender apron upper inner panel along thecutlines.

7. Remove the fender apron upper inner panel.

8. Prepare all surfaces to be welded.

9. After removing, apply the welding primer.

BEDBP6105

BEDBP6106

290mm

BEDBP6106A

BEDBP6106B

BEDBP6106C


INSTALLATION

1. Transcribe the fender apron upper inner panel cutlineto the new fender apron upper inner panel, cut to lengthand 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 BODYDIMENSIONS) and correct the installation position.

4. MIG butt weld all seams.BEDBP6106D

BEDBP6106E

BEDBP6106F

BEDBP6106G


5. Clean and prepare all welds, and remove all residue.


7. Drill 6mm holes in the new fender apron upper outerpanel for MIG plug welding.

8. Fit and clamp the fender apron upper outer panel inplace.


10. MIG plug weld all holes.

BEDBP6106H

BEDBP6105A

BEDBP6107

BEDBP6104B

BEDBP6104C

BEDBP6104D




13. Drill 6mm holes in the new fender apron inner panelassembly for MIG plug welding.

14. Fit and clamp the fender apron inner panel assemblyin place.

BEDBP6104E

BEDBP6106I

BEDBP6108

BEDBP6102A




17. Apply the two part epoxy primer to the interior of theeach panel.

18. Apply an anti-corrosion agent as required.(Refer to the BODY CORROSION PROTECTION)

19. Prepare the exterior surfaces for priming using waxand grease remover.

20. Apply metal conditioner and water rinse.

21. Apply conversion coating and water rinse.

22. Apply the two-part epoxy primer.

23. Apply the correct seam sealer to all joints carefully. (Refer to the BODY SEALING LOCATION)

BEDBP6102B

BEDBP6102C

BEDBP6102D

BEDBP6102E


FRONT SIDE MEMBER

WELDING POINTS



BEDBP6203

BEDBP6202F

260mm

143mm


This procedure is to be used only for repair of minordamage to the front side member and when it isimpossible to straighten the damaged front sidemember. The following procedure illustrates a repairfor the front left side member.The procedure may also be applied to the front rightside member.

REMOVAL

1. Before cutting the front side member, remove the frontcrash member assembly.

2. Measure and mark the vertical cutlines on front sidemember from tooling hole edge.

NOTE

BEDBP6101

BEDBP6201

BEDBP6202

143mm

BEDBP6203

260mm


3. Drill out all the spotwelds to separate front side member.

4. Cut the front side member inner and outer panel alongthe cutlines.

BEDBP6202A

BEDBP6203B

5. Remove the front side member.


7. After removing, apple the welding primer.

BEDBP6204

BEDBP6204A

BEDBP6203A


4. MIG plug weld all holes and MIG butt weld seams.


INSTALLATION

1. Transcribe the front side member inner and outer cutlineto the new front side member, cut to length and chamferbutt end to improve weld surface.

2. Fit and clamp the front side member in place.


BEDBP6205

BEDBP6206

BEDBP6203C

BEDBP6203D


6. Apply the two part epoxy primer to the interior of theeach panel.

7. Apply an anti-corrosion agent as required. (Refer to the BODY CORROSION PROTECTION)

8. Prepare the exterior surfaces for priming using waxand grease remover.




12. Apply the correct seam sealer to all joints carefully. (Refer to the BODY SEALING LOCATION)

13. Install the front crash member assembly.

BEDBP6203E

BEDBP6202B

BEDBP6201A


FRONT PILLAR

120mm

BUNBP6307

WELDING POINTS

A


B

A

B

150mm

B

100mm 90mm


REMOVER

1. To remove the front pillar, drill out and grind away allspotwelds(19) and plug welds(4) attaching the cowl sideupper 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. Before cutting the front pillar, be sure to support roofpanel.

4. Measure and mark the each cutline on the front pillarouter panel 150mm and 270mm from the roof panelcorner as indicated in the illustration.

5. Cut the front pillar outer panel along the cutlines.

When cutting the front pillar outer panel, take care notto cut through mating flanges or front pillar outerreinforcement.

NOTE

BEDBP6303

BEDBP6321

NOTE

BEDBP6305

120mm

150mm

BEDBP6305A


6. Drill out all the spotwelds(8) attaching the front pillarouter panel.

7. Remove the front pillar outer panel.

8. Measure and mark the cutlines on front side sill outerpanel as indicated in the illustration.

9. Cut the front side sill outer panel along the cutlines.

When cutting the front side sill outer panel, take carenot to cut through mating flanges or the side sill outerreinforcement.

BEDBP6305B

BEDBP6306

BEDBP6307A

100mm 90mm

NOTE

BEDBP6307B


10. Drill out all the spotwelds(8) attaching the front sidesill outer panel.

11. Remove the front side sill outer panel.

12. Measure and mark the cutline on side sill outerreinforcement as indicated in the illustration.

13. Cut the side sill outer reinforcement along the cutline.

When cutting side sill outer reinforcement, take carenot to cut through mating flanges.

BEDBP6307C

BEDBP6308

BEDBP6308A

130mm

NOTE

BEDBP6308B


14. To remove the front pillar outer panel, drill out allspotwelds(85) and bolt (1).

15. Remove the front pillar outer panel.

16. To remove the front pillar inner panel, drill out and grindaway all spotwelds(37) and lap welds(2).

BEDBP6306A

BEDBP6309

BEDBP6304

BEDBP6311

BEDBP6313

BEDBP6313A


17. Remove the front pillar inner panel.

18. Clean cut portions with a disc grinder.


BEDBP6314

BEDBP6316

BEDBP6318

BEDBP6316A

BEDBP6316B

BEDBP6312B


INSTALLATION

1. Drill 8mm holes in the front pillar inner panel for MIGplug welding.

2. Fit and clamp the new front pillar inner panel in placefor welding.

3. Measure and each measurement point (Refer to theBODY DIMENSIONS) and correct the installationposition.

BEDBP6319

BEDBP6315

4. MIG plug weld all holes and MIG lap weld seams.


BEDBP6315A

BEDBP6315B



7. Transcribe the cutlines to the new front pillar outer panel,adding 30mm overlap to each end and cut to length.

8. Drill 6mm holes along front pillar outer panel flangesfor attachment to other panels.

9. Install the front pillar outer panel in place.




BEDBP6315C

BEDBP6320

BEDBP6309A

BEDBP6309B

BEDBP6309C



14. Reattach the cut away front pillar outer panel section,then MIG plug weld all holes and MIG butt weld seams.

15. Clean all welds with a disc grinder.


17. Apply the two-part epoxy primer to the interior of thefront pillar.

BEDBP6309D

BEDBP6321A

BEDBP6321B

BEDBP6321C


18. Before welding the cowl side upper outer panel, applythe two part epoxy primer and anti-corrosion agent tothe interior of the fender apron panel.

19. Install the cowl side upper outer panel in place.


21. Clean and prepare all welds, remove all residue.

22. Apply an anti-corrosion agent to the welded parts andinside of front pillar (Refer to the CORROSIONPROTECTION).

23. Prepare exterior surfaces for priming, using wax andgrease remover.




27. Apply the correct seam sealer to all joints carefully(Refer to the BODY SEALING LOCATIONS).

28. Reprime over the seam sealer to complete the repair.

BEDBP6303A

BEDBP6303B

BEDBP6302

BEDBP6312


SIDE SILL PANEL

REMOVAL

1. Measure and mark the horizontal cutline on front pillarouter panel 50mm from the door hinge mounting holeas indicated in the illustration.

BEDBP6401

WELDING POINTS


70mm

50mm

50mm

BEDBP6401A

50mm

2. Measure and mark the horizontal cutline on center pillarouter panel 70mm from the door hinge mounting hole.

3. Measure and mark the vertical cutline on rear side sillouter panel 50mm from the rear door step trim mountinghole as indicated in the illustration.

BEDBP6401B

70mm

50mm




4. Cut the side sill outer panel along the cutlines.

When cutting the side sill outer panel, be careful not tocut mating flanges.

5. Drill out all spotwelds(79), attaching the side sill outerpanel.

6. Remove the side sill outer panel.

NOTE

BEDBP6401C

BEDBP6401D

BEDBP6402A

BEDBP6402B

BEDBP6402C


6. Clean and prepare all welds and remove all residue.

7. Apply body filler to the side sill outer seams.

8. Apply the two-part epoxy primer to the interior of theside sill.

9. Apply an anti-corrosion agent to welded parts andinterior of the side sill (Refer to the CORROSIONPROTECTION).

10. Prepare the exterior surfaces for priming, using waxand grease remover.




14. Apply the correct seam sealer to all joints (Refer tothe BODY SEALING LOCATIONS).

15. Reprime over the seam sealer.

INSTALLATION

1. Transcribe the cutlines to the new side sill outer panel,adding 30mm overlap to each end and cut to length.

2. Using service panel for replacement of side sill outerpanel, drill 6mm holes in overlap areas and along upperand lower flanges.

3. Fit and clamp the side sill outer reinforcement in place.



BEDBP6401E

BEDBP6401F

BEDBP6401G

BEDBP6401H

BEDBP6401I


CENTER PILLAR

BEDBP6508

WELDING POINTS A

100mm


100mm80mm100mm 20mm

CB

A

B C

100mm


REMOVAL

1. Before cutting center pillar, be sure to support roofpanel.

2. Measure and mark the horizontal cutlines on centerpillar 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 tocut through mating flanges or center pillar outerreinforcement.

4. Drill out all spotwelds(5), attaching the center pillar outerpanel.

BEDBP6501

BEDBP6502

100mm

100mm

NOTE

BEDBP6502A

BEDBP6502B


5. Remove the center pillar outer panel.

6. Measure and mark the horizontal cutlines on centerpillar outer reinforcement as indicated in the illustration.

7. Cut the center pillar outer reinforcement along thecutlines.

When cutting center pillar outer reinforcement, takecare not to cut through mating flanges or rear doorhinge mounting upper reinforcement.

8. Drill out all spotwelds(3), attaching the center pillar outerreinforcement.

NOTE

BEDBP6503

BEDBP6503A

40mm

130mm

BEDBP6503B

BEDBP6503C


9. Remove the center pillar outer reinforcement.

10. Measure and mark the horizontal cutline on rear doorhinge mounting upper reinforcement as indicated inthe illustration.

11. Cut the rear door hinge mounting upper reinforcementalong the cutline.

When cutting rear door hinge mounting upperreinforcement, take care not to cut through matingflanges.

12. Measure and mark the vertical cutlines on front sidesill outer panel 80mm and 180mm from the front doorstep trim mounting hole.

NOTE

BEDBP6504

BEDBP6504A

150mm

BEDBP6504B

BEDBP6505

80mm 100mm


13. Cut the front side sill outer panel along the cutlines.

When cutting the front side sill outer panel, take carenot to cut through mating flanges or side sill outerreinforcement.

14. Drill out all spotwelds (5) attaching the front side sillouter panel.

15. Remove the front side sill outer panel.

16. Measure and mark the vertical cutlines on front sidesill outer reinforcement as indicated in the illustration.

NOTE

BEDBP6505A

BEDBP6505B

BEDBP6506

BEDBP6506A

110mm 50mm


19. Remove the front side sill outer reinforcement.

20. Measure and mark the vertical cutline on side sill innerreinforcement as indicated in the illustration.

17. Cut the front side sill outer reinforcement cutlines.

When cutting front side sill reinforcement, take carenot to cut through mating flanges.

18. Drill out all spotwelds(3), attaching the front side sillouter reinforcement.

NOTE

BEDBP6506B

BEDBP6506C

BEDBP6507

BEDBP6507A

130mm


21. Cut the front side sill inner reinforcement along the cutline.

22. Measure and mark the vertical cutlines on rear sidesill outer panel 20mm and 120mm from the rear doorstep trim mounting hole.

23. Cut the rear side sill outer panel along the cutlines.

When cutting rear side sill outer panel, take care notto cut through mating flanges or side sill outerreinforcement.

24. Drill out all spotwelds (5) attaching the rear side sillouter panel.

BEDBP6507B

BEDBP6508A

100mm 20mm

NOTE

BEDBP6508B

BEDBP6508C


25. Remove the rear side sill outer panel.

26. Measure and mark the cutline on side sill outerreinforcement as indicated in the illustration.

27. Cut the rear side sill outer reinforcement along thecutline.

When cutting rear side sill outer reinforcement, takecare not to cut through mating flanges.

28. Drill out all spotwelds (77) attaching the center pillarouter panel.

BEDBP6509

BEDBP6509A

70mm

NOTE

BEDBP6509AB

BEDBP6510

BEDBP6509C


29. Remove the center pillar outer panel.

30. Remove MIG lap welds (3) and spotwelds (13) attachingthe center pillar inner panel to side sill inner panel.

BEDBP6511

BEDBP6512

BEDBP6513

31. Remove the center pillar inner panel.


BEDBP6514

BEDBP6514A



BEDBP6514B

INSTALLATION

1. Fit and clamp the new center pillar inner panel in placefor welding.


BEDBP6516

BEDBP6511A





6. Transcribe 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 center pillarouter panel flanges.

8. Fit and clamp the new center pillar outer panel in placefor welding.


10. Check the fit of the front and rear doors.

11. Reinstall center pillar outer panel.

12. Apply body filler to the outer center pillar seam. Sandand finish.

BEDBP6513A

BEDBP6513B

BEDBP6511B

BEDBP6517

BEDBP6510A


16. Reattach the cut away center pillar outer panel section,then MIG plug weld all holes and MIG butt weld seams.

17. Clean all welds with a disc grinder.




BEDBP6510B

BEDBP6510C

BEDBP6510D

BEDBP6501A

BEDBP6501B


18. Apply the two-part epoxy primer to the interior of thecenter pillar.

19. Apply an anti-corrosion agent to the welded parts andinterior of the center pillar (Refer to the CORROSIONPROTECTION).





24. Apply the correct seam sealer to all joints carefully(Refer to the BODY SEALING LOCATIONS).

BEDBP6513C

BEDBP6513D


QUARTER PANEL

BEDBP6601

WELDING POINTS


80mm

80mm

70mm


REMOVAL

1. Depending on the extent of damage, measure and markcutlines on the quarter outer panel as indicated in theillustration.

2. Cut the quarter outer panel along the cutlines andremove the quarter outer panel as illustration.

When cutting the quarter outer panel, be careful not tocut quarter inner panel.

BEDBP6603

80mm

80mm

BEDBP6602

70mm

NOTE

BEDBP6601A

REMOVAL

1. Depending on the extent of damage, measure and markcutlines on the quarter outer panel as indicated in theillustration.

2. Cut the quarter outer panel along the cutlines andremove the quarter outer panel as illustration.

When cutting the quarter outer panel, be careful not tocut quarter inner panel.

3. Drill out all attaching spotwelds(81) on the quarter outerpanel, including the seam around the door lip opening.

BEDBP6606

BEDBP6604

BEDBP6605




4. Remove the quarter outer panel.


BEDBP6607

BEDBP6607A

BEDBP6607B




INSTALLATION

1. Transcribe the cutlines to the new quarter outer panel,adding 30 mm overlap each end.

2. Drill 6 mm holes in overlap areas and along upper andlower flanges of the new quarter outer panel for MIGplug welding.

3. Apply body filler to the welded seam. Sand and finish.Apply the two-part epoxy primer to the interior of thequarter outer panel.

4. Fit and clamp the quarter outer panel in place.


BEDBP6608

BEDBP6601B

BEDBP6601C

BEDBP6601D


8. Apply an anti-corrosion agent to the welded parts andinterior of the quarter outer panel (Refer to theCORROSION PROTECTION).





13. Apply the correct seam sealers to all joints.


15. In order to improve corrosion resistance, if necessary,apply an under body anti-corrosion agent to the wheelwell (Refer to the CORROSION PROTECTION).

BEDBP6601E

BEDBP6604A

BEDBP6601F


BACK COMPLETE PANRL ASSEMBLY AND REAR FLOOR SIDE MEMBER

BEDBP6705

WELDING POINTS


140mm


REMOVAL

Because the rear floor side members are designed toabsorb energy during a rear collision, care must beused when deciding to use this repair method. Thisrepair is recommended only for moderate damage tothe vehicle, where distortions do not extend forward ofthe trunk region. If the damage is more severe, thenthe entire side member assembly should be replacedat the factory seams without employing this sectioningprocedure.

The following procedure applys when only one rear floorside member needs to be replaced. If both sidemembers are damaged and need to be replaced, thenthe procedure of rear floor side members and rearfloor section should be followed.

Refer to the body dimension charts and measure thevehicle to determine straightening and alignmentrequirements.The body must be returned to its original dimensionsbefore beginning the repair procedure.

1. Drill out all the spotwelds(43) attaching the rearcombination lamp housing panel.

2. Remove the rear combination lamp housing panel.

3. Drill out all the spotwelds(86) attaching the backcomplete panel assembly.

NOTE

BEDBP6701

BEDBP6702

BEDBP6702A

BEDBP6703


4. Remove the back complete panel assembly.

5. Depending on the extent of damage, measure and markcutline on the rear floor side member as indicated inthe illustration.

6. Cut rear floor side member along the cutline.

7. Drill out all spotwelds(20) and MIG lap welds(1),attaching the rear floor side member to rear floor panel.

8. Remove the rear floor side member.

BEDBP6704

BEDBP6705A

140mm

BEDBP6705B

BEDBP6706

BEDBP6707





INSTALLATION

1. Transcribe 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 forMIG plug welding.

3. Fit and clamp the rear floor side member in place.


BEDBP6707A

BEDBP6707B

BEDBP6708

BEDBP6705C




BEDBP6706A

BEDBP6706B


8. Fit and clamp the new back complete panel assemblyin place.


BEDBP6706C

BEDBP6709

BEDBP6702B





BEDBP6702C

BEDBP6702D

BEDBP6702E

13. Fit and clamp the new rear combination lamp housingpanel assembly in place.


BEDBP6710

BEDBP6701A




17. Apply the two-part epoxy primer to the interior of therear floor side member.

18. Apply an anti-corrosion to the interior of the rear floorside member (Refer to the CORROSIONPROTECTION).





23. Apply the correct seam sealer to all joints (Refer tothe BODY SEALING LOCATIONS).

BEDBP6701B

BEDBP6701C

BEDBP6701D

BEDBP6701E


24 Reprime over the seam sealer to complete the repair

25 After completing body repairs, carefully apply Undercoating to the Under body (Refer to the CORROSIONPROTECTION).

26 In order to improve corrosion resistance, if necessary,apply an Under body anti-corrosion agent to the panelwhich is repaired or replaced (Refer to the CORROSIONPROTECTION).

BEDBP6705D

BEDBP6705E


FRONT AND REAR DOOR OUTER PANELS

WELDING POINTS



CON-0750

CON-0800

FRONT DOOR

REAR DOOR


REMOVAL

1. Cut door outer panel hem with a sander.

2. After grinding off the hemming location, remove theouter panel.

3. Dress rusty part with a sander and prepare surface tobe hemmed.

INSTALLATION

1. Apply adhesive or equivalent to outer panel hem.

2. Apply mastic sealer or equivalent to the door uppermember and door reinforcement beam as shown inthe figure.

PRO-1831

PRO-1840

PRO-1771

PRO-1860


3. Bend the flange hem with a hammer and dolly, thenfasten tightly with a hemming tool.

Hemming work should be done in three steps asillustration.If a hemming tool cannot be used, hem with a hammerand dolly.

NOTE

4. After completing the hemming work, make MIG spotwelds at 50 mm intervals on the inside.


6. Apply the two-part epoxy primer to the interior of thedoor panel.

7. Apply an anti-corrosion agent to the welded parts andlower inside of the door panel (Refer to theCORROSION PROTECTION).





PRO-1870

PRO-1880

PRO-1900

PRO-2000

PRO-2010


12. Apply the correct seam sealer to whole panel edge.


PRO-2021

Body SealingLocations

BS

FLOOR ..............................................................BS - 2

UPPER BODY AND SIDE BODY ............ BS - 5

UNDER BODY .................................................BS - 9

HOOD ..............................................................BS - 10

TAIL GATE ........................................................BS - 11

DOOR ..............................................................BS - 12

BS-2 BODY SEALING LOCATIONS

FLOOR

BEDBS6306

BEDBS6001

BEDBS6302BEDBS6301

A B

C D

BEDBS6303

L L M M

C

A

B

I K

D G

F

EH

J

BODY SEALING LOCATIONS BS-3

BEDBS6307

BEDBS6311

BEDBS6309 BEDBS6310

BEDBS6308

E F

G H

I J

K

BEDBS6305BEDBS6304


BEDBS6004

BEDBS6003

Cowl top outer panel

Cowl inner lower panel

Dash panel

Dash lower center reinforcement

Dash lower center reinforcement

Center floor panel

Rear floor front fillerCenter floor reinforcement

Rear floor front cross member reinforcement

Fuel tank mounting bracket

Rear floor front cross member

Rear floor front panel

Rear floor front extension

Center floor panel

Center floor reinforcement

Muffler hanger mounting bracket

L - L

M - M


UPPER BODY AND SIDE BODY

BEDBS6103

BEDBS6006

BEDBS6102

A B

A

C

B

F

ED

H

IGK

J

L

L

M

M

S

S

R

R

P PQ Q

T

T


BEDBS6205

BEDBS6402BEDBS6203

BEDBS6201 BEDBS6202

BEDBS6204

C D

E F

G H

I J

BEDBS6206BEDBS6101


BEDBS6008

BEDBS6011BEDBS6012

BEDBS6010

BEDBS6009

K

BEDBS6007BEDBS6401

L - L

M - M N - N

O - O P - P

Q - Q

Side outer panel

Side outer panel


Rear bumper mounting reinforcement

Back panel

Side outer rear extension

Back panel

Rear floor panel

Front side outer member

Dash panel

Front inner lower pillar

O

O

N N


BEDBS6014

BEDBS6015

BEDBS6013

S - SR - R

T - T

Side outer panel

Fender apron upper inner panel Shock absorber housing cover

Fender apron upper outer panel

Shock absorber housing panel


Front side inner member

Quarter inner lower panel


Side outer panel


UNDER BODY

BEDBS6502

BEDBS6002

BEDBS6501

A B

A B


HOOD

BEDBS6020

BEDBS6016

BEDBS6018BEDBS6017

BEDBS6019

A

A

B

B

X

Y

1.5 mm

5 mm+2-1

A - A B - B

YX

1.5 mm

5 m

m+2

-1


TAIL GATE

BEDBS6024

BEDBS6021

BEDBS6022

Z

BEDBS6023

A

A

B

B

Z

A - A B - B

2.5

mm

5mm


BEDBS6029

BEDBS6025

BEDBS6027BEDBS6026

BEDBS6028

V

94

5 m

m+ _

A - A B - B

C - CV

EC

C

C

C

E

G1, G2

H1, H2

E

T

V

E

F1, F2

D1, D2A A

B

B

Rear door front frame

Rear door rear frame

Front door rear frame

DOOR


BEDBS6032

BEDBS6037BEDBS6036

BEDBS6034 BEDBS6035

BEDBS6033

T D1

E

BEDBS6031 BEDBS6030

D2

F1 F2

G2G1

Front door inner panel

Front door outer panel

Front door frame assembly




Rear door outer panel

Rear door frame assembly

Front door inner panel


Rrar door frame assembly

Rear door inner panel


1.5 mm

5 m

m


H2H1

BEDBS6039 BEDBS6038


Rear door inner panel

Rear doorouter panel


Rear door outer panel

Corrosionprotection

CP

ZINC-PHOSPHATE COAT & CATIONICELECTRODEPOSITION PRIMER ........... CP - 2

ANTIVIBRATION PADS-LOCATION& SECTION ...................................................... CP - 3

ATTACHMENT OF ANTIVIBRATIONPADS ..............................................................CP - 6

UNDER BODY & SIDE BODY COAT ..... CP - 7

CAVITY WAX INJECTION ........................... CP - 11

HOOD ..............................................................CP - 12

TAIL GATE ........................................................CP - 13

FRONT DOOR & REAR DOOR ............... CP - 14

UNDER BODY ANTI-CORROSIONAGENT ..............................................................CP - 15

CP-2 CORROSION PROTECTION

ZINC-PHOSPHATE COAT & CATIONIC ELECTRODEPOSITION PRIMERIn order to improve the adhesion of the paint coat on the steel panel, and also to improve the corrosion resistance, the entirebody is coated with a film of Zinc-phosphate and a cationic electrodeposition primer.

BMCCP6020

Cationic electrodeposition primer

Zinc-phosphate film

Body steel panel

CORROSION PROTECTION CP-3

ANTIVIBRATION PADS-LOCATION & SECTION

BEDCP6002

[ Wagon ]

[ 3 Door / 5 Door ]

Under body coating (Thickness : 0.8 mm , :1.0 mm )

Y

X

I

I

H H

G GK K

F

F

E

E

D

D

C

C

A A

B B

J J

[ Y ]

LHD

RHD

17mm

12mm

[ X ]

Front

Front

21mm

14mm


BEDCP6007

BEDCP6005

BEDCP6006

BEDCP6004BEDCP6003

B - B

C - C

A - A

D - D

E - E

Dash panel

Dash panel

Center floor panel

Center floor panel

Center floor side memberCenter floor panel

Rear seat inner mounting bracket

24mm

25mm


BEDBC6307

BEDBC6308 BEDBC6309

BEDBC6306BEDBC6305

BEDCP6008

F - F

G - G H - H

I - I

J - J K - K

Rear floor front panel

Center floor panelCenter floor side member

Front seat mounting member

Spare tire mounting bracket

Rear floor rear panel

Rear floor side member


Cowl inner lower panel

Cowl top outer panel

82mm

22mm 33mm

36mm

9mm


1. Heat the "antivibration pad" with a blow drier to softenit.

2. Align the antivibration pad layer in the position whereit is to be installed, and then press it down with a rolleror a block of wood so that it adheres well.

NOTEAn infrared lamp can also be used to heat both theantivibration pad layer and the body panels(be sure towear gloves).

BMCCP6041

BMCCP6042

ATTACHMENT OF ANTIVIBRATION PADSAntivibration pads are attached to the upper surface of the floor and at the interior side of the dash panel in order to absorbvibrations and shut out exhaust gas heat. If these antivibration pads are peeled off in the course of replacement or repair ofa welded panel, cut and attach replacement material (in the shape shown in the figure).

BEDCP6001


UNDER BODY & SIDE BODY COATIn order to provide corrosion, stone chipping and vibration resistance, under body coat is applied to the under sides of thefloor and wheel house.Therefore, when such panel is replaced or repaired, apply under body coat to that part.


BEDCP6102

D

D

F

F

G

G

A

A

C C

B B

E E

YX


BEDCP6107

BEDCP6104

BEDCP6105BEDCP6103

BEDCP6106

Fender apron upper inner panel

Fender apron upperouter panel

Shock absorberhousing cover

Shock absorberhousing lowerpanel

Front side inner member


Sub frame mounting rear support

Sub frame mounting rear reinforcement

Sub frame mounting rear bracket

Side outer rear extension

Tie down frontreinforcement


Center floor panel

Side sill inner panel

Side outer panel

Rear floorcenter cross member

Fuel tank mounting rear bracket


A - A B - B

C - C

D - D

E - E20mm

70mm


BEDCP6109BEDCP6108

BEDCP6110 BEDCP6111

F - F G - G

YX

Y

BEDCP6112

Side outer panel

Wheel house inner panel

Rear suspension mounting bracket

Quarter inner upper panel

Side outer panel




Rear floor panel

Rear floor side member


[ Wagon ]

[ 3 Door / 5 Door ]


BEDCP6114

BEDCP6113


Rear floorcenter cross member

H - H

70 mm

20 mm

H H

[ Wagon ]


CAVITY WAX INJECTIONIn order to provide greater corrosion resistance, cavity wax injection has been performed for the lower areas of the vehicle,such as the sidemember, the side sill and the inside of other panels which are a hollow construction.When replacing these parts, be such to apply cavity wax to the appropriate areas of the new parts.

BEDCP6202

BEDCP6021

Side outer panel

Side sill outerreinforcement

Side sill inner panel

A - A

40 mm

A

A

16 mm

25 mm

SIDE BODY


BEDCP6205

BEDCP6203

BEDCP6204

Wax injection holes

Wax injection holes

Wax injection holes

Cowl side upper panel

Hood hinge assembly

B - B C - C

200mm 200mm

250mm 250mm

300mm

30m

m

30m

m

300mm

B

B

C

C

HOOD


TAIL GATE

BEDCP6207

BEDCP6206

Side outer panel

Tail gate outer panel

Tail gate inner panel

D - D

D

D

150 mm

30 mm

30 mm


BEDCP6210

BEDCP6208

BEDCP6209

Wax injection holes

E - E F

80 m

m

130 mm130 mm

100 mm

80 m

m

E

E

E

E

F

30 m

m

FRONT DOOR & REAR DOOR



BEDCP6102A

UNDER BODY ANTI-CORROSION AGENTThe undersides of the floor and wheel house are undercoated to provide greater corrosion resistance. Therefore, when suchpanel is replaced or repaired, apply under body anti-corrosion agent to that part.

NOTEDo not apply the under body anti-corrosion agent to come in contact with tires, muffler and exhaust pipe.

Body ModificationTools

BT

MODIFICATION TOOLS .............................. BT - 2

CUT AND DISASSEMBLY TOOLS ......... BT - 3

ASSEMBLY TOOLS ....................................... BT - 4

MEASUREMENT TOOLS ............................ BT - 4

WELDING MACHINE .................................... BT - 5

BUFFING AND GRINDING TOOLS ........BT - 6

HANDHELD TOOLS .....................................BT - 8

REPAIR TOOLS SET .................................... BT - 9

BT-2 BODY MODIFICATION TOOLS

Frame straightener

Port power

Body puller

Modify twisted or bent body

Push out, stretch, pull in damaged area

Stretch damaged area

BODY MODIFICATION TOOLS

MODIFICATION TOOLS

A3EB3501

A3EB3502

A3EB3503

A3EB3504

A3EB3505

Name Used for Figure

BODY MODIFICATION 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 DISASSEMBLY TOOLS


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 welding area, to

finish a hole

A3EB3506

A3EB3507

A3EB3508

A3EB3509

A3EB3510

A3EB3511


ASSEMBLY TOOLS

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


Finish contact area of flange and finish

a hole for plug welding

MEASUREMENT TOOLS

Centering gauge

Tracking gauge

Measure distortion of body and frame

Measure body and frame


A3EB3512

A3EB3513

A3EB3514

A3EB3515

A3EB3516

A3EB3517


Gas welding machine

Spot welding machine

Stud welding machine

Cut a panel

Weld a panel

Weld a panel

A3EB3518

A3EB3519

A3EB3520

A3EB3521


WELDING MACHINE

Carbon arc welding

machine

Stretch a panel, weld a stud bolt to fix

front window mold clip


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 TOOLS


Grind rough area of puttee assembled

area

A3EB3522

A3EB3523

A3EB3524

A3EB3525

A3EB3526

A3EB3527

Grind rough area of puttee assembled

area


Orbital sander(long)

Flexible file

Surform tool

Hand file

Used for puttee grinding of wide area

Buff rough area of puttee area

Grind body puttee, pulley, finish puttee


A3EB3528

A3EB3529

A3EB3531

Grind touch up area, uneven area of a

panel

A3EB3530


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 TOOLS


Punch a hole in the middle of a spot

welding area

A3EB3532

A3EB3533

A3EB3534

A3EB3535

A3EB3536

A3EB3537

Used for an area where not reached by

hand


Body chisel

Wire brush


A3EB3538

A3EB3539

Remove paints, rust, slag on welded

area which are hard to recognize

Window tool set Repair window collar

Repair plastic parts


A3EB3540

A3EB3541

Bend rough body line damaged or sheet

metal etc.

REPAIR TOOLS SET

Repair tool set for

plastics

Plastic Parts

PP

POLYPROPYLENE(PP) BUMPERREPAIRABILITY ............................................. PP - 2

BUMPER REPAIR PROCEDURE ...................PP - 3REPAIR METHOD FOR PP BUMPER .............PP - 4

PP-2 PLASTIC PARTS

POLYPROPYLENE(PP) BUMPER

REPAIRABILITYThe three types of damaged bumpers shown below can berepaired. Because of cost and quality considerations,bumpers with more damage may be repaired, but replacingthe 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 4 in.(100 mm).

3. If a crack on bumper sectionis [A] is less than 4 in.(100 mm) (less than half of the bumper height).

A3EB3601

A3EB3602

Bumper height Crack on section [A]

A3EB3603

PLASTIC PARTS PP-3

BUMPER REPAIR PROCEDURE

Remove paint.

Sand damaged area smooth.

Apply aluminum tape on the rear side of bumper.

Weld damaged area.

Sand damaged area with a rough sandpaper.

Clean and degrease damaged area(use TCE de-oil material).

Apply primer for polypropylene over damaged area.

Apply solvent over damaged area.

Spray primer surface over bumper and let dry.

Sand surface of bumper with sandpaper.

Clean and degrease with TCE de-oil material.

Wipe the surface of bumper with a tack cloth.

Paint bumper with a paint of the same color and let dry.

Surface ofbumper is not

visible.

Surface ofbumper isvisible.

Replace damaged bumper with a new bumper.Apply primer for polypropylene over bumper surface.

VQPP001

PP-4 PLASTIC PARTS

REPAIR METHOD FOR PP BUMPER

Damage to the bumper that reaches the surface of the polyporpylene cannot be fixed just by painting. Use the repair methodsshown 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' Section D-D'Section B-B'Section C-C'

Crack Scar

421

DD

D'D'

3

1

2

3

4

Upper layer (coating)Primer layer

Primer surface layerPolypropylene layer

VQPP002

CC

C'C'

BB

B'B'

AA

A'A'

Surface of polypropylene

A-A'B-B'C-C'

Angle of 45 is required for accumulation of polypropylene welding rod.

VQPP003

Cut with a knife. SectionSection D-D'Cut with knife.

Make an angle with a sander.

45

Make an angle with a sander

PLASTIC PARTS PP-5

2. Welding damaged areaa) To repair cracked area, melt the area using a heat gun and attachment.

b) To repair a hole, remove 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.

NOTE• Heat and melt the area indicated.• Melt the welding rod carefully so that it does not over-melt. If the welding rod over-melts like jelly, the welding

strength will deteriorate.• Use the heat gun 0.4~0.8 in.(10~20 mm) away from the repair area to be welded.

Welding rod should not move until the welded area is cooled.

Heat gun

Apply on surface

Surface of polypropylene Section view after melt

Melt the surface using a heat gun.

VQPP004

Remove oil.Section A-A’

Apply aluminum tape on the rear side of the damaged area.

VQPP005

Melt here

Polypropylenewelding rod

Melt here.Polypropylenewelding rod

A-A’B-B’C-C’

Section

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Polypropylene welding rod

Tape Plane view

Section A-A’ Polypropylene welding rod

Surface ofpolypropylene

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PP-6 PLASTIC PARTS

4. Grind polypropylene surface carefully. It melts easily due to the heat generated 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. Mix main filler material and hardener at a ratio depending on paint specifications. Mix filler material and apply over thedamaged area.

NOTE• Mix main filler material and hardener so that no bubbles are made.• Work immediately after mixing filler material because the filler material hardens quickly(in about 5 minutes).• Dry it at 20 C (68 F) for about 30 minutes before sanding.

• Filler material consists of two types of epoxy.When the filler material hardens, you will have a desirable finish with flexibility like polypropylene.

• Use only filler material designed for use on polypropylene bumpers.

Do not grind continuously.Area to apply solvent

Paint

Grind painted area and rough surface.VQPP008

Apply primer wider than the area to repair.

Polypropylene primer

VQPP009

Filler material

Weld Surface of polypropylene

Do not allow bubbles to be created.

VQPP010

PLASTIC PARTS PP-7

7. Sand the damaged area with sandpaper using #180~#240 grit paper.

NOTE• 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 ratio depending on paint specifications.Spray polypropylene primer on the surface of the damaged area and the bumper.

10. Apply polypropylene primer.

NOTEUse only water to clean after applying polypropylene primer. Solvent, if used, will melt the primer.

11. Lightly sand the sprayed area using a primer a sandpaper(#400~#600).The polypropylene surface should not be exposed.(Either wet sanding or dry sanding is all right.)

12. Use agent(TCE(Tri Chloro Ethane) degreasing material) to remove any grease or oil, and wipe the finished surface of thebumper quickly with a clean cloth.

NOTE• The painting method for the polypropylene bumper is the same used to paint the urethane bumper.• Therefore, use urethane primer only on urethane bumpers and polypropylene primer on polypropylene bumpers.

13. Air dry at 20 C(68 F) for about 8 hours, or dry in 60 C(140 F) for about 2 hours.(Since drying time varies according to the type of paint used, follow paint manufacturers directions for drying times.)

NOTEAir dry if possible. Forced drying may create air bubbles on the top layer.

VQPP011

Use the primer within 16 hours after it is mixed.

Polypropylene primer Primer hardener

VQPP012

7. Sand the damaged area with sandpaper using #180~#240 grit paper.

NOTE• 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 ratio depending on paint specifications.Spray polypropylene primer on the surface of the damaged area and the bumper.

10. Apply polypropylene primer.

NOTEUse only water to clean after applying polypropylene primer. Solvent, if used, will melt the primer.

11. Lightly sand the sprayed area using a primer a sandpaper(#400~#600).The polypropylene surface should not be exposed.(Either wet sanding or dry sanding is all right.)

12. Use agent(TCE(Tri Chloro Ethane) degreasing material) to remove any grease or oil, and wipe the finished surface of thebumper quickly with a clean cloth.

NOTE• The painting method for the polypropylene bumper is the same used to paint the urethane bumper.• Therefore, use urethane primer only on urethane bumpers and polypropylene primer on polypropylene bumpers.

13. Air dry at 20 C(68 F) for about 8 hours, or dry in 60 C(140 F) for about 2 hours.(Since drying time varies according to the type of paint used, follow paint manufacturers directions for drying times.)

NOTEAir dry if possible. Forced drying may create air bubbles on the top layer.

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