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RE-1

BODY PANEL
REPLACEMENT
Page
RADIATOR 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 RENFORCEMENT
BRACE (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

RE

RE-2

BODY PANEL REPLACEMENT

RADIATOR UPPER SUPPORT (ASSY)


REMOVAL

BODY PANEL REPLACEMENT

RE-3

INSTALLATION

2
1

1.

Temporarily install the new parts and measure each part in accordance with the body dimension diagram.

HINT: First install the hood lock support.

RE-4

BODY PANEL REPLACEMENT

RADIATOR SIDE SUPPORT (ASSY)


REMOVAL (With the radiator upper support removed.)

Radiator Side Support

RH:
LH:

Radiator Support to
Front Fender Bracket

Radiator Side
Lower Support
4

1.

Replace the radiator side support, radiator


side lower support and radiator support to
front fender bracket at the same time.

6
5

BODY PANEL REPLACEMENT

RE-5

INSTALLATION

RH:
LH:

8
7

6
[LH Side]
[RH Side]
3
4

Radiator Support to
Front Fender Bracket

1.

Temporarily install the new parts and measure each part in accordance with the body dimension diagram.

HINT: First install the radiator upper support.

Radiator Support
to Front Fender
Bracket

RE-6

BODY PANEL REPLACEMENT

RADIATOR SUPPORT UPPER BRACE (ASSY)


REMOVAL (With the radiator upper support removed.)

BODY PANEL REPLACEMENT

RE-7

INSTALLATION

1.

Temporarily install the new parts and measure each part in accordance with the body dimension diagram.

HINT: First install the radiator upper support.

RE-8

BODY PANEL REPLACEMENT

FRONT CROSSMEMBER (ASSY)


REMOVAL

3
1

3
4

BODY PANEL REPLACEMENT

RE-9

INSTALLATION

1
2

2
2

1.

Temporarily install the new parts and measure each part in accordance with the body dimension diagram.

HINT: First install the hood lock support.

RE-10

BODY PANEL REPLACEMENT

RADIATOR SUPPORT (ASSY)


REMOVAL

5
3

RH:
LH:

10
9

BODY PANEL REPLACEMENT

RE-11

INSTALLATION

3
5

RH:
LH:

1.

Temporarily install the new parts and measure each part in accordance with the body dimension diagram.

13
12

RE-12

BODY PANEL REPLACEMENT

FRONT FENDER FRONT APRON (ASSY)


REMOVAL (With the radiator side support removed.)
7

BODY PANEL REPLACEMENT

RE-13

INSTALLATION
10

1.

Temporarily install the new parts and measure each part in accordance with the body dimension diagram.

RE-14

BODY PANEL REPLACEMENT

FRONT APRON TO COWL SIDE UPPER


MEMBER (ASSY)
REMOVAL (With the front fender front apron, front panel
upper reinforcement brace removed.)
3

10

BODY PANEL REPLACEMENT

RE-15

INSTALLATION
4

3
4

10

1.

Temporarily install the new parts and measure each part in accordance with the body dimension diagram.

2.

Temporarily install the front fender and hood


and check the fit.

RE-16

BODY PANEL REPLACEMENT

FRONT FENDER APRON (ASSY)


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

6
8

13

BODY PANEL REPLACEMENT

RE-17

INSTALLATION

6
8

13

1.

Temporarily install the new parts and measure each part in accordance with the body dimension diagram.

2.

Measurements must be accurate with the


body dimension diagram, as this affects the
front wheel alignment.

3.

Temporarily install the front fender and hood,


and check the fit.

RE-18

BODY PANEL REPLACEMENT

FRONT PANEL UPPER RENFORCEMENT


BRACE (ASSY)
REMOVAL

10

Cut with
disc Sander, etc.

BODY PANEL REPLACEMENT

RE-19

INSTALLATION

Tack Weld
(30 mm each)

Tack Weld
(25 mm)

mm

in.

25
30

0.98
1.18

RE-20

BODY PANEL REPLACEMENT

FRONT SIDE MEMBER (CUT-P)


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

60 mm

RH:
LH:

Cut and Join Location


(Front Side Member)

RH:
LH:

[LH Only]
9

2
3

80 mm

6
4

Front Side
Member
Extension
2

Cut and Join Location


(Front Side Member Plate)

RH: 120 mm
LH: 100 mm

RH:
LH:

9
6
RH:
LH:

6
5

Battery Carrier
Support

1.

mm

in.

60
80
100
120

2.36
3.15
3.94
4.72

After removing the battery carrier support (LH


only), cut and join the parts at the locations as
shown above.

Cut and Join


Location

2.

Front Side Member


Reinforcement

Shift each cut and join location of the front


side member plate, front side member and
front side member reinforcement.

BODY PANEL REPLACEMENT

RE-21

INSTALLATION

Butt Weld
RH:
LH:

7
5

Front Side Member Plate

RH:
LH:

RH:
LH:

3
4

9
6

8
Front Bumper
Mounting
Reinforcement

Front Suspension
Member Mounting
Bracket

RH:
LH:

[LH Only]

Butt Weld

RH:
LH:

6
4
9
RH:
LH:

1.

6
5

Temporarily install the new parts and measure each part in accordance with the body dimension diagram.

Butt Weld

6
5

RE-22

BODY PANEL REPLACEMENT

FRONT SIDE MEMBER (ASSY)


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

12

6
1

11
8
Floor Side Member
No.1 Reinforcement

3
8
4

1.

Leave the floor side member No.1 reinforcement to the vehicle. Remove the front side
member.

2.

3
3

Replace the front side member extension at


the same time.

BODY PANEL REPLACEMENT

RE-23

INSTALLATION

RH:
LH:

6
4

Front Side
Member Extension

RH:
LH:

12

5
5

11

3
8
4

1.

Temporarily install the new parts and measure each part in accordance with the body dimension diagram.

HINT: Make sure each measurement is correct, as


this parts affects the front wheel alignment.

3
3

6
5

RE-24

BODY PANEL REPLACEMENT

FRONT BODY PILLAR (CUT)


REMOVAL (With the front panel upper reinforcement
brace removed.)

[Cut and Join Location]

Cut and Join Location


(Cut Location for
Supply Parts)

2
80 mm

[Cut and Join Location]

18
7
Cut and Join Location
(Cut Location for
Supply Parts)

40 mm
mm

in.

40
80

1.57
3.15

1.

Cut and join the parts at the locations as


shown above.

2.

Shift the each cut and join locations of the outer pillar and inner pillar.

Rocker Panel No.1


Reinforcement

3.

Shift the each cut and join locations of the outer panel and rocker panel No.1 reinforcement.

BODY PANEL REPLACEMENT

RE-25

Cut with disc


Sander, etc.

4.

Remove the remaining foamed material from


the vehicles side.

RE-26

BODY PANEL REPLACEMENT

INSTALLATION

Rocker Panel No.1 Reinforcement

270 mm

Outer Piller
Cut Location
16
Cut Location
3
13
80 mm

22
10
3
5
7
Outer Piller
6

Inner Piller
2
Rocker Panel No.1
Reinforcement

Reinforcement

1.

mm

in.

80
270

3.15
10.63

Cut the new parts for the outer pillar and rocker panel No.1 reinforcement at the locations
shown above.

HINT: After butt welding the rocker panel No.1 reinforcement attach it to the lower area of the outer
pillar.

2.

Before temporarily installing the new parts,


weld the outer pillar, reinforcement, inner pillar and rocker panel No.1 reinforcement with
standard points.

3.

Temporarily install the new parts and measure each part in accordance with the body dimension diagram.

BODY PANEL REPLACEMENT

RE-27

Tack Weld
(45 mm)
3

Butt Weld

A
2

AA
[Foamed Material
Application Areas]

1
1
2

BB
[Foamed Material
Application Areas]

12

Butt Weld

Butt Weld
15

B
8

7
B
4

12
Butt Weld

4.

Before welding the new parts, check the fit of


the front door, front fender and windshield
glass.

5.

mm

in.

45

1.77

Apply framed material to the pillar section.

RE-28
MEMO

BODY PANEL REPLACEMENT

BODY PANEL REPLACEMENT

RE-29

CENTER BODY PILLAR (CUT)


REMOVAL

Cut and Join


Location
(Cut Location
for Supply
Parts)

Cut and Join


Location
(Cut Location for
Supply Parts)
2

Cut and Join Location


(Cut Location for
Supply Parts)

410 mm

2
2

13

[Cut and Join Location]

11

Cut and Join Location

[Cut and Join Location]

[Cut and Join Location]

80 mm
50 mm

Rocker Panel No.1 Reinforcement

1.

Cut and join the parts at the locations as


shown above.

HINT:
1) Shift the each cut and join locations of the outer piller, inner piller and reinforcement.
2)

Shift the each cut and join locations of the outer piller and rocker panel No.1 reinforcement.

mm

in.

50
80
410

1.97
3.15
16.14

RE-30

BODY PANEL REPLACEMENT

INSTALLATION
Rocker Panel No.1 Reinforcement

580 mm
Cut Location

Rocker Panel No.3 Reinforcement


Rocker Panel No.1 Reinforcement

28

26

Center Body
Pillar
Reinforcement
Butt Weld

11

Inner Pillar
Butt Weld

3
mm

in.

580

22.83

1.

Cut the new parts for the rocker panel No.1 reinforcement 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 with
standard points.

12

3.

Temporarily install the new parts and measure 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 REPLACEMENT

AA
[Foamed Material
Application Areas]

RE-31

Butt Weld

40

41

1
A

2
Butt Weld

Butt Weld

21
Butt Weld

11

5.

After welding the inner pillar, center body pillar reinforcement and rocker panel No.1 reinforcement to the vehicle install the outer pillar.

6.

Apply framd material to the pillar section.

RE-32

BODY PANEL REPLACEMENT

FRONT DOOR OUTER PANEL (ASSY)


REMOVAL

Positioning Tape

Braze
Installation
Position

Braze

Hemming Location

Disc Sander

1.

Before removing the outer panel, make the


installation position with a tape.

2.

After grinding off the hemming location, remove the outer panel.

BODY PANEL REPLACEMENT

RE-33

INSTALLATION

Body Sealer

Positioning
Tape

Braze
Body Sealer

Braze

about 10 mm
Do not close the
drain hole.

Cloth Tape
Body Sealer

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 reinforcement 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.

mm

in.

10

0.39

Bend the flange hem about 30_ with a hemmer and dolly, then fasten tightly with a hemming tool.

HINT:
1) Perform hemming in three steps, being careful not to warp the panel.
2)

If a hemming tool cannot be used, hem with


a hammer and dolly.

RE-34

BODY PANEL REPLACEMENT

REAR DOOR OUTER PANEL (ASSY)


REMOVAL

Positioning
Tape
Installation
Position

Braze

Braze

Hemming Location

Disc Sander

1.

Before removing the outer panel, make the


installation position with a tape.

2.

After grinding off the hemming location, remove the outer panel.

BODY PANEL REPLACEMENT

RE-35

INSTALLATION

Body Sealer
Body Sealer

Positioning
Tape

Braze

Braze
about 10 mm
Do not close the
drain hole.

Cloth Tape
Body Sealer

30_

Hemming Tool

1.

Bofore 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 reinforcement 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.

mm

in.

10

0.39

Bend the flange hem about 30_ with a hemmer and dolly, then fasten tightly with a hemming tool.

HINT:
1) Perform hemming in three steps, being careful not to warp the panel.
2)

If a hemming tool cannot be used, hem with


a hammer and dolly.

RE-36

BODY PANEL REPLACEMENT

ROCKER OUTER PANEL (ASSY)


REMOVAL

Cut and Join Location

9
70 mm
16

2
Cut and Join Location
(Cut Location for
Supply Parts)

24

Cut and Join Location


(Cut Location for
Supply Parts)

[Cut and Join Location]

[Cut and Join Location]

1.

[Cut and Join Location]

mm

in.

70

2.76

Cut and join the parts at the locations as


shown above.

HINT: Take care not to damage the internal reinforcement of the center body pillar.

2.

Remove the remaining foamed material from


the vehicles side.

BODY PANEL REPLACEMENT

RE-37

INSTALLATION

AA
[Foamed Material
Application Areas]

Butt Weld

12

21

2
Butt Weld
Butt Weld

1.

32

Temporarily install the new parts and check


the fit of the front door and rear door.

2.

After installing the new parts, apply foamed


materials.

RE-38

BODY PANEL REPLACEMENT

QUARTER PANEL (CUT)


REMOVAL

Cut and Join


Location
Cut and Join
Location

22

Fuel Filler
Opening Lid
27

[Cut and Join Location]

9
21
140 mm
10
Cut and Join Location
(Cut Location for Supply Parts)

[Cut and Join Location]

145 mm

1.

mm

in.

140
145

5.51
5.71

Cut and join the parts at the locations as


shown above.

2.

Replace the fuel filler opening lid at the same


time as the quarter panel.

BODY PANEL REPLACEMENT

RE-39

2.

Bend a part of the body lower back panel and


removed the quarter panel.

RE-40

BODY PANEL REPLACEMENT

INSTALATION

Butt Weld

A
AA
[Foamed Material
Application Areas]

Butt Weld

A
22

B
Body Sealer

B
36

12

28

Butt Weld

13

BB
[Foamed Material
Application Areas]
Body Sealer

about 5 mm

1.

mm

in.

0.20

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.

3)

For other sealing points, refer to section AR.

2.

Temporarily install the new parts and check


the fit of the rear door, back door and rear
combination light.

3.

After installing the new parts, apply foamed


materials.

BODY PANEL REPLACEMENT

RE-41

Fuel Filler
Opening Lid

2
Waterproof Rivet
7

4.

Attach the fuel filler opening lid by rivets to


the quarter panel.

HINT:
1) Use water proof rivets.
2)

Refer to the introduction when installation reivets.

RE-42

BODY PANEL REPLACEMENT

QUARTER PANEL (CUT-P)


REMOVAL

Cut and Join


Location

7
5
9

2
2

1.

Cut and join the part at the location as shown


above.

2.

Bend a part of the body lower back panel and


removed the quarter panel.

BODY PANEL REPLACEMENT

RE-43

INSTALLATION

Butt Weld

Body Sealer

7
7
2
11
2

Body Sealer

5
about 5 mm

1.

mm

in.

0.20

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.

3)

For other sealing points, refer to section AR.

2.

Temporarily install the new parts and check


the fit of the back door and rear combination
light.

RE-44

BODY PANEL REPLACEMENT

QUARTER WHEEL HOUSING OUTER PANEL


(ASSY): Right Side
REMOVAL (With the quarter panel removed.)
Cut and Join
Location

4
1

130 mm
6

10

2
18

Roof Side
Outer Panel

18

8
1

1.

Cut the roof side outer panel at the location


shown in the above figure and remove the
quarter wheel housing outer panel.

mm

in.

130

5.12

BODY PANEL REPLACEMENT

RE-45

INSTALLATION

Butt Weld

AA
[Foamed Material
Application Areas]

4
A

2
4
4

4
6

7
24

Assembly
Mark

24

8
1

1.

Determine the position of the new parts by the


assembly marks of the inner and outer panels.

2.

Before welding the new parts, temporarily


install the quarter panel and check the fit.

3.

After installing the new parts, apply foamed


materials.

RE-46

BODY PANEL REPLACEMENT

QUARTER WHEEL HOUSING OUTER PANEL


(ASSY): Left Side
REMOVAL (With the quarter panel removed.)
Cut and Join Location

2
130 mm
Roof Side
Outer Panel

7
3

2
6

18

8
12
1

1.

Cut the roof side outer panel at the location


shown in the above figure and remove the
quarter wheel housing outer panel.

mm

in.

130

5.12

BODY PANEL REPLACEMENT

RE-47

INSTALLATION
Butt Weld

A
AA
[Foamed Material
Application Areas]

4
3
5
2

24

Assembly
Mark

8
1

16

1.

Determine the position of the new parts by the


assembly marks of the inner and outer panels.

2.

Before welding the new parts, temporarily


install the quearter panel and check the fit.

3.

After installing the new parts, apply foamed


materials.

RE-48

BODY PANEL REPLACEMENT

BODY LOWER BACK PANEL (ASSY)


REMOVAL
2

3
5

19

10

BODY PANEL REPLACEMENT

RE-49

INSTALLATION
2

4
5

25

1.

10

Temporarily install the new parts and check


the fit of the back door.

RE-50

BODY PANEL REPLACEMENT

BACK DOOR OPENING TROUGH, REAR BODY


REAR SIDE CORNER PANEL (ASSY)
REMOVAL (With the quarter panel removed.)

Back Door
Opening Trough
Rear Body Rear
Side Corner Panel

2
1

10

2
2
1

1.

Replace the back door opening trough and


rear body rear side corner panel at the same
time.

BODY PANEL REPLACEMENT

RE-51

INSTALLATION

1
2

13
2
2

1.

Before welding the new parts, temporarily


install the quarter panel and check the fit.

RE-52

BODY PANEL REPLACEMENT

ROOF SIDE INNER REAR PANEL (ASSY)


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

Cut and Join Location


2
100 mm

1
10

1
1
Quarter Panel Upper
Rear Extension

10

1.

Cut the quarter panel upper rear extension at


the location shown in the above figure and remove the roof side inner rear panel.

mm

in.

100

3.94

BODY PANEL REPLACEMENT

RE-53

INSTALLATION

Butt Weld

1
1
13

1
1

13

RE-54

BODY PANEL REPLACEMENT

ROOF SIDE INNER LOWER PANEL, ROOF SIDE


INNER FRONT PANEL (ASSY)
REMOVAL (With the roof side inner rear panel, body
lower back panel removed.)

Roof Side Inner


Lower Panel

1
Quarter Inner
Panel Bracket
(LH only)
Roof Side Inner
Front Panel
6

1.

Replace the roof side inner lower panel, roof


side inner front panel and quarter inner panel
bracket (LH only) at the same time.

BODY PANEL REPLACEMENT

RE-55

INSTALLATION

3
6

[LH Only]
2

RE-56

BODY PANEL REPLACEMENT

REAR FLOOR CENTER CROSSMEMBER (ASSY)


REMOVAL
[LH Side]

[RH Side]

6
15

15

BODY PANEL REPLACEMENT

RE-57

INSTALLATION
[LH Side]

[RH Side]

6
4

15

6
6
15

RE-58

BODY PANEL REPLACEMENT

REAR FLOOR PAN (ASSY)


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

28

12

12

11

15

15

RH:
LH:

3
2

BODY PANEL REPLACEMENT

RE-59

INSTALLATION
Tack Weld
(Weld Bolt)

5
3

28

12

12

11

15

15

RH:
LH:

1.

Attach the weld bolt to the center of the bearing surface.

3
2

RE-60

BODY PANEL REPLACEMENT

REAR FLOOR SIDE PANEL (ASSY)


REMOVAL(With the rear floor pan removed.)

BODY PANEL REPLACEMENT

RE-61

INSTALLATION

RE-62

BODY PANEL REPLACEMENT

REAR FLOOR SIDE REAR MEMBER (ASSY)


REMOVAL (With the body lower back panel removed.)

RH Only:

RH Only:

12

BODY PANEL REPLACEMENT

RE-63

INSTALLATION

RH Only:

4
9

RH Only:

Assembly Mark

12

1.

When temporarily installing the new parts,


determine the installation position by the assembly mark, Then, measure each part in accordance with the body dimension diagram.

RE-64

BODY PANEL REPLACEMENT

REAR FLOOR NO.2 CROSSMEMBER (ASSY)


REMOVAL

3
4

15

BODY PANEL REPLACEMENT

RE-65

INSTALLATION

7
4

15

RE-66

BODY PANEL REPLACEMENT

ROOF PANEL (ASSY): w/o Moon Roof


REMOVAL

39

39

28

Braze
1
12

20

BODY PANEL REPLACEMENT

RE-67

INSTALLATION
Body Sealer

51

8
A

51

8
16
AA
[Foamed Material
Application Areas]
Braze
1
12

3
16
3

1.

Before temporarily installing the new parts,


apply body sealer to the windshied header
panel, roof panel reinforcement and back
door opening frame.

HINT:
1) Apply just enough sealer for new parts to
make contact.
2)

For other sealing points, refer to section AR.

2.

After installing the new parts, apply foamed


materials.

RE-68

BODY PANEL REPLACEMENT

ROOF PANEL (ASSY): w/ Moon Roof


REMOVAL
[If reusing the roof panel reinforcement]

Hemming Location

Disc Sander
36

12

36

28

12

Braze
1

20

BODY PANEL REPLACEMENT

RE-69

INSTALLATION
Body Sealer

47

8
A

16

47

8
16
AA
[Foamed Material
Application Areas]

Braze
1

12
Cloth Tape

3
16
3

1.

Before temporarily installing the new parts,


apply body sealer to the windshield header
panel, roof panel reinforcement and back
door 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.

Wooden Hammer

3.

Bend the flange hem with a wooden hammer


and dolly.

HINT: Perform hemming three steps, being careful not to warp the panel.

MEMO