FOREWORD This Body Repair Manual contains information, instructions and procedures for repairing the body structure of the TERRANO II (R20) model. In order to achieve reliable repair work and ensure customer satisfaction, the technician should study this manual and familiarize himself with appropriate sections before starting repair and rebuilding work It is especially important that the PRECAUTIONS section be read, understood and followed completely. This Body Repair Manual is prepared for use by technicians who are assumed to have a high level of skill and experience In repairing collision-damaged vehicles and also use modern servicing tools and equipment. It is not recommended that persons untamiliar with body repair techniques attempt to repair collision-damaged vehicles by using the manual Technicians are also required to read the TERRANO II (R20) Service Manual and Body Repair Manual (Fundamentals) in order to ensure that the original functions and quality of the vehicle can be maintained. Please note that these manuals are prepared far worldwide usage, so certain procedures might not apply in some regions or countries. All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice. NISSAN EUROPE N.V. © 199 NISSAN EUROPE N.V. Printed in The Netherlands [Not to be reproduced in whole or n part without the prior written permiasion of Nissan Europe N.V. ‘Amsterdam, The NetherlandsCONTENTS HOW TO USE THIS MANUAL GENERAL INFORMATION IDENTIFICATION NUMBERS. LIFTING POINTS VEHICLE DIMENSIONS BODY COMPONENT PARTS UNDERBODY COMPONENT PARTS, BODY COMPONENTS PARTS CORROSION PROTECTION DESCRIPTION ANTI-CORROSIVE WAX UNDERCOATING STONE GUARD COAT BODY CONSTRUCTION BODY CONSTRUCTION BODY SEALING DESCRIPTION BODY ALIGNMENT BODY CENTER MARKS PANEL PARTS MATCHING MARKS, DESCRIPTION ENGINE COMPARTMENT UNDERBODY PASSENGER COMPARTMENT AND REAR BODY HANDLING PRECAUTIONS FOR PLASTICS HANDLING PRECAUTIONS FOR PLASTICS LOCATION OF PLASTIC PARTS PRECAUTIONS PRECAUTIONS IN OPERATION REPLACEMENT OPERATIONS DESCRIPTION RADIATOR CORE SUPPORT RADIATOR CORE SUPPORT (Partial Replacement) HOODLEDGE FRONT PILLAR CENTER PILLAR (Wagon models) OUTER SILL OUTER SILL (Partial Replacement) REAR FENDER REAR FENDER (Partial Replacement) REAR END CROSSMEMBER REAR FLOOR REAR OUTER DOOR PANELHOW TO USE THIS MANUAL oopL.coGe HOODLEDGE ® (Work after RADIATOR CORE SUPPORT has been removed): Ine replacement operation of the hoodledge panel is shown here, beginning from the condition where the radiator core support has already been removed. If the radiator core support and the hoodledge reinforcement are installed on the vehicle to be serviced, refer to "RADIATOR CORE SUPPORT" in REPLACEMENT OPERATIONS. ® SERVICE JOINT: Welding methods and No. of welding points for performing body repair work are described (replacement of body parts). To maintain the integrity of the vehicle body, work should be done, observing the instructions described here (particularly No. of welding points). [Example] 5 aos Portion Ln. of wetuing p MIG plug weld (See symbol mark on page 47.) © Symbols are used in illustrations to clearly i © PORTIONS TO BE WELDED: Portions to be welded are listed, including descriptions of those areas to which the portion under the subtitle (e.q. Hoodledae panel) will be welded. (© REMOVALI/INSTALLATION NOTES Main service points and special notes for body repair work are described, intify welding methods. (See symbol mark on page 47.) 2GENERAL INFORMATION IDENTIFICATION NUMBERS, (chassis number) VEHICLE IDENTIFICATION NUMBER ARRANGEMENT vsK i Tie placard (Driver side center pillar) — \ st Identication plate a 8 Manufacturer code —————1_ | N Body | K = Hardtop | T : Wagon B: KA24E Vv: To2T Axle | N : 4-wheel drive, short wheelbase U_: 4-wheel drive, long wheelbase Vehicle serial number Stopgap (no meaning) —— U : for Europe X : Make EBROGENERAL INFORMATION LIFTING POINTS GARAGE JACK AND SAFETY STAND WARNING: © Never get under the vehicle while it is supported only by the jack. Always use safety stands when you have to get under the vehi © Place wheel chocks at both front and back of the wheels on the ground, and apply handbrake where appropriate. © Do not start the engine while the vehicle is supported only by the jack. /-arage jack point Sar pont cote coo 4-POLE LIFT WARNING: Do not use a 2-pole lift. Due to weight balance of the vehicle and shape of underbody, lif! arms can not be allached in a sate way. ‘Therefore it Is recommended to use a 4-pole lift only.GENERAL INFORMATION VEHICLE DIMENSIONS Unit: mm (in) Hardtop Wagon “Overall length | 4,105 (161.6) 4585 (1805) Overall width (*) 1,736 (68.3) | 1,735 (68.3) ‘Overall height 1,805 (71.1) 1,810 (71.3) Front tread 1.455 (67.3) 1,455 (67.3) Rear tread alee 1,480 (66.3) 1,480 (66.3) Wheelbase 2,480 (96.5) 2,650 (104.3) Ground clearance 215 (8.5) 210 (8.3) “Front overhang 740 (28.1) 740 (29.1) Rear overhang 915 (36.0) 1.195 (47.0) ("): Without mirrorsIndicates two-side ant-corrosive precoated steel portions. BODY COMPONENT PARTS UNDERBODY COMPONENT PARTS indicates high strength steel (HSS) portions. 9 10 12 13 14 15 16 Radiator core support ascombly Lower radiator core support Side radiator core support Hand lack stay Upper radiator core support Hoodiedae assembly Hoodiedge Battery support bracket (R.H.) Hoodledge reinforcement Air box assembly Side cow! top (RH. & LH.) Lower dash assembly Accelerator pedal stopper loner sill (RH. & Lt) Front floor assembly Parking brake reinforcement Console bracket 2nd body mounting bracket 2nd crossmember 8rd body mounting bracket Front seat mounting bracket Rear floor assembly Rear end crossmember Rear floor side Rear crossmember Rear floor rear Rear floor tront assembly Rear cross member reinforcement Rear seat crossmember 4th body mounting bracket Frame assemblyBODY COMPONENT PARTS, [Il]: ndtontnn two-tlde anticorroaive precoated steel portions. * : Indicates high strength steel (HSS) portions. Front bumper reinforcement Hood Front fender (RH. & LH) Front pillar assembly (RH. & LH) Feont pillar drip (RH. & LH) Inner trot pillar (FH. 8 LH) (RH LH) Outer side root rail aeeambly (RM. & LH) Cantar aot drip channel (RM. & LH) Outer sill assembly (RH. & LH.) Outer sill extension (RH. & LH) Lower front pillar reinforcement (RH. & LH) "3 Front door assembly (PLM. & LH) Outer front door panol (RH. & LH.) Root No, 1 root bow No.2 rt bow No. 3 ro9t bow No. wo bow Front rat reinforcement Fear roo! reinforcement BODY COMPONENT PARTS 2 28 a 8 2 30 2 3 "4 "5 6 7 = x «0 4 a 45 6 HARDTOP Inner rear pillar assembly (Al & LAL) Rear root brace (RW. RLM) Seat belt anchor reinforcement (RH. & LM.) Tapping plate (RH. & LH) Side window handle retainer (RH. & LH.) ri cachet (RH) ‘Jack mounting brackot (LM) Outer rear wheelhouse (RHA LH) Back door Rear bumper reinforcement ear bumper brace Rear fencer assembly (RM. & LM.) Rear pillar seatbelt anchor assembly (RH. & Li) Rear fender cover (RH & LH) ear fender extension (RM. & LHL) Fuel filler base Rear combination lamp base (RH. & LH) Striker retainer (HH. & LH) Lower inner rear pillar FH.) Tail pillar (LH) Outer back pillar Striker retainer (P.M)BODY COMPONENT PARTS BODY COMPONENT PARTS = nace igh “1 Front bumper reinforcement 2 Hood 3 Front fender (RH. & LHL) 44 Front pillar assembly (RH. & LH) 5 Front pillar drip (LH. 8 LH) 8 Inner Wont pillar (HH. & Lit) 7 ve side 10 rail assembly (RIN. & LIL) ner 8ige root rail (RH. BLM) 9 Inner centr pillar assembly (RH. & LH.) Outer side root eal assembly (RH. & LM) 11 Genter rool drip channel (RH. & LH) 12 Outer sill assembly (RH. A LH) 1 Lower trot pillar reintorcenment (RLM. & LH) Front door assembly (A.M. & LH) tar trant decor panel (RH. LH) Rear door assembly (RH. & LH.) Outer rear door pane! (RH. & LH) Root No, 1 rot bow No.3 root bow No, root Bow rength steot (#39) portions. ear root cal Front root reinforcement Rear root reinforcement Inner rear pillar assembly (RIM. & LH.) Fear rot rail brace (RH. & LH) ‘Seat belt anchor reinforcement (RM. & LH) Tapping plate (LH. & Let) ‘Side window handle retainer (LM. & LM) Rear wheelhouse assembly (RH. & LH) Filler neck protector bracket (RM) Jack mounting bracket (LH) ‘Outer rear wheelhouse (FLH. & LM.) Rear bumper reinforcement Fear bumpae brace Rear fender assembly (RM. & LH) Roo! side drip (RH. & LH) Rear fender cover (RH. & LM) Hear tenaer extension (HH. & LH) Fuel filler base Rear fender drip (RM. & LH) Striker retainer (RH. & LH} Upper hinge brace (RH. & Li) -R- WAGON “7 brace (RH. LH) v8 face (RH. BLM) 49 Rear tender patch (RM. & LH) 50 Lower inner rear pillar (RM) ‘51 Rear combination lamp base (RH. 8 LH) se Tal pla (4) 159 Outer back pillar 54 Strkar retain (RH)CORROSION PROTECTION DESCRIPTION In order to provide improved corrosion prevention, the following anti-corrosive measures have been implemented in our production plants. When repairing or replacing body panels, it is necessary to use those came anti-corrosive measures. re ‘ANTI-CORROSIVE PRECOATED x STEEL \ 8: ten (DURASTEEL) In order to improve repairability and corrosion : rosistanco, a now typo of anti-corrosivo eeercoes precoated stec! shect has been adopted, taking aan the place of conventional zinc-coated steel ‘One-side precoated sheets, Zn-Ni alloy under organic film, which provides excellent \\ seamen corrosion resistance. . a Durastel is classified as villher one-side precoal- ed steel or two-side precoated steel. The two- side precoated steel provides excellent corrosion resistance. Sousa Two-side precoated Nissan Genuine Service Parts are fabricated from durasteel sheets. Therefore, i GENUINE NISSAN PARTS or equivalent be used for panol replacement to mai performance built into the vohicle at the factory. is recommended that tain the anti-corrosive PHOSPHATE COATING TREATMENT AND CATIONIC ELECTRODEPOSITION PRIMER ‘A phosphate coating treatment and a cationic electrodeposition primer, which provide an excellent anti-corrosion effect, are employed on all body components. CAUTION: Contine paint removal in the welding operation to the absolute minimum. Phosphate coating treatment Cationic eecrodeposton primer = Nissan Genuine Service Parts also are treated in the same manner. Therefore, it is recommended that GENUINE NISSAN PARTS or equivalent be used for panel replacement to maintain anti-corrosive performance built into the vehicle at the factory.—————_ CORROSION PROTECTION ANTI-CORROSIVE WAX In order to improve corrosion resistance, anti-corrosive wax is applied inside the body sill and inside other closed sections. Accordingly, when replacing these parts, be sure to apply anti-corrosive wax to the appropriate areas of the new parts. Select an excellent anti-corrosive wax which will penetrate after application and has a long shelt life. + Indicates ant-corrosive wax coated portions. Section AA ‘Section B—B ‘Section C—C Section D—D ‘Section EE. ‘Section FFCORROSION PROTECTION —_ UNDERCOATING The undersides of the floor and wheelhouse are undercoated to prevent rust, vibration, noise and stone chipping. Therefore, when such a panel is replaced or repaired, apply undercoating to that part. Use an undercoaling with the following properties. rust preventive, soundprvof, vibration-proof, shock-resistant, adhesive, and durable, Precautions in undercoating 1. Do not apply undercoating to any place unless specified (such as the areas above the muffler and catalytic converter which are subjected to heat). 2. Do not undercoat the exhaust pipe. other parts which become hot, and rotary parts. 3. Apply bitumen wax after applying undercoating. Indicates undercosted portions. “1CORROSION PROTECTION STONE GUARD COAT In order to prevent damage caused by stones, the lower outer body panels (fender, door, etc.) have an additional layer of Stone Guard Coat over the ED primer coating. Thus, when replacing or repairing these panels, apply undercoat to the same portions as before. Use a coat which is rust preventive, durable, shock-resistant and has a lona shelf life. 7]: natcates stone quara costed portions. Seotlon EBODY CONSTRUCTION ——__ BODY CONSTRUCTION HARDTOP ‘Section AA [Section 0-0 Section @—G. ‘Section HHBODY CONSTRUCTION BODY CONSTRUCTION WAGON _ kh ERP oS ike he \ Sh 7” RS YEE ga \ Section AA Section C—CBODY SEALING DESCRIPTION The following figure shows the areas which are scaled at the factory. Scalant which has been applicd to these areas should be smooth and free from cuts or gaps. Care should be taken not to apply an excess amount of sealant and nol lo allow other unaffected parts lo ‘come into contact with the sealant HARDTOPBODY SEALING DESCRIPTION View Ht HARDTOPBODY SEALING DESCRIPTION View L View M View N View UBODY ALIGNMENT BODY CENTER MARKS HARDTOP ‘A mark has been placed on each part of the body to indicate the vehicle center. When repairing parts damaged by an accident which might affect the vehicle frame (members, pillars, etc.), more accurate, effective repair will be possible by using these marks together with body alignment data. Pention O Portion A 1 Upper radiator core support Front root Portlon D a a Cu) ST LAY MZ Oo LE OLS Ky 1+ Rear and crosemembor -18-BODY ALIGNMENT ——__ BODY CENTER MARKS WAGON A mark has been placed on each part of the body to indicate the vehicle center. When repairing parts damaged by an accident which might affect the vehicle trame (members, pillars, etc.), more accurate, effective repair will be possible by using these marks together with body alignment data. OES LES 7 ie = —4 A ~ ~ Portion E \ Portion A Portion B Portion © hea ot | a marine |? Rau ond rosmenber 19BODY ALIGNMENT PANEL PARTS MATCHING MARKS ‘A mark has been placed on each part of the body to indicate the panel parts matching positions. When repairing parts damaged by an accident which might affect the vehicle frame (members, pillars, etc.), more accurate, effective repair will be possible by using these marks together with body alignment data HARDTOP Soy ke Ly 26 =~ Me WAGON View £ 20 -BODY ALIGNMENT. PANEL PARTS MATCHING MARKS View A - View 8 ny pip A) py Al || K/O [7 ). ™ Pete | || q | NUBODY ALIGNMENT DESCRIPTION # All dimensions indicated in figures are actual ones. ‘© When a tram tracking gauge is used, adjust both pointers to equal length and check the pointers and ‘gauge itself to make sure there is no free play. © When a measuring tape is used, check to he sure there is no elongation, twisting or bending Measurements should be taken at the center of the mounting holes. All measurements and mounting hole diameters are expressed in millimeters (mm). © An asterisk (*) following the value at the measuring point indicates that the measuring point on the other side is symmetrically the same value. © The coordinates of the measurement points are the distances measured from the standard line of ox" and "Z BB ng te ste D tet rane sido ZA. ~ a™ YG \ LA a a A \nagiray base line Cntr tine of front axle 2" + Imaginary base tne [200 em (11.81 i) Kane Front —— venice contre“ below datum ne COZ" at design plan] ~ 22BODY ALIGNMENT ENGINE COMPARTMENT MEASUREMENT ‘on Both right and let hand sides ofthe vehicle. Una: reer 23BODY ALIGNMENT ENGINE COMPARTMENT |_____ MEASUREMENT POINTS __| Hole dia. Coordinates mm Points Detailed points mm ™~*o Doo De" | |Cowl top hole at iN 0.0 | 250.0 | 1,006.9 _ | vehicle center Cowl top side eoa.s | -110.1 | 9247 hole Upper radiator core support 01.0 | -450.5 | adg.0 location hole Side radiator core support 680.0 | -551.7 | 700.0 location hole @ Coordinate indicated isc Eg. GED coordinate is - GD coordinate eoordinate is: 698.5, GD coordinate is: ~698.5. - 24 -ENGINE COMPARTMENT BODY ALIGNMENT Hole dia. mm Points Delailed points Coordinates mm. aa ° ]Hood lock stay mounting hole fon upper radiator core support 37.0 589.0 794.0 Lower radiator Jcore support mounting hole 00 5at 1 245 9 ®@ 12 Lower radiator core support location hole 280.0 | 608.9 277.0 e ® 72 Front fender mounting hole |on hoodledge 608.5 110.1 924.7 ©: Cuurdinale indivaled is@P. Gi coordinate is -¢ E.g. if coordinate is: 698.5, GD coordinate, > coordinate is: ~698.5. 25 -BODY ALIGNMENT UNDERBODY MEASUREMENT Hardtop model Dimensions for centering gauge - 26 -BODY ALIGNMENT UNDERBODY Wagon modo! 27BODY ALIGNMENT UNDERBODY : Wagon models [MEASUREMENT POINTS] HD. Hardtop models Coordinates mm Points Detailed points “xa 450.0 | -4885 | 358.0 _ ~ 6050 | 5975 | 9087 LSE 5935 | 1,597.0 | 3100 A Cc Body mounting | @: bracket hole 600.0 | 2,135.0 | 440.2 | wt 3,477.5 ® ® 593.5 495.5 sorzraa 2,907.5 Front shock ®o absorber bracket] 442.0 16.0 496.5 mounting hole Compression rod - i) |mounting hote | 9626 | 2900 ] 141.1 D\ conseaten 00) 3 | ~ “t Front | L vero} @: Coordinate indicated is E.q. if PHD coordinate is: aD coordinate is - LD coordinate. 18.5. HD coordinate is: -698.5, - 28BODY ALIGNMENT UNDERBODY MW > Wagon models i : Hardtop models Points Detailed points Coordinates mm w Lower link 2,059.0 mounting bracket] 538.0 154.0 hole 4 1,859.0 Upper link 2,982.8 mounting bracket 270.7 | 305.0 hole Bw: | | 2,182.8 Rear spring 2,610.0 mounting brackel 375.0 510.0 hole Al 2,410.0 | Ty | | | | | w Rear panhard | 28437 | rod mounting 245.0 bracket hole 495.8 H 2,643.7 E.9. ifm coordinate is: 698.5. coordinate is: ~698.5.BODY ALIGNMENT UNDERBODY ; Wagon models Hardtop models Coordinates mm Points Detailed points ie ] pa w w awl | sth 2,961.0 | 564.4 oo le /\, | |crossmember 225.0 _ location hole 8 2ea70 | 5844 coo) wi 6th 3,530.0 o @ icrossmember 300.0 540.6 Bier location hole a 3,050.0 @: Coordinate indicated isc. > coordinate is - CG coordinate. E.g. if coordinate is: 698.5, CB coordinate is: ~698 5 ~ 30 -BODY ALIGNMENT —____ PASSENGER COMPARTMENT AND REAR BODY HARDTOP MEASUREMENT Straight ine dimensions other than shown Tale me ) Front bumper fase ror (AAS) er) turn signa tsher (PP & PC) founany | sia turn signal tamp lane (PMMA) i rromag amp en (run tran ede poet 9 A ut gil (ABS)—) St ame MMA) Rear step plate (PP) [7a \ Instrument panel \ (PPC, PVC, AES & PP) | Front over fender —) >) \ Mudguard ren)! Wicking plate PP)! fear combination tmp tens (PMMA) wear over fender (PP)! | Re or Rear bumper fascia (PP) eel © ne om 36HANDLING PRECAUTIONS FOR PLASTICS LOCATION OF PLASTIC PARTS WAGON ear door nih VC) ene nae UF il tis f oe aimmimameen | 1 Rear par anni PP) Fron par geri (2) | fy Rear ot garish (0) | | Bsc seer ein [or Cowl top cover (AES) deck dor side Front door tnisher (PVC) 1 ‘amish (PPC) ath eide tim (8) Front tun signal lamp lens (wma) side turn signa lamp fens (PMMA) | \Front tender protector (PP) Front bumper fascia (PP)! | Lower center pillar aernish (PP) Alt outlet grille (ABS)—) Stop lamp tons (PARKA) Instrument pane! (PPC, PVC, AES & mr Rear stop plate P) Front over tenaer omy | Kicking plate (em)! kicking plate (PP) Rear over fender (PF | \ r Console box (PP) —/ \_ muaguara (TPR) - 37PRECAUTIONS PRECAUTIONS IN OPERATION WELDING PRECAUTIONS __| Wear protectors Be sure to wear goggles, earplugs, rospirator, gloves and ¢o forth dopending on the work to be performed. Working clothes, safety shoes, and working cap must be worn as usual Safety stand After jacking up a vehicle body. be sure to supp: positions, refer to “Lifting Points" Inflammables Before starting repair work, be sure to disconnect the negative terminal of the battery. When welding parts near the fuel tank, be eure to remove the fuel tank. Plug the filler port of the tank Plug the fuel pipe and brake pipes to avoid leakage when removing connectors from the pipes. Working environment Pay attention to ventilation and operators safety. Paint and sealant may generate poisonous gases when heated by fire. To prevent this, do not use a gas welder for cutting off damaged portions. Use an air saw or an air chisel. Use a belt sander or rotary wire brush for removing paint from the panel. - 38PRECAUTIONS | 5. Vehicle body straightener © Be sure to use correctly according to the instruction manual propared by the straigh tener manufacturer. When straightening a damaged porlion, never sland in front of the machine in the direction that the body is to be straightened. Equip with a safety chain in case of emergency. PROTECTION OF BODY AND EXTERNALLY ATTACHED PARTS. Protection of body @ Remove or cover interior components (seats, instruments, carpet). When welding, cover glasses, seats,instruments and carpet with a heat-resistant material. (This protection is necessary especially when M.LG. welding.) 2. Protection of exterior parts . tape to the body to prevent scratchina surface may cause corrosion. PRECAUTIONS IN REPLACING OPERATION Use of genuine parts . use genuine Nissan parts or equivalent. - 39 PRECAUTIONS N OPERATION Never stand in front of the machine When removing external parts (moldings and finishers) attached to the body, apply cloth or protection If the painted surface is scratched, be sure to repair that portion: even a small flaw in the painted In order to maintain the original functions and high quality of the vehicle, it is recommended that youPRECAUTIONS PRECAUTIONS IN OPERATION |_____ WELDING PRECAUTIONS __| General precautions Welding must be properly performed so that vehicle body will retain sufficient strength and durability. © Tho REPLACEMENT OPERATION section in the Manual deale with the welding methods, locations to be welded, number of welding spots (or welding pilches) for each body portion. It is recommended to perform welding according to the instructions. © Resistance spot welding is faster and more, efficient than other welding processes. In addition, it features a low amount of thermal strain, less rust formation and finishing is unnecessary. For these reasons. it is recommended that resistance spat welding be used whenever possible. Further, use of MiG. welding ie recommended for locations where resistance spot welding cannot be utilized and for structural parts (members, pillars, etc.), CAUTION: Gas welding (oxyacetylene gas welding) must not be used because it causes a deoline in strength of areas surrounding the welded parts. There are a variely of resisance spol welders on the markel. Be sure lo use a welder wilh a sufficient capacity to secure weld strength. Also, Inspect welded parts to confirm weld strength. - 40PRECAUTIONS PRECAUTIONS IN OPERATION Spot welding 1. Spot welder To obtain sufficient strenath at the spot welded portions, perform the following checks and adjustment on the spot welding machine before starting operation. (1) Adjustment of arm a. Keep the gun arm as short as possible to obtain the maximum pressure for welding. b. Securely tighten the gun arm and tips so that they will nat become loose during operation (2) Alignment ot electrode tips Align the upper and lower electrode tips on the same axis. Poor alignment of the tips causes insufficient pressure, resulting in insufficient current density and poor strength at the weld 8) Diameter of electrode tip The tip diameter must be properly controlled to obtain the desired welding strength. Betore starting operation, make sure that the tip diameter (D) is kept the proper size, and file it cleanly to remove burnt or foreian matter from the tip surface. Unit mam tn) Thickness (7)] Diameter (0)] | Thickness (7 ] Diameter (0) oero0e | «zie || room | sowien oro) | savor | | taco | s4 029 os ,aasy | sere | | 1400s) | 5010220) 02 0035) | 48180) | | 19/0069) | 620.244 2. Condition of the panel un arm | ou” TH vo ot ; os Use the minimum possible length of arm Uneven length of oe | = slectrode tip length Motadjusted lectrode tip length —T Align both Correct Incorrect b= at 3mm) B= 2T + 032 (in) Gaps, paint flim, rust, or dust on the panel surface causes poor current flow and reduced spot area resulting in interior welding. Before beginning, it is necessary to thoroughly check the panel condition, and make any necessary corrections. -4tPRECAUTIONS PRECAUTIONS IN OPERATION (1) Gaps between welding surfaces Gaps between the surfaces to be welded cause poor current flow. Even if welding could be done without removing such aaps. the welded area would be smaller, resulting in poor strength. Flatten the two surfaces to remove the gaps, and clamp them tightly with a clamp before welding, (2) Panel surfaces to be welded Paint film, rust, dust, or any other contamination on the metal surfaces to be welded causes insufficient current flow and poor results, Remove all foreign matter from the surfaces to be welded by Osanding or wiping clean (3) To prevent corrosion in the welding process Anti-corrosive agent has high conductivity. 1 Is Important to evenly apply the agent to the end tace ot the panel. 3. Precautions in performing spot welding (1) Selection of spot welding machine Use the dircet welding method whenever possible. (When direct welding cannot be applied, use M.L.G. plug welding.) (2) Application of electrode tips Apply electrodes at right angle to the panel. If they are not applied properly, the current density will be low resulting in poor welding strength, (3) Lap welding of more than two steel sheets — Where three or more steel sheets overlap, spot welding should be done twice. ~ 42 - ‘Spot-weld twice If three oF mare eiael sheots overlap.PRECAUTIONS PRECAUTIONS IN OPERATION (4) No. of spot-welding points Generally. the capacity of repair shop spot welding machines is smaller than that of factory welding machines. Accordingly, the number of spot-welding points should be increased by 20 - 30% (8) Minimum welding pitch Tho minimum wolding pitch varios with the thickness of panels to be wolded. In gonoral, observe the values in the following table. Note that excessively small pitch allows the current to flow through surrounding portions, resulting in poor welding strength. Lunt om (in) Thickness (t) __ Minium pitch (0) } | oe 0028 13035) os ea 20m : 100%) 079 1200 20079) - 1.60089 27 (009 18,007) 31 (12) (6) Minimum lap of panels TOO Observe the following values for the lap 7 distance of panels. Too short a lap distance results in reduced strength and also in a strained panel 5 —_—| Un: mm (in) x “4 Thickness ( Minimum pitch (0 wey) ‘ ceo rea ml oncom 11043) — 1.0 0.030) 12 (047) 120087 140058) 1.6 2083) 16,063) sa oom son) Be sure to spot weld at the center of the overlapped portion. (7) Spotting sequence: Welding _ Do not spot continuously in only one sequence —> direction. This results in weak welding due to 4 5 the shunt effect of the current. If the welding Goo ts 2 4 8 | tips become red-hot, stop welding and cool SSS the tips. wong 4 29 ~ 43 -PRECAUTIONS PRECAUTIONS IN OPERATION (8) Welding corners Do not weld the curved corner. Welding this portion results in stress concentration, which leads to cracks. Examples Upper corner ot tront and center pillars Front upper portion of rear fender Corner portion of front and rear windows Curves corner 4. Inspection of welded portion I Spot-wolded portions can be checked by | visual inspection and destructive inspection The destructive inspections are explained below can be easily adopted when welding Belore and after welding, be sure to perform these inspections to check the strength of the welded portions. % The welding spots should be equally spaced and arranged at the center of the flange to be came both test “Nw welded pieces securely. (1) Check by using test piece (Confirmation before operation) Clamp both test pieces together so that they will Sa Good not slip or move during welding. =——- rox. 3 mm (0.12 In) dia. formed by tearing, © Weld together test pieces with the same thickness as the panel to be welded. Break the weld by twisting and examine the break ————— © With this test, a hole should be made on one —~S test piece by tearing at the welded portion. If Wrong no hole is formed, it indicates that the | welding conditions are incorrect. Adjust the — —— pressure, welding current, current passing time and other conditions, and repeat tost I until the best result is obtained, 44PRECAUTIONS PRECAUTIONS IN OPERATION (2) Check by using chisel and hammer (Confirmation after welding) © Insort a chisol tip between the welded panels, and tap the end until a clearance of 3. 4 mm {0.12 - 0.16 in) [when the plate thickness is 0.8 = 1.0 min (0.031 - 0.039 in)) is formed between the panels. If the welded portions do not separate, it indicates that the welding has been done properly. This clearance varies with the location of the welded spots, length of the flange, panel thickness, welding pitch, and other factors. Note that the value shown above is only for reference. ‘@ If the thicknoss of the panols is different, tho clearance must be limited to 1.6 2.0 mm {0.059 - 0.079 in). Further opening of the panels can become a destructive test Be sure to repair the deformed portion of the panel after inspection. M.LG. welding 1. Condition of panel to be welded Paint film, rust, or oils attached to the panel surface degrades welding conditions causing blowholes and spatter Thoroughly remove any foreign matter from the surface to be welded by using a belt sander or wire brush. 2. Precautions in welding (1) Plug welding a. Open a hole of 5 - 6 mm (0.20 - 0.24 in) diameter on one of the two panels to be welded and keep the upper panel and lower panel in tight contact. b. Apply the torch at right angle to the panel and ill_metal into the hole at a stretch Intermittent welding leads to the generation of oxide film on the surface and this causes blowholes. If this occurs remove the oxide flim with a belt sander or a wire brush. c. Make sure that the upper and lower panels are welded together tightly. - 45 Surrounding portion of hole Wola of 5 & mm (0.20 = 0.28 in) glameter Reference value (0.2 0.16 in) Tap with a hammer Reterence value 4s-20mm (0.039 - 0.079 im) \ cia N\A, Tap with @ hammer But weldingPRECAUTIONS PRECAUTIONS IN OPERATION (2) Butt welding a. Before performing this welding. tack-weld the two panels to he welded to prevent generation of strains and to align their surfaces. Tack two pancls by placing point welds and then fill in the spaces by placing short welding beads. b. Long weld line is apt to cause strain. Use the method shown at the left to reduce strain. c. To fill the spaces between intermittently, placed beads, first grind the beads along the surface of the panel using a sander, then fill metal into the space. If weld metal is placed without grinding the surface of the beads. blowholes may be produced (8) Inspection of welded portion Refer to the Inspection method described for spot welding. fs a whol ~ 46 - Grind surace of beads.———_________ REPLACEMENT OPERATIONS DESCRIPTION _sywsois For curtina AND WELDING/BRAZING OPERATIONS The identification of the cutting and the welding/brazing symbols used throughout this guide is given in the following pages. MW ‘Saw cut or air chisel cut coco 2 spot we pow g dow | eae welds £ Spot weld 000 _ a-spot — deapot wade welds. °F (G-panel overlapping portions) MG. plug wola - 2 comm ML.G. seam weld! sn Point weld ED Brazing Bay Saldering Bp a7REPLACEMENT OPERATIONS RADIATOR CORE SUPPORT Service Joint ‘Indicates thet there isan equivalent welding portion ‘with the same dimensions on the opposite side. Sf 40) Hf aN S| / R/S | {/ Zepot welds ——S.spot welds © MLLG. plug weld MG. seam weld! Point wele eK ag € Hoodlodge ascomtiy INSTALLATION NOTES © Measure various dimensions of part loca- tions. Refer to “BODY ALIGNMENT" (p.23) drawingREPLACEMENT OPERATIONS RADIATOR CORE SUPPORT © Apply sealant. ~ 49 -REPLACEMENT OPERATIONS RADIATOR CORE SUPPORT (Partial Replacement) Service Joint LL sesame WLS AN M.LG. plug weld -MLL.G. seam weld! Portions to be welded 12 Upper radiator core support © Heodtedge © Hoodiedge Side radiator core support 4. Hoodleage Five (6) individual eervice parte are available for the radiator core support. In addition to this, it is available as an assembly. Thus, only the damaged part needs to be replaced. Pertorm the operations using proce- dures outlined in the section titled “RADIATOR CORE SUPPORT” Radiator core support assemblyREPLACEMENT OPERATIONS HOODLEDGE (Work after radiator core support has been removed.) Service Joint ams 2apot welds 4. Side cow! top panel Front illar REMOVAL NOTES © Cut off damaged portion to facilitate removal Be careful not to cut off side cowl top 51 Side cow! top panelREPLACEMENT OPERATIONS HOODLEDGE ‘© Spot cut completely through welded portion Tack weld each clamping point. (b). Use these holes as M.LG. plug weldholes @ Install hood, fender and door, check when installing service part. clearances, grades and parallelism. INSTALLATION NOTES * Position service part with matching marks correclly aligned © Measure various part location dimensions. Refer to “BODY ALIGNMENT” (p.23) draw- Ing 52 -REPLACEMENT OPERATIONS HOODLEDGE © Apply an anti-corrosive wax to welded parts.REPLACEMENT OPERATIONS FRONT PILLAR (Work after hoodledge reinforcement has been removed.) Service Joint teaeoss ett ppd oe moa eB ee ae Fortons 10 be wees eaten % toni prose sil & outer Lower front piiar reinforcement & inner © 9 |_______ REMOVAL NOTES ‘© Before cutting front pillar, be sure to support roof. 64REPLACEMENT OPERATIONS FRONT PILLAR © Buttina position is 260 mm away from locating hole. It is better to butt at this position due to its conetruction. © Determine cutting position and record distance from locating hole Use this distance when cutting service part. Cut outer front pillar at 60 mm above cut position of upper inner front pillar. ‘© Using a cutting jig makes it casior to cut, Also, it will permit a service part to be accurately cut at joint position. sop. tne ton ptr | © An example of cutting operation using a cutting jig is as follows: @ Mark cutting lines A: Cut position of outer front pillar B: Cut position of uppor inner and outer front pillars @® Align cutting line with mark on jig and clamp itg. @ Cut off along groove ot jig. (At position B) @ Remove jig and cut remaining portions. © Cut off at position (A) same manner. © Spot cut welded portion (I) with a mini belt sander. 55 -REPLACEMENT OPERATIONS FRONT PILLAR © Grind the surfaces of M.I.G. seam welded portions (C), (D) with a mini belt-sander. Re careful not to grind lower front pillar reinforcement. SS sth KOSS /° *| WW © Tack weld each clamping point and butting point. © Install front fender and front door. Check clearances, grades and parallelism. INSTALLATION NOTES ‘© Align service part with mating part, cut off at, position (A) from outside, and at position (B) © Position service parts and measure various part location dimensions. Refer to “BODY ALIGNMENT” (pp.31 and 33) drawing * Wold parts to be butt welded as far as flange end portion. ~ 56REPLACEMENT OPERATIONS FRONT PILLAR © Apply an anti-corrosive wax to welded parts and inside of front pillar. - 57REPLACEMENT OPERATIONS. CENTER PILLAR (Wagon models) Service Joint Une im Zapotwois pot wee ‘MUG. pug weld MAG. nam wl nae = . mf Portions to be welded tine sd oll race centr tera 1 tera - 58 -REPLACEMENT OPERATIONS CENTER PILLAR (Wagon models) This vehicle's outer side panel is made ot one piece of sheet metal, Ihis section gives replacement procedures tor center pillar assembly. cover ple sve {_______ REMOVAL NOTES ___| © Before cutting center pillar, be sure to support roof. © Butt welding position can be determined anywhere within shaded area as shown in tho figure. Owing to the construction, it is better to butt weld in this area. To mm © Cut off center pillar. Be careful not to damage seal bell anchor reinforcement. ‘Seat belt ancnor reinforcement ‘© Spot cut only center pillar at portions (b), (c), (a). (2), (f), (g) and (h). Do not cut fully through it ||| |)))—tecating ote I Unt am - 59 -REPLACEMENT OPERATIONS CENTER PILLAR (Wagon models) ‘® Spot cut welded portion (j) from inside, as @ Align service part odds and ends with mating shown in the figure. part. ‘© Do not cut through, welded portion (jx). Spot @ Scribe a line (A) at the end of service part. cut only two panels © Cut off remaining part along the scribe line. Service part Position service part and measure various dimensions of part locations. Refer to “BODY ALIGNMENT" (pp.31 and 33) drawing. [_____ INSTALLATION NOTES © Cut off center pillar service part to use as a jig. Be careful not to damage center pillar seat belt anchor reinforcement. 60REPLACEMENT OPERATIONS CENTER PILLAR (Wagon models) © When welding, temporarily weld each press line first to prevent movement. Before seam welding, be sure to arind surface of tack welded portions. © Tack weld each clamping point and butting point. © Install front door and rear door and check clearances, grades and parallelism © MI.G. seam weld butt ends. -61-REPLACEMENT OPERATIONS. CENTER PILLAR (Wagon models) © When dressing butt weld part, cover up holes in upper part of outer sill with tapes to prevent debris from entering. © Apply an anti-corrosive wax to inside of outer sill G 62 -REPLACEMENT OPERATIONS OUTER SILL Service Joint 2epotwelde spot welds MLL. plug weld n eet OS af Portions to be welded 18 center pilar ' 1 Conterpittar reinforcement 2. Inner sill Inner all & tower front pilar reinforcement & front pillar REMOVAL NOTES © Before cutting outer sill. be sure to support root.REPLACEMENT OPERATIONS OUTER SILL © Cut off damaged portion leaving old outer sill about 5 mm away from lapped portion of center pillar so that it is easy to work with. © Spot cut welded portions (e) and (f) from outside. Vo not drill through remaining outer sill 64 © Spot cut welded portion (h) from outside as shown in the figure. © Cutoff outer sill service parts. AZ LE a YF a INSTALLATION NOTES lign lower end of service part with matingREPLACEMENT OPERATIONS OUTER SILL © Position service part with vise clamps and measure various dimensions of _ part locations. Refer to "BODY ALIGNMENT” {pp.31 and 33) drawing © Drill M.LG. plug weld holes, with a flat drill, in Portion (f) using spot cut holes in mating panel, and M.I.G. plug weld them. ‘© When welding, temporarily weld each press line first to prevent movement. © Tack weld each clamping point and butting point, then install tront and rear doors. Check clearances, grades and parallelismREPLACEMENT OPERATIONS OUTER SILL © After painting, apply an anti-corrosive wax to inside of outer sill. - 66 -OUTER SILL (Pa _______ REMOVAL NOTE ___| © Determine butting position, avoiding outer sill brace and holes. | Permissible \\ < arash \eus ee INSTALLATION NOTES ‘© Cut off service part, so that its hole is in the same position as that in vehicle body for Positionina, Position service part, align its hole with that of vehicle body, and perform overlap cutting 67 REPLACEMENT OPERATIONS. rtial Replacement) © When welding, temporarily weld each press line firet to prevent movement. © When dressing butt weld part, cover up holes in upper part of outer sill with tape to prevent dobris from entering.REPLACEMENT OPERATIONS REAR FENDER Wagon models L.H. & R.H. Service Joint sims, xR orm same +b OB or m6 Acero me sae corms > Indicates that there is an equival Depot welds spot welds M.LG. plug weld -MLLG. seam weld/ Brazing =~ “f- an ff Bes. / ~ 68 -REPLACEMENT OPERATIONS REAR FENDER Hardtop models L.H. & R.H. Service Joint pone aeons +n O13 0r M10, + Indicates that thare Ie an aquivaleet walding postion with the same dimensions on the opposite side, Depot welds Dapotwelde MIG pligwald MIG. snamweld) Brazing Point weld $0 ST tH af By - 69REPLACEMENT OPERATIONS: REAR FENDER Portions to be welded 1 A. Rear fender k 8. Rear tenaer u ©. Rear tener F. Roar ond eroeemembor n Gear and crnasmamnar 8. laner rear pillar assembly & seat belt anchor reinforcement P. Inner rear pillar assembly ‘c.Quter rear wheelhouse 8 Outer house & inner sill C 1d. Rear fender patch & inne sil! fe. Inner sill 1 Inner sill . 9. Outer rear wneeinouse ¥ Outer rear wheethouse i. Near faor aide ¥ Roar floor sida & rear ond REMOVAL NOTE! ‘© Cut off line can be determined within shaded area as shown in the figure. Irmer rer par asseby Inner rear pillar axsombiy & seat bet ar pillar assombly & teat bolt Inner rear pillar assombiy Inner sill & inner rear pillar assembly Inner sill & outer sil Outer sill Outer sill & inner sill Outer rear wheelhouse Rear tloor side Fear lloor side & rear end Feat fender cover Inner rear pillar assembly Inner rear pillar aeeombly & eldo Inaer rear pillar assambly & seat bet anchor reinforcement anywhere W. Rear root ral brace & inner rear pillar Inner rear pillar assembly pillae Rear end erossmember & lower inner rear pillar be. Inner rear pillar assembly & lower inner rear pillar 2, Lower inner rear pillar 4. Inner rear pillar assembly 20. Inner rear pillar assombly HI. Inner rear pillar assembly , ower inner rear piiar 98. Inner rear pillar assembly & lower hn Inner rear pillar assembly & lower Inner rear pillar © Cut off damaged portion as shown in the figure to facilitate removal ‘Wagon moaeis Haratop models outside. Do not drill through mating part. 70 | | © Spot cut welded portion (h) or (q) from | | | | | | } IG h (Wagon models) 4 (Haraiop models)REPLACEMENT OPERATIONS INSTALLATION NOTES © Cut off service part along previously scribed lines as shown in ‘A (wagon mods) ey 1D (Hardtop models) \\7 Position service part and measure various dimensions of part locations. Refer to “RODY ALIGNMENT” (pp 31 and 38) drawing. REAR FENDER Cut off rear fender along the scribe lines (A), BO) 8) 'R (wagon moaels) D (Hardtop modele) > © Before installing rear fender, apply sealant to wheel arch ZA, ZA LT @ Align service part with mating part. When welding, temporarily weld each press line first to prevent movement portion of service part. @ Scribe lines (A), (B), (D) & (E) at the cut 18 (wagon models) === D (Herdiop models) -71-REPLACEMENT OPERATIONS REAR FENDER © After tack welding each clamping point and butting point, install rear door and back door. Check clearances, grades and parallelism. Unit: men © Weld paris (v be bull welded as far as flange end portion, Finish welded parts with an air grinder. "A (Wagon models) D (Haratop models) © Apply sealant. ‘© After painting, apply an anti-corrosive wax to 1d portions.REPLACEMENT OPERATIONS REAR FENDER (Partial Replacement) REMOVAL NOTE ‘© Cutoff damaged portion with lap allowance of about 50 mm, INSTALLATION NOTES © Cut off service part leaving 50 mm lap allowance with mating part 0 mm lapping allowance © Position service part with vise clamps, and cul off in middle of lapped part. 73 - © ML.G. seam weld butt ends. © Remove any debris with a vacuum cleaner to prevent rust and corrosion. hy \\\ — © Perform subsequent operations using procedures outlined in section titled “REAR FENDER".REPLACEMENT OPERATIONS REAR END CROSSMEMBER Service Joint / / SN } ie Front / 7 : ss natn toe an agua ewe / +A ED ‘welding po oa / Seer pect Sa ne ogo mola Mateay mots ‘pot welt——Sapotweltn MG. pg weld MILO. sen wel) azng Nee : an — me . ST a e To rE on ff a De / Portions to be welded Rear fender assembly & lower inner 4. Inner rear end crossmember Rea nde assemsy Ina er endcossmember INSTALLATION NOTES Remove any debris with a vacuum cleaner to prevent rust and corrosion = 74REPLACEMENT OPERATIONS REAR END CROSSMEMBER © Apply sealant to ice part joint. @ After painting, apply an anti-corrosive wax to welded parts. 75 -REPLACEMENT OPERATIONS REAR FLOOR REAR (Work after rear end crossmember has been removed.) Service Joint Wagon models “+ Indloates that there ie an oquivalant welding portion SS “with the same dimensions on the opposite side. ] FRONT ——}} \\\ Sy AWA {fit rront < —s / Lona valent welding portion ™ fon the opposite aide, Sepotwaide —-MLLG. plug weld MLLG. seam weld! Pol ia om. &REPLACEMENT OPERATIONS REAR FLOOR REAR Portions to be welded 8, Quter rear wneeinouse 8 Inner rear pillar 4. Rear floor front assembly floor side fh. Outer rear wheethouse b. Rear crossmember ® Moor tront assembly Rear floor side ©. Inner rear piiar 1. Rear crosemomber |_____ REMOVAL NOTES INSTALLATION NOTES © Spot cut welded portions (d) or (h) from © Alter dressing, remove any debris with a outside as shown In the figure. vacuum cleaner to prevent rust and corrosion. © Cut welds with a mini belt sander at portions (c) oF (g)- ‘(Wagon model) ey ie fake 4 (Hardtop models) || (ULI I i \ NN \ | L—¥} | AUN ES \ \ / 7 Ne Tm £ -7-REPLACEMENT OPERATIONS REAR FLOOR REAR © Under coat the underside of rear floor © After painting, apply an anti-corrosive wax to welded portions.REPLACEMENT OPERATIONS OUTER DOOR PANEL Service Joint eenormo bettorme a poor guard bar Door guard bar L “dam Luter door waist L sameeren ea aa ap Tce ee oS ae Portions to be welded REMOVAL NOTES ___| ‘Cut door panel hem with a sander. ler pone \ 7 A\\ | = \— outer par Cutting with a candor WN 79REPLACEMENT OPERATIONS OUTER DOOR PANEL © Remove outer door panel odds and ends with pliers or chisel © Alter removing outer panel, dress rusty part with a sander and treat with an anti-corrosive agent. Inner panel cuweyoonof INSTALLATION NOTES © Apply adhesive to outer panel hom vate © Hemming work of outer duor panel should be done, referring to the following tips. (1) Use wooden block as a dolly to avoid distorting outer panel. If it is not available, use dolly covered with cloth or other soft material Ai JS Zz L ian went wh BE aS we (2) Hemming work should be done in three steps as shown in the figure. 0 nat hammer panel end oe . ae Zane round shave.REPLACEMENT OPERATIONS. OUTER DOOR PANEL (3) When using hemming tool, temporarily bend panel with hammer in advance and then use hemming tool Be eure to protect outer panel with rubber Rubber cheat © Apply anti-corrosive wax to lower inside of door. 81