¢ NISSAN _- -) BODY REPAIR MANUALCONTENTS HOW TD. USE-THIS-MANUAL + ‘GENERAL INFORMATION. 7 IDENTIFICATION NUMBERS LIFTING :POINTS.. *“ VEHICLE-DIMENSION WHEEL ALIGNMENT ... BODY ‘COMPONENT PARTS UNDERBODY. COMPONENT PARTS 9 BODY COMPONENTS PARTS . CORROSION PROTECTION e BODY CONSTRUCTION 2 BODY CONSTRUCTION BODY SEALING ... BODY ALIGNMENT. 7 BODY~ CENTER meni ENGINE COMPARTMENT. . UNDERBODY ... PASSENGER COMPARTMENT PASSENGER » ROOF PANEL®(COUPE)?? : ROOF PANEL (FASTBACK) = OUTER DOOR PANELHOW TO USE THIS MANUAL The’ replacement operation of the hoodiedge panel is shown hero, beginning from the condition where the radiator core support has alréady. been removed. If the radiator core support and the hoodledge =, feinforcement are in: alled. on the vehicle. 9 be serviced, fefer to “RADIATOR CORE SUPPORT" in, REPLACEMENT OPERATIONS. - | ® SERVICE JOINT: Welding methods and No. of welding p points ‘for performing body repair work are described (replacement of body parts). 5 <2 To maintain the integrity of the vehicle body, work should beione, observing the instructions described 5 here (particularly No. of welding points). [Example] 8 am 27 : Portion —I [2S Ne S riding Baines MIG plug weld (See symbol mark on page 43.) © Symbols are used in illustrations to clearly identify welding methods. (See symbol mark on page 43.) © PORTIONS To BE WELDE 2 Portions to be welded are listed, including descriptions ‘of those areas to which the portion under the subtitle (ex. Hoodledge panel) will be welded.: ». © REMOVAL/INSTALLATION NOTES 4 ct Sea Main service points and special notes for body repair work are described. -2-— _— GENERAL; INFORMATION. ict DENTIFIGATION NUMBERS s(Fér,U.S.A\ & Canad Vghiele identification plate ~ ete idensinton number (Chis number / FMN.8S. corification label Information fabet — Vehicle identification number plate : VEHICLE IDENTIFICATION NUMBER ARRANGEMENT. INT H2S 3 6° XAK AW 000051 Monufecurer 2 Engine type Hi KA24E-5 Model year Vehicle tine K: 1989 year model S: NISSAN 2408x Check digit (0 t0.9 oF X) “The cde Yer the ‘chee’ Model change (0 t0 9) computation, Body type 4: Coupe,. 6: Fastback Restraint system sas i 8: Stands P: Automat{GENERAL INFORMATION. eee IDENTIFIGATION.. NUMBERS (Ex¢ept for U'S:A. “8 Canada) Vehicle identification plate scissa VEHICLE IDENTIFICATION NUMBER ARRANGEMENT (For Europe) INE 10 >RX Sid U ANT 2 Nissan eerie © = Stopgap {no meaning) > Stopgap (no meant Ro: Fast Back For Eufope * Vohiete serial Model 11: means no indicationGENERAL: INFORMATION. > ALIFTING ‘POIN WARNING: © Never get under the vehicle whil the frame when you have to get under the vehi © Place wheel chocks at the front wheels when th wheels when the front wheels are raised, CAUTION: Bai Theil Fim deforming / sit prepare wus / se sm anton ae ome sc1853GENERAL: INFORMATION — ; SanAnaaaa VEHICLE: DIMENSIONS Except EurdpelA Overatl length 4,535 (178.5) 4,520 (178.0) mk aw + Querall wid 1,690, (66.5) » “ aris aque a 2° al s * Overall heigl 1,290 (60.8) 5 Fronttread gol 469, 087.2). i Bead 7° ‘aes (b7.7)" 9/460 (67.5) Wheelbase 2,475 (97.4) 2.475 (97:4) FRONT WHEEL ALIGNMENT (Undaden*1) FoUSA | Exepr torus For 2 canaie 2 Conode Boras Comber drawe | rarer | 12505 aber draw | 196 10-0796 3 (0 0.20 Toeia (Total) svn tin) 0-28 degree +, Tanktulof fuel, racator coolant and engine ol ful Spare te, jack, hand! toot, mats in designated position. Kingpin inclination ‘tegroo | 12°90" 14°00" Front whee! corning ang 36° -40"/92"*3 / | 39° - 499/894) 43°13" “15 Tankful of fue, radintor coolaat she aigna ol fll, Spars ui Jack, hand tools, matsn desgated position +2: On power stering models, wel wrnina force {at circum ference of steering wheel) of 98 to 147 N (10 20 15 kg,se i Antiorrosive proconted steel Indies high Strath stool (HSS) portions, Kinucs ene $001 OH LEAS PHY 1 Radiator.core:support,essembly 3 Side radiator core support i *3. Lower radiator cote support : 5 Headlamp bracket 6 Hood lock stay 7 Front bumper reinforcement. * 8 Front side mémber e * 9, Front sidé member closing plate 19,5 Inner'side/éowl top (RH. & LH.) 20 3Side'dash’ panel (RH LH.) 21 5Outépside cowl top (R.H.'& LH.) 722 SFroiit footie "23 yRearengine mounting bracket 425 SCenterssidamombor (R:H, & L.H) [26 2nd erotsmemben 728 Sinner EXO. & LH.) 30 Rear floonstrontextension: 31 {Rear floorfrontoust | 32 | Centerreacerossmemberee5 fay 9 (/33 !Rear'side member:(R.H.82L:H.) 114 Upper hoodlede.pane! (R. 845 Hocdledgo reinforcarnah (RH. & LH). ~ 16 -Lower,désh panel... | P38 J Rear loorside:{RiH.(& LH; 17 Air box dsembly. | a6 s Sparestire clamp bracket? (: #18 Cowl top pani HOE": __1 3, 1Reanfloorerediy {. $14 Hoodledge (RIK. &oLHP oS 1 | 12° Battety:mourting 1. "13 Lower front hoadlede (Ri } 29 SOutrigger.reahside:member(R:H. & LH.) 24 SFronttjack.up»point bracket (R.H. & LH.) 727, 3Front'sida momber extersion (R.H, & LH.) -| 34, 1Reariside membersextension (R:Fi: Bok: H.) AGOguaaNN now 1swd adnoo Q 5 9 5 Zz a z a‘COMPONENT PARTS. ‘COMPONENT. PARTS: Bopy:' =) SBODY COUPE CHL 8 Hy) sued! CHT HY) eBeoyout Init poinssid éagdiboa ay?SUN ROOF“MODEL strangth ste! (HS) portions, 4 2 Soa Outer front pillar (R.H. & LH.) Inner front pillar (RH. & L.H.) Roof rail Brace (R.H. & LH.) Inner side;root rail (R.H. 8 L.H:}.) Outer sit (RI a &LA YL ry, Front og ejomblv (RH. & LHL) Frontdoor-otiter panel (RH. & LH.) Rear fender (RH, & LH.) Upper:fedtpiller reinforcement (R.H. & LH.) Rear rdof tal’brace (R.H. & LH.) dar ilar seat bel anchorage (R.H. 8 Innere pillar eiforeoment (RH. & LH.) "17 Outer rear whee! houise (RH. &¢ LH.) 18 Fuel filler lid-base : 19 Rear ferider corner (R.H. & L.A) © 20 Rear combination lamp baso (F.H& LLM.) 21 Rear buttipet reinforcement.” 22 Rear patil » fs *23. Back door E 24 Front rddf fail 25. 1st roof bow, 26 2nd reof bow 27 Rearsroo! rail 28 Root) % 29 Roof (Fér sin roof model)“ > 80 Roof fram SLaVd LNINOdWOD AGO Ova Lsv4 SLUVd ‘LNANOAWOD AdoANTI-CORROSIVE PRECOATED STEEL (DURASTEEL) lity’ and, ire resistance, a new of anti-corrosiye lt into the vehicle at the factory. PHATE COATING TREATMENT AND ELECTRODEPOSITION PRIMER A phosphate, coating. treatment and a cationic electrodepo: corrosion effect, are employed on all body components. CAUTION: | Confine paint removal ion primer, which, provide an excellent anti- ‘the welding operation to the absolute minimum. Phosphate coating treatment san Gefiuine Service Parts also’ are treated in. the same. manner. Therefore, it is recomended: that GENUINE: NISSAN PARTS bo used for panel replicement to maintain anti-corrosive performance built = 10CORROSION PROTECTION |______ANTI-CORROSIVE. WAX__| : In order. to improve corrosion resistance,-anti-corrosive.wax is applied -inside-the body sill/and iiside other” closed sections. Accordingly, when replacing these parts, be sure to apply anti-corrosive wax to the appro: + priate areas of. the-new parts, Select an excellent’anti-corrosive wax which willspenetrate after application and has a long sheli.life,.> = 2 ‘nonit us Res sce Front floor Outer door Node Section D-D | SectionF-F | SeaionH-H | Sections ‘Gut rear —|Fartback model whertno ve (Outer trunk tk Outer hood | Rear floor ror ~ \ XY Y N yp | doer trunk SB) | Concer ‘Lower desh Peciee | te tner hood | rocememberCORROSION‘ PROTECTION: a UNDERCOATING: _ ‘Thet undersides” of the:floorand:vhieelhiouse are’ undefcoated ‘to: prevent tust) = SEF S908 21Sse: BODY ALIGNMENT. UNDERBODY' (Except for U:S! x: 5422 ¥: 635 E1287 0.0. x: 4745 ¥: 2500 Zz: 0559 [Front and rear strut tower centers jaz Coordinates: Front: ©),@ 87 din, Roo: D/O 8 dia, 1.0 x: 535 ¥: 2.050 Zz: 1163 Coordinatos: — - 5 eee, sar2ne| coordi ©, [Center side member, rear side member and rear extension saron1e 28COUPE —— BODY ALIGNMENT z PASSENGER COMPARTMENT.AND REAR: BODY MEASUREMENTel BODY ALIGNMENT PASSENGER COMPARTMENT ‘AND REAR’ BODY — cour +: MEASUREMENT POINTS. aia #3 Unit: mm (oof cantar positioning monk |@®@ + Front pillar outer upper joasle _ ]@© + Outer front pil tandord hole rf se. SSE D+ Extensfonenie oor ont hole center (8 ea.) EG): Rear fender jomie [OO 7 Rew Fmd coma awe BB — BH! Rear fonder ioate | a) [® + var waist mold hole canter + Roar waist Range ond sar Fal renforeoment 7K Fal |@ = ane crosmamberindention conor = { 7 2nd crossmember @as= Le ey (BO + Separsion mounting ssorber — |OO 7 Rear floor rer bump ay ole hole (10 dia) ‘center (80 dla.) (OI VinaisBODY. ALIGNMENT PASSENGER COMPARTMENT AND REAR BODY MEASUREMENT FAST BACKBODY ALIGNMENT. PASSENGER COMPARTMENT AND REAR BODY 4 MEASUREMENT POINTS. FAST BACK Una mm @ = Roof center positioning mark 1® © :. Front pillar outer upper jogale G@O «+ Omer front pio stan enter (6 dia.) ]©G@ = Front pitta ovier upper loose BS + Outer font pier standard hole conter (14 di.) | + Coud top standard hola center (aia) @: Rear floor front extension hole center (8 a.) ° DO + Rear fender indention center ® = Roof center positioning mark OD + Reer fender jogste Rear fender flange end Oa ~ ese fondor ‘Roar panel upper reinorcoment positioning marke e: ® Reinforos rea panel upper ‘DO ¢ Sispersion mounting absorber hole (10 i.) DG ? Bear floor rer bumper say hole center (30 dia.) panes COa JEM =32-HANDLING PRECAUTIONS FOR PLASTICS, HANDLING PRECAUTIONS FOR PLASTICS Heat resisting c Abbreviation Material name ‘temperature Resistance to garoline and Other cautions Lari solvents c (°F) Gasoline and most solvents PE Polyethylene s0(176) | Oasclne and Flammable aaa ee ‘re harmless if applied fora | Poison gas is emitted Pvc | Potwiny hiorise 90.1084) T Jory sort time twine up. | when borne quickly) Gesoline and most solvents PP Polypropylene 90194) | Gettin an Flammable aes | Revvionirie 90 (194) © | Avoid gating ndsolvents, | Avoid bake fu nes | Aevloniieehytne 80,194) | Avoid esotine and slwins, | Avoid brake fu Pu [Potmetiimemeryise | 901198) | Avid ote onsen. | Avoisiay ta | PuR | Poiyuiethane go (rq) | Baseline and mest solvents | noid brake uid. Aerylonitite erylic a tek aed etal Fade aed eto As ee 952081 | Avoid gotne nd solvents, Avo rake fi 0: | Poiphonvins onde 110 (280) | Avoid getoine and solvents. Pom Potyaciial 120 (248) | Gascling.and solvents are Avoid battery acid, fe harmies. PC. Polycarbonate : [Avoid gasoline and solvents, PA Polyamide (Nylon) | 450,302) Sealing ine MostspWvents | avoid immersing in water. eechiGn |. “Gatoline and most solvents FR | ber tanvrced pass | ro ane) | Seng cmon ste PPC "| Polypropylene compo 115 (230) ° | Stoling andl most solvents” | Fisamable are hacmleis ee PET Polybutylene terephthalate | 140 (284) | Gasoline and most solvents ss) ou. are harmless. TPR ‘Thrmoplastic rubber” 80 (176) Avoid gasoline and solvents, E = TPE ‘Thermoplastic elastomer 80 (176) Avoid gasoline and solvents. ™ i 1, When repairing and painting a portion of the body adjacent to plastic parts, consider their characteristics (influence of heat and solvent) and remove them if necessary or take suitable measures to protect them, 2. ‘Plastic parts should be repaired and painted using methods suiting the materials.i PRECAUTIONS For PLASTICS! LOCATION GF PLASTIC PARTS” COUPE Lpsat side tishet (2) [oe EWickiog pias (ory L-caoter console box \ (prc) 7 \ Rear side finish (PP) lamp lens (PAINE) NOTE: Arrows” 43} (in enlarged portions) indicate the location of symbols used to identify plastic material used.HANDLING PRECAUTIONS FOR PLASTICS. LOGATION..OF: PLASTIC; PARTS FAST BACK Fur spcee ne fewrade, (PPC) 7 finisher Rady sid weatherstrip (ABS) (PP) , Roar pillar finisher (FP) Front pillar finisher (PP) Door finisher. WA a ee iQ) ; Hy re oe an (aes) ge Sst Urront tender protector (PP) tens (PntMA) Back-uplamp tens (PIMA) instrament ear sic spoiler (PUR Puree : Hi-mounted stop are lamp lore (PMMA) fie toed deetah fear pOgA 7) Ce \ / aner corse box \ far ume tac ru ey MO Rear finisher AFP) Dash side finisher! anes om NOTE: Arrows" 4 (in enlarged portions) indicate the location of symbols used to identify plastic material used.; sou os 6 PRECAUTIONS 128 PREGAUTIONS: IN ‘OPERATION WELDING PRECAUTIONS. cae i 1, Wear protectors Coggies SS * Be sure to Wear gouglés, earplugs, respirator, | forth, dependirig of, the work to red. Working clothes,"safety, shoes, Respi- @ ; and working éép must be worn as usual. 2. Safety stand 1 © After'jacking up a vehicle body, refer to.”'Lifting Points"})~ =" Inflammables® ~:~ i y we Before starting repair work, be sure to discon: nect the negative terminal of the battery, ¢ When welding parts near the fuel tank, Bé'sure ! to remove the fuel tank. Plug.the filler port of I the tank. : 7 7 | © Plug the fuel pipe and brake pipes to avoid | leakage when removing connectors from the pipes.” © 4. Working environment 7 © Pay attention to veritilation and the health of operators, Pe © Paint and: sealant may generate poisonous gases when heated by fire. To prevent. this, do not™ use a-gas welder for cutting off damaged’ por- tions, Use an air saw or an air chisel, © Use a belt’ sander or rotary wire brush for re- moving paint from the panel,PRECAUTIONS. PRECAUTIONS IN OPERATION 5. Vehicle body straightener * Be sure to use correctly according to the in- struction manual prepared by the manufacturer of the straightener. When straightening a dam- aged portion, never stand 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 L_EXTERNALLY ATTACHED PARTS __| 1. Protéction of body ‘* Remove ‘or cover. interior’ components (seats, instruments, carpet). : When welding, cover glasses, seats, instruments and carpet with a heat-resistant matetial. (This Protection is necessary especially-when CO, arc welding.) ‘ 2. Protection of exterior parts S pais See Ww daraisecal *¢ When removing external parts (moldings and finishers) attached to the body, apply cloth or protection tape to fhe body to prevent scratching: ~~. sure t0 repair that portion: even a smal flaw in the painted gutta ‘may cause corrosion, *"RECAUTIONS IN REPLACIN fw retin wae cs : OPERATION. i ne A oi mame aL ye8g Use of genuine parts 1 * In order to maintain the original functions and high quality of the vehicle, it is recommended that you { use genuine Nissan parts.~ PRECAUTIONS, PRECAUTIONS: IN ‘OPERATION General precautions Welding must be properly performed so that vehicle body will retain sufficient strength and durability. locatisiist6"Be welded; numbi spots (or welding welding is superior in weld ses: In_addi- thetinal unnecessarys\. " For these reasons, itis recommended that fe sistance spot welding be used. whenever possi- plete Boe Further, use of mig welding is recommended for locations where resistance spot welding cahnot be'utilized. ° eee CAUTION: : Gas welding (oxyacetylene gas welding) must not be used because it causes a decline in strength of areas surrounding the welded parts, There are a variety of resistance spot welders on the market, Be sure to. use a welder with a sufficient. ~38-PRECAUTIONS PRECAUTIONS IN: OPERATION Spot welding fs : 7 ' 1. Spot welder ¢ S To obtain sufficient strength at the spot welded portions, perform the following checks and adjustment on the spot welding machine before starting operation. y (1) Adjustment of arm a, ‘Keep the gun arm as short as possible to obtain the maximum pressure for welding, 2 b. Securely tighten the gun arm and tips so that they will not become loose during operation. (2) Aligntnent of electrode tips ind lower electrode tips on the oor alignment of ‘the tips causes insufficient: pressure, resulting in: insufficient current density and insufficient strength at the weld. ! nous yiGorrent 22° 5 (3) 180° to obtain’ the desired welding strenath. Before starting operation, make sure that "the tip diameter (D) is kept'the proper size, aid file it cleanly to remove burnt or foreign matter from. the surface of the tip. De2T+3 (mm) + 0.12 (in) Unit: mm int Thickness (7) | Diameter (0) | [Thickness (1) | Dismeter (0) 06 (0.028) *| 420.168) || 1.0 0.039) | 5.0 (0.1971 ss 07 (0.028) | 4.4 (0.173) || 1.240.087) | 4 (0213) 8 (0.031).| 48 (0.181 || 1.4 (0.055) | 52 (0.228) 08 (0.035)"| 480.189) | | 18 to.063)-| 6.240.244) wis Ta aeraghgce 1th | 2. Condition of the pane! Presence of aap, paint film, rust, or dust on the surface of the panel causes poor current flow. and reduiction is spot area and these lead to unsuccessful welding. é Before beginning, itis necessary to thoroughly check the condition of the panel, and make any necessary corrections. ase. te * 3 iei =. PRECAUTIONS PRECAUTIONS ‘IN ‘OPERATION: (1) Clearance between welding surfaces: Any clearance between the surfaces to be S-welded’ calises'poor ‘current flow. Even if weld- Bay ry oo pam ing an be made without removing such gap, [a bacome smaller, result- ‘ng in insufficient strength. Flatten the two surfaces:to"remove the gaps, and’ clamp them tightly with a clamp before welding. A & (2) Metal surfaces to be welded: Paint film, rust, dust, or any other contamina- tion on the metal surfaces to be welded cause sufficient current flow and poor results. 3 Remove.all foreign matter from the surfaces to- | be welded. (3) Corrosion prevents the welding process on metal suiface: corrosion agent that has higher conductivity, It is important.to apply the agent evenly even _ “to the end face of the panel, Before operation... Apply agent to the whole © gunface including the and face, 3. Precautions in performing spot welding: (1) Selection of spot welding machine — Use the direct’ welding ‘metiod...(For the por- : tions to which direct’ welding cannot be er fl applied, use plug welding by mig welding.) f) (2) Application of electrode tips — 5 Apply electrodes at right angle to the panel. if 7 the electrodes are not applied at right angle, ll) the current ‘density will be: low résulting “in s-witdeytse ini oe insufficient welding strength. ‘ore motal sees veri. (3) Lapwelding of mote than three metal sheets ~ For portions where three or more metal sheets are overlapping, spot welding should be done twice. ~~PRECAUTIONS - PRECAUTIONS IN OPERATION’ (4) No. of points of spot-welding: Generally, the capacity of spot welding machines available'in repair shop is smaller thai that of welding ‘machines at the factory. Accordingly, the number of points of spot welding should be increased by 20 to 30% in a service shop compared to spot-welding in the factory. (5) Minimum welding piteh: ‘The minimum welding pitch varies with the thickness of plates to be welded.:In general, the values given in the following table must be observed. Note that excessively smail pitch allows the current to'flow through surrounding portions, and this results in insufficient welding strength of the metal.72" 22 Unit: mm fin) Thickness (2) ‘Minimum piteh (2) 0.6 (0.024) 10 (0.39) 0.8 (0.031) 120.47) 1.0 (0.039) 18(0.71) 1.2 (0.047) 20(0.79) 1.6 (0.063). > 27 (1.06) 1.8 (0.071) 31 (1.22) (6) Minimum fap of panels: pe 7 Observe the following values for the lap distance of panels. If the lap distance i is too small, it results i ine insufficient strength and also in a strained panel. 7 Thickness) 1am pitch (8) 70.6 (0.02 >. 11(0.43) >" 0.8 (0.031) 11 (0.43) 1.0 (0.038) 12 (0.47), 1.2 (0.047) 14 (0.55) 1.6 (0,063) 16 (0.63) 18 (0.071) 17 (0.67) Be sure to spot weld at the center of the overlapped portion, nas (7) Spotting sequence: Do not spot continuously in only one direc- tion. This-method provides weak welding due -to the shunt effect of the current. If the weld- ing tips become hot and change their color, stop welding and allow the tips to cool,{8) Welding corners: Porat Do: not weld the corner. radius portion. Welding!isys <}.n’- this, portion. results: in’ stress. concentration, which leads to cracks. nash Examples ¢ Upper. corner of front and.center pillars-=2<)- °c : * Front upper portion of reat fender: » © Corner portion of front and rear. windows: & 4, Inspection of welded partion — inspection explained below can be adopted easily at the time of welding, Before and after welding, be sure to perform this destructive inspection to check the strength of the welded portions. The welding spots should be spaced equally and arran (1) Check by using test piece (Confirmation before operation). «Prepare test pieces having the sare thickness os the panel to be welded and weld them togeth- er. Break the welded portion by twisting and examine the condition of the ruptured portion, Clamp: both tést: piéces: together ‘so that they will not slip or move during welding. * With this test, a hole should be made on one test piece by tearing at the Welded portion. If med;-it indicates: that the welding conditions are incorrect. Adjust the pressure, ir 7 oe a, ad welding current, current passing time and other oR conditions; and repeat test until the best result Insel tebdeie'= tues in eu ae is obtained, be formed by tearing : = dl nl —4z~PRECAUTIONS PRECAUTIONS: IN ‘OPERATION : (2) Check by using chisel and hammer (Confirma tion after welding) aoa Reena value © Insert the tip of @ chisel between the welded i : (0.059 0.079 in) plates, and tap the end of the chisel until the clearance of 3 to 4 mm (0.12 to 0.16 in) [when the plate thickness is 0.8 to 1.0 mm (0.031 to 0.039 in)] is formed between the plates, If the welded portions remain normal, it indicates that the welding has been done properly. This clearance varies with the location, of the welded spots, length of the flange, plate thickness, welding pitch, and other factors. Note that the Feforoce value value shown above is only a reference value, 34mm Tap with a hammer * If the thickness of the plates is riot equal, the clearance between the plates mist be limited to 1.8 to 2.0 mm (0.059 to.0.079 in). Note that further, opening of the piates can-become a de- structive test. ©. Be sie to rir the deformed portion of the panel after inspection. Mig welding ~ = aan 1. Condition of panel to-be welded -—— Paint film, rust, or oils attached to the surface of the panel reduces the welding conditions, causing blowholes and spatter. Thoroughly remove eny 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 to er mm (0.20 to 0.24 in) Plug woiding Butt welding diameter on one of the two metal plates to be ba 7 welded and keep. the upper plate-and lower CE | plate in tight contact. (0.20 100.28) camorar b. Apply the torch at right angle to the plate and fill metal into the hole at a stretch, Note that intermittent welding leads to the generation of oxide film on the surface and this ceuses blow- holes, If this occurs remove the oxide film with awire brush. c. Make sure that the upper and lower plates are welded together tightly, pie oe Section A~A,< PRECAUTIONS: PRECAUTIONS IN OPERATION ((2) Buitw a eeore ‘of:St"ains’ and to align two metal | surfaces. Tack tWo-metal_ pieces by- placing c. To fill, the spaces between.: intermittently surface of the pafel.using a Sander, then fill metal into the space. If weld metal is placed ithout grinding the, surface of the beads, 3. Inspectioti’of welded portion Refer.to the inspéction meth: = a ese tain? ‘ill Be © saused if, Fee! section by?————————_——REPLACEMENT OPERATIONS—___ SYMBOLS FOR CUTTING AND DESCRIPTION . 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 out or alr chisel cut esos 2-spo8 wade ————— (2>pane! overapping portions Spot welds Spot (pane! overlapping portions) ==. ‘MIG (metal inert gas) lug weld ‘Mig seam weld Point weld Dp Sealingfront aleting |_____INSTALLATION NOTE _-» ‘© Align locating holes and install, front: bumper >. bolt, when installing service part, "=~ 246sREPLACEMENT OPERATIONS RADIATOR: CORE:SUPPORT ‘(Partial Replacement) ”, Service Joint tt - i oe Portions to be welded © Side radiator core support {Lower radiator cor support 8 Upper haodledge 4. Upperhoodteaye Loner radiator core support assembly Side radiator coe support ‘©. Front lowor hoodiedge on ‘Side redistor core support assembly Service parts for radiator core support are available in 4 parts in addition to an. assembly. Thus, only the damaged part need be replaced. The procedure, whereby side radiator core support and upper radiator cofe support are replaced simulta neously, is described in the page that follows. Sido radictor ‘core support Lower radiator core support —47—REPLACEMENT. OPERATIONS RADIATOR: CORE ‘SUPPORT |(Partial: Replacement) INSTALLATION NOTES gn ‘ing -holes- (positioning marks)“and- 2. “install headlamp: bracket and Hood tock stay, : - ~ ‘© Install service part with vise clamps according to “BODY ALIGNMENT” drawing. “Viistall™ ieadlamp cover, hood and front fe ~~ cheek clearances, grades ‘and parallelism.” —48~——_—__—__—__—__ REPLACEMENT OPERATIONS. HOODLEDGE (Work after radiator core support has been removed.) Service Joint Portions to be welded Front closing plate pach "Front side member closing pate & place late & plate placa ~ REMOVAL NOTES. © Portion (i) is 2layered'spot weld. But spot cut only one panel for hoodledge reinforcement.REPLACEMENT ‘OPERATIONS HOODLEDGE © Stop” cut” ‘only“top panels oF 2”and’3-layered welds at portions (g), (h) and (j). Use spot cut holes in sidé cowl-top for MIG plug holes ‘when welding service part. ~ ' Align locating holes as shown |____INSTALLATION NOTES’ : the figure. ‘* Spot cut‘through weld portion (2) from inside, r erisk)., Use drill with 5 to 6” mm dig. becatise holes.on-lower dash panel will be used as MIG plug weld holes. MIG piug weld portion le). from inside. while portion wiith * (asterisk) should” be’ ‘welded = from outside. # As lower dash panel is sandwich steel plate, it is difficult to align: weld, points when welding from outside, (Weld failure’ will occur “if, welding is made ‘at. portions with melt sheet overlapped.) = 505REPLACEMENT OPERATIONS *HOODLEDGE® =< ees ‘® ~Apply”an anti-corrosive agent to welded parts ide oF side cowl top.” —s1—REPLACEMENT OPERATIONS HOODLEDGE ‘(Partidi:Replacement) (Work after radiator core support has been removed.) Service Joint Portions to be welded &. Front side mambar clsing plate & A. Upper hoodledse ‘& Frontclosing plore pateh front side momber (Not welded to Front closing alate patch & front ride front lover hoodledse) ‘member closing plate 4. Front strut housing Front side mambor closing pate 2 Hoodlodge reinforcement Front site member closing plate & 1. Upper hoodieage front stat housing 5. Heodledge reinforcement Service parts for hoodledge are available in 4- individual service parts in addition to an assembly. Hooilodge reinforcement Thus, the damaged part alone can be replaced. ‘The procedure, whereby partial replacement of upper hoodiedge and front lower hoodledge are replaced simultaneously, is described below. Sac Ure hoa = SS f — / eS Fron ower hodlodge —52-REPLACEMENT: OPERATIONS‘ REMOVAL NOTES] © Cut off upper hoodledge as shown in figure, then remove with front lower hoodledge. * When cutting upper hoodledge, be careful Not to damage hoodledge reinforcement. Hoodtedge: reinforesmer © Cut Off servige pait, leaving its projected area~ in same position as that of vehiclebody for,REPLACEMENT OPERATIONS: seeene FRONT 'SIDESMEMBER © O~ Portions to be welded ‘4, Lower desh panel & front side member = 2” Enaateltng ptate patch 2 Front closing alate patch extension = Frontside member closing plate & Frontside member closing plate & | Front side membsr closing plate & front ebpting plat patch front closing plate patch front ede member extension io Front se mamber closing plate & b. Front sto member closing plato +. Front side member closing plate {frost side memnbor extension Lower dssh panel 9. Frontside member reinforcement & —, x, Front side member oxtension Lower dash panol front side member extension = [Lower dash pane! Lower dath ponel & front side member. Front sida member closing plate fh. Lower dash panel & front side member extension Frontside member closing plate & Gxtension front side member extension 9... Lower dash panel & front side member REMOVAL NOTES. * Spot cut through weld portions (c}, (e), (f) and * (asterisk) in (b). a4© "Beta piriels“as shown’ in figure’ to facilitate removal. REPLACEMENT OPERATIONS it “FRONT ‘SIDE:MEMBER SAlighi “front “suspension” membes installing front side member cl Frontside membor ri Frontside 7 rmombor closing plate ou \ Fron se member extension INSTALLATION NOTES. * Install front side member, correct bent front side member extension, then weld front side member and front side member extension, * Apply. anti-corrosive agent to inside of front side member.REPLACEMENT OPERATIONS! FRONT SIDE MEMBER (Partial: Replacement) (Work after radiator core support has been removed.) Ey “= Portions to bie welded é. Front side member rvinforcement-~ f. 8 Frontelosing plate patch 4. Front lower hoediedge a Front closing ats patch & front side Front lower hoodledge & trot side Front closing plate pate & front sido member closing plete ‘mornbor closing plate smimbar closing plate Front sice mamber closing plate fe, Front side member closing plate A... Front sie member ©” Front side member and ‘front side member closing plate service parts are available, The front side member closing plates are available in 2-divided .single” parts in addition to: an assembly.” : ‘Thus, the damaged area alone can be replaced. The proceduré for feplacing the front closing -platé patch and partially: front side member simultaneously are described below.REPLACEMENT OPERATIONS FRONT SIDE MEMBER: (Partial. Replacement) Butt Joint: Welding- REMOVAL NOTES -INSTALLATION NOTES. © Scribe a straight line on the front side mem- ber along the hole centers as shown in figure. +: Dimansions of loft side parts Units mom © Cut off front side member along scribe line. Be careful not to damage front side member reinforcement and do not cut on the hole. ox. No. Put.gum. tape on the front side member. Cut. off gum tape along front side member edge and make holes in the gum tape at front side member holes. Remove gum, tape and. fix it to. servicepart,, aligning the front side member flange end and holes: ee Ee Scribe a line at the end of the gum tape.REPLACEMENT’ OPERATIONS. FRONT::SIDE MEMBER‘ (Partial: Replacement) -Butt JdintsWelding- ore ee aR a IT front side member reinforcement. Front sido ramon —/ reinforcement. jaft.~as indicated’ in’ wing. When ~doing this, member hole'and front closing “plate patel bolt as shown in fi 7 © Install--service ALIGNMENT! © Apply an anti-corrosive agent to welded parts - and inside of front side member. = 58REPLACEMENT OPERATIONS FRONT SIDE MEMBER ‘(Partial Replacement) REMOVAL NOTE_ in section titled “BUTT-JOINT WELDING". INSTALLATION NOTES. © For patch-joint welding, proceed as follows: © Prepare a patch panel [20 mm (W) x 40 mm, (L) x 1.8 thf (T)]_ as shown in figure below. Use service part leftovers to make a patch panel to improve work efficieney. Unit:_mm| * Drill 6 mm dia. plug weld holes on portion (A) of service part “nd~portion (A+) of side" member... ~~ — 59 When removing panel, use procedures outlined. -Patch Joint Welding- Fit patch panel to service part and plug Weld Align service part with body. Plug weld at portion (A*) first and then MIG seam weld as specified, Perform subsequent operations using pro- cedures outlined in section titled “BUTT- JOINT WELDING”.REPLACEMENT OPERATIONS ——_ vee FRONT PILLAR’. - Side cod top & uoiper dash ‘Upper dash & lower dasn Upper das &e sie ; = REMOVAL NOTES. Before cutting front pillar, be sure to support roof. ° 60REPLACEMENT, OPERATIONS —____ FRONT ‘PILLAR Butting position is 300 mm away, from locating hole. It is better to butt at.this position due to its construction, 1» Determine cutting position and record distance from locating holé..,Use this distance in cutting service part. Cut outer front pillar at 60 mm above cut position of inner front pillar. ‘Record distance * Using a cutting jig. makes'it easier to-cut.’Also, it will permit’sefvice part to"be accurately-cut at joint position, Inner front pillar — *, Al. example of cutting oper Cutting jig is & follows: : @ Mark cutting lines. 7 ‘A: Cut position of outer pillar B:_ Cut position of inner pillar ® Align cutting line with mark on jig and clamp ® Remove jig and cut remaining portions: , | ® Cut off position B in same manner.REPLACEMENT’ OPERATIONS FRONT PILLAR aa ee ag N era # Weld parts’ to’ be ‘butt weldéd 25 far a8'flangé INSTALLATION NOTES, end portion. Finish welded part with 4 ander. © Drill MIG plug weld hole at ‘portion’ {i) of 1” SH smooth ‘finish’ is “not“obtainied: “finish by ~ eee soldering, nvisaunsenos — service parts * ‘Install’ service partes indicated in “BODY ALIGNMENT” drawing. When doifig 1 front fender attaching hole and locatin side dash, ~ ie ‘Apply an ahticcofrosive agente welded parts inside of front pillars: a1 reget ‘© ‘Install doorzand front fender. Check clear- lances, gfadés and parallelism, F 63REPLACEMENT:-OPERATIONS - OUTER’ SILL Service Joint Rate . ove qasray lS] ~63—INSTALLATION NOTES. Accurately cut off service part as shown in figure, ‘Outer sit Dress tne Install service part: by-all fender at holes. ** % Front tendor installing hole ° Drill, MIG plug weld holes, with a-flat drill, Portions {e) using spot cut holes in m: panel, and MIG plug weld them. ih REPLACEMENT: OPERATIONS. OUTER’ SILL 8 MIG Seam Weld portions (A). Fihish welded; parts with a sander, 9,_ebply an anti-corrosive agent id€ Of outer sill.REPLACEMENT:OPERATIONS r OUTER SILL(Partial Replacsitient) Service Joint =A oe and f: Welding pitch is approximately 25 mm. |________ REMOVAL NOTE. ‘@° “Determine butting position, avoiding ‘outer sill brace and holes. oe— REPLACEMENT OPERATIONS QUTER«SILLE (Partial Replac INSTALLATION NOTES. © Cut. off service part, leaving its hole in same position as that of vehicle body for po: _ ing. ‘ l© Place service ‘part, hole=with th vehicle body, and perforniavertap cuttif ‘© When dressing butt weld part, cover up, holesin upper part of outer sill with tape to prevent chips from entering. first to Prevent movement. When welding, temporarily weld each press line Ce es a Lif \REPLACEMENT OPERATIONS. REAR ‘FENDER Service Joint — ee = / 1G A. Rear fender 8 parcel shel with lar 8 parcel shelf with =67~REPLACEMENT, OPERATIONS. REAR:FENDER © Panel can be jointed at any portion. Wheft cutting rear fender, be careful ‘not to damiagé lock pillar seat belt anchor. REMOVAL NOTES___| Butt weld position 300 mm of roof flange end. © Make rear pillar part (A) of butt weld within << sander. MIG seam weld and finish we jelded parts with a INSTALLATION NOTES. ‘© When , installing seryice part, set rear panel and rear combination lamp base in place simul- taneously, and check various dimensions of part locations according to "BODY ALIGN- MENT” drawing. Install door and trunk lid, and check clearances, grades and parallelism.REPLACEMENT OPERATIONS | es REAR ‘FENDER couPE © Solder” joint at ‘portion (A) (root and Tear fender), and then apply an ahti-corrosive agent | 3 jing of inner rear pillar and other welded |REPLACEMENT OPERATIONS. — REAR-FENDER: FAST BACK Portions to be woldad 4. Trunk floor sa & rear combination Fieer side membor ‘A. Rear fonder famp base ©. Rour pans! Rear fondor 0. Upper inner pillar Fer panel & rear floor rear 12 Upper inne pill & lock pillar seat ‘Upper inne pillar & rear plilarseat boit p. Rear fender corner bolt anchor anchar far fender corner & reer panel 1b. Upper & lower inner pillar fh. Lower inner pitt ‘a. Rost fender corner Lower inner pillar Upper a tower inner pillar r Outer si 1. Upper inner pillar (Queer sill & inner si Upper innar pillar & rear roof ail brace 1. Outer sil & outer rear whoetnouse j. Outer st ® (Outer rear uheathouse ‘Outer sill & outer rear wheothouse ‘ Outer reer whesthouse k. Rear combination lame base Cuter rar ihaethouse & trunk floor Feet fender comer & rear combination femp base “Trunk floor sca Rest floor rear side “Trunk floor seo 70REPLACEMENT OPERATIONS. REAR? FE REMOVAL NOTES. The inside body construction is shown in the figure. ear pila sat [batt enctor Cut off rear fender portions (A) and-(B) as shown in figure. Be careful not to damage lock pillar seat belt anchor and-rear pillar seat belt anchor, 1 NDER FAST BACK 1, When cutting portion’ (B), -use -a,chisel'so as not to damage mating parts. 2)" INSTALLATION NOTES. ¢ Before “installing rear fender, apply sealant to fuel filler lid base“and fender. \ eetREPLACEMENT ‘OPERATIONS REAR’ FENDER FAST BACK be*sureto%align’ ~ # Weld part:fo be butt Welded up-to flange”énid portion: Fi After welding, apply an anti-corrosive agent +o inside of welded part. 2REPLACEMENT OPERATION: ., REAR°FENDER {Partial :Replacéiient) =<) REMOVAL NOTE. ‘* Cut off damaged portion with lap allowance of about 60 mm: ‘* Remove any iron particles with vacuum cleaner + can be easily spot cut later. REMOVAL NOTE. ‘© Cut off ‘damaged portion’so that welded part INSTALLATION NOTE __. © When installing service part, align “locating holes: {Js t—/|REPLACEMENT“OPERATIONS. REAR FLOOR: REAR (Work after rear panel has been removed.) Service Joint © 4 indicates that shoo ig an 04 __with the same dimensions Portions to be welded a. Rear floor side aR B. Rearside member REMOVAL NOTE. INSTALLATION NOTE ___| work with, ‘© Cut off damaged portion so that itis easy to ~-After welding, spray in an anti-corrosive agent from rear opening of rear side member. —7B-REPLACEMENT OPERATIONS. REAR. SIDE-MEMBER (Work after rear panel and rear floor rear have been removed.) ‘Service Joint INSTALLATION NOTES. © Drill MIG plug weld holes in service part por- tion (h). ~T9-REPLACEMENT: OPERATIONS ——_—____— REA EMBER © > Aligniservige part at“center-rearcrossmer ‘Apply anti:corrosive wax to inside of rear side positioning mark when installing." members “and undercoating to underside’ of it in place with 2 ja clamp. A —80-REPLACEMENT-‘OPERATIONS. — REAR ‘SIDE MEMBER ‘EXTENSION © Rear side member service parts are available as ‘an_assembly and. two single parts. This section gives- replacement procedures for rear side ‘member extension. ~81—REPLACEMENT“OPERATIONS. REAR-SIDE: MEMBER’ EXTENSION (a), (f) and (g) when a8 MIG plug weld. < ber. ‘* Drill MIG plug weid holes on rear side mem- = INSTALLATION NOTES: =< ‘© To remove weided panel (e), proceed as-fol-~ lows: @ Spot cut welded portion (e*). ® Roughly cut panel off with an air saw. as —-~shown. Remove extension, eee @® Remove points spot jvelded to rear side.mem- ber. |o (See hoxt ——— dy -82-REPLACEMENT OPERATIONS — REAR SIDE: MEMBER*EXTENSION © Measure” dimensions and properly position Treat welded part under bedy with, an anti” service part according to BODY ALIGN- corrosive agent, and apply an undercoat to it, MENT" drawing. c ‘Then spray an anti-corrosive egent from rear openiig of rear side member. * MIG plug weld points (a), (b), (c), (d), (e), and (g]. — a3—_——————— REPEACEMENT. OPERATIONS: 2 ROOF: PAN! COUPE Service Joint’ = indicate with the same Portions to be welded A. Front pillar BR Aront 1064 rit brace——_________ REPLACEMENT: OPERATIONS: eee ROOF PANEL? FAST BACK Service Joint “indicates that there isan equivalent welding persion \ with the same dimersions on the FH, side. 6 CF af BP apy Portions tobe welded ‘pe tower rea 0 vil b, Front roof ra brece er A. Front plist 7 Front roof raiLbrace & outorupper ig,” Roof rll ace & roar fender 8. Reor fencer ‘ont pillar Root eal brace & lower rear roof rai 8 -Frontroot ral fe... Outer upper & inner front pillar h. Lower rear roof sil Front root ral & front roof rilbrace ‘Root drip Ki Upper a lower rear root rai 2 Rear fender Feor fendar & upper reer root all —85>REMOVAL NoTE_____ © Remove brazing from joint portions between roof and rear fender, roof and front pillar. REPLACEMENT OPERATIONS ———_____.. ROOF ‘PANEE FAST GREE es NppIY sealer dh ply rosive, agent to inside of brazed ‘ortions & MIG plug welded portions. INSTALLATION NOTES: —- © When spot welding portion (d), use en offset Brazed portions (A), (B) and dress it with a sander.REPLACEMENT: OPERATIONS. OUTER ‘DOOR sPANEL Service Joint Portions to be welded ner panel ce. Inner panel nr panel 1. Door walstrelnforcement REMOVAL NOTES. '* Cut door outer panel hem with a sander. After removing outer panel, dress rusty part with a sander and treat with anti-corrosive’ agent. = nove sow OMe {nner panel i i \~ our paet Sate hs an ~87—REPLACEMENT OPERATIONS —————______ OUTER ‘DOOR ‘PANEL INSTALLATION NOTES. © Apply sealant to outer panel hem. ‘© Apply sealant to whole panel edge. © Hemming work carried out in two steps. ts = Note: Bend panel edge round. ofouter panelshould be. - ot ‘¢ .-Apply-anti-corrosive..wax to. lower ‘door, ic } Sate. fee NG. ot ‘00D © MIG wold edge after hemming outer panel.