SIDE SILL PANEL INSTALLATION [PANEL REPLACEMENT]

id098008743800

1.  When joining the new and old parts, temporarily install and fit the new part in position, measure each dimension according to the body dimension, then adjust the position to align it to the standard dimensions.

2.  Drill holes for plug welds before installing new parts.

3.  Weld the six locations indicated by (A) and install the side sill rear reinforcement.

4.  Weld the 28 locations indicated by (B), then temporarily install the side sill gusset.

5.  Weld the 12 locations indicated by (C) and install the side sill reinforcement.

6.  Weld the 110 locations indicated by (D) and install the side sill outer.

7.  After temporarily installing new parts, make sure the related parts fit properly.

ar8uub00000056

Drill Hole Install for Rear Deflector

1.  Cut out the templates along the cut lines.

2.  Face the printed side of the templates to the rear deflector, align two sides of the templates, and affix them to the rear deflector using double-sided adhesive tape.

ar8uub00000073

Caution

•  Affix double-sided adhesive tape on the printed side of the templates.

Note

•  Paper type double-sided adhesive tape is recommended.

3.  Align the rear deflector with the installation position with no clearance with the body, and temporarily fix using a rivet.

ar8uub00000074

4.  Align the rear deflector bottom surface with the body, press it so that there is no clearance with the body.

ar8uub00000075

Caution

•  Be careful of the alignment of the rear deflector with the body and verify that it is firmly attached to the lower surface of the rear deflector with its height equal with the body from front to back.

5.  Place the templates along the bodyline and affix them using tape.

ar8uub00000076

6.  Remove the fastener and remove the rear deflector with the templates affixed to the body.

Caution

•  When removing the rear deflector, be careful that the templates do not slip or become ripped.

7.  Place the templates along the bodyline and punch holes through the center of the templates.

am2zzb00000104

Caution

•  Punch holes through the center of the templates with the templates affixed to the body.

8.  Remove the templates.

9.  Wrap packing tape around the drill bit.

am2zzb00000018

Note

•  To prevent damage and overdrilling.

10.  With the drill bit pointed perpendicular to the body, drill a hole gradually using a φ3 mm {0.1in}, φ6 mm {0.2in}, then φ10mm {0.39in} drill bit.

am2zzb00000178

11.  Grind the drilled hole to remove any metal burrs with a round file to finish the surface.

am2zzb00000105

12.  Wipe off dirt from the rear deflector installation surface on the body using a clean rag dampened with isopropyl alcohol.

ar8uub00000077

13.  Apply sealant for rust protection.

14.  Apply touch-up paint.

Caution

•  Make sure rust protection is performed properly.

Template

ar8uub00000078