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CAUTION)
NOTE ON REPAIR WORK
INSTALLATION
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- To reinforce the strength of the front pillar cut area, cut the side outer panel 160 mm above the front pillar cut area, 120 mm above the front pillar reinforcement upper and 80 mm above the front pillar support.
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- To reinforce the strength in the side sill cut area, cut the side outer panel 100 mm behind the side sill cut area and 50 mm behind the side sill outer reinforcement centre.
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- When assembling a new front pillar inner lower parts, cover the front pillar inner lower hole with aluminium tape since it is not possible to fill the area shown in the figure of the instructions with foam materials.
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- Divide the new front inner pillar upper parts into A (front pillar inner upper reinforcement and front pillar inner upper) and B (front pillar reinforcement upper and front pillar support).
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- When assembling Part A, weld the areas shown in the figure of the instructions from the outside and inside. After assembling, to prevent the foaming materials from dripping in the area shown in the figure of the instructions, adhere urethane foam to fill (bury) the front pillar interior.
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- Cut Part B in alignment with the front pillar reinforcement on the body-side. Next, cut only the front pillar reinforcement upper 80 mm from the cut area to create a cover, then cut the front pillar support 40 mm above the front pillar reinforcement upper cut area.
CAUTION)
- To assemble Part B, weld the front pillar support then weld the cover of the front pillar reinforcement upper.
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- Remove the side outer panel from the new front pillar outer parts. Cut the front pillar outer by aligning it with the side sill outer reinforcement centre on the body-side. Next, cut only the side sill outer reinforcement centre 100 mm forward from the cut area to create a cover, then cut the side sill reinforcement support 50 mm behind the cut area of the side sill outer reinforcement centre.
CAUTION)
- When assembling a new front pillar outer parts, apply a front pillar silencer protector in advance, bury the clearance with butyl tape then apply structural adhesives in the areas shown in the figure of the instructions.
Adhesive : Epoxyayresin adhesive
Brand : 3M ATD Part No.8115 or equivalent
Brand : 3M ATD Part No.8115 or equivalent
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- Weld the side sill reinforcement support then weld the cover of the side sill outer reinforcement centre.
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- Apply in advance body sealant in the areas shown in the figure of the instructions when assembling the side outer panel.
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- Assemble the side outer panel, then bolt and tape the hole and flange with aluminium tape and fill the hole with foam materials as shown in the figure of the instructions.
FOAM: 3M ULTRAPRO Panel foam-Yellow
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- Wait 2 hours after filling the foam materials to remove the bolt and aluminium tape, then melt the foam materials with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with foam materials.