GENERAL DATA AND SPECIFICATIONS . . . . . . . . . . . . . . .
00-15
00-2
GENERAL HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL ABBREVIATIONS The following abbreviations are used in this manual for classification of model types. 2.0 L Engine:1.998 liter <4B11> engine, or a model equipped with such an engine. MFI: Multiport fuel injection, or engines equipped with multiport fuel injection. PCM: Powertrain control module
TARGETS OF DEVELOPMENT Since first launched in 1973, the LANCER has always been acknowledged as a motor sport based vehicle in the sporty sedan market. Keeping with the tradition of these LANCERS, the new LANCER has been developed aiming at acquiring additional LANCER users, and even more, Mitsubishi customers.
PRODUCT FEATURES STYLING The global standard body size has been adopted to match the market trend.
DRIVING PERFORMANCE • The newly-developed aluminum block engine and CVT have been adopted to achieve excellent power and performance. 1. The power and performance greatly exceeds that of the previous LANCER. 2. The fuel efficiency in cruising range has been greatly improved from the previous LANCER, both for M/T and CVT. • High rigidity of body and suspension has been achieved. • With fine tuning of suspension, sporty steering, flat cornaring and superior driving comfort have been achieved. • The paddle shift has been adopted to achieve "Fun to Drive."
M2000029000758
M/T:Indicates manual transaxle, or models equipped with manual transaxle. CVT: Indicates the continuously variable transmission. FWD: 2-wheel drive vehicles. SWS: Simplified wiring system A/C: Air conditioning.
M2000004001215
M2000005000594
COMFORT • The Rockford Fosgate premium sound system has been installed. • The comfort equipment such as keyless operation system (KOS)*1, HDD navigation, handsfree phone for Bluetooth*2 has been adopted. NOTE: . • *1: In this manual, F.A.S.T.-key (Free-hand Advanced Security Transmitter) is described as Keyless Operation System (KOS). Refer to P.42B-2. • *2: Refer to P.54A-29.
SAFETY • The impact safety body aiming at high score in New Car Assessment Program (NCAP) has been developed. • With consideration of Insurance Institute for Highway Safety (IIHS), going ahead of competitors, the knee air bag has been equipped as a standard feature in addition to the driver's and passenger's (front) air bags, side-air bag, and curtain air bag.
00-3
GENERAL TECHNICAL FEATURES
TECHNICAL FEATURES EXTERIOR
M2000017000966
DESIGN FEATURES The robust styling to create the image of LANCER EVOLUTION, the symbol of Mitsubishi Motors sport DNA, has been established.
12
10, 11
1
3, 8
4 6
5
2,7 9 AC607908AC .
.
BETTER APPEARANCE
BETTER USER-FRIENDLINESS
1. Radiator grille integrated front bumper 2. Side air dams 3. Rear spoiler 5. Air dam skirt panels
10. Electric remote-controlled door mirrors 11. Heated door mirrors
.
BETTER AERODYNAMIC CHARACTERISTICS 4. Aerodynamic front bumper 5. Air dam skirt panels 6. Engine room under cover with bulges at left and right (Refer to P.51-3) 7. Side air dams 8. Rear spoiler 9. Aerodynamic rear bumper
SUPPORT RECYCLING OF RESOURCES Uses PP (polypropylene) materials that are easy to recycle and easy to stamp material symbols on the plastic (resin) parts.
00-4
GENERAL TECHNICAL FEATURES
INTERIOR
M2000018000969
DESIGN FEATURES Functionality, interior comfort, and safety have been emphasized, giving interior design for elegance and relaxation. Various measures have been taken to protect the environment and recycle resources.
AC609922
Quality improvement • Two-tone interior • Full interior trim Usability improvement • Armrest (floor console, rear seat, front door trim, rear door trim) • Cup holder (floor console, rear seat armrest) • Bottle holder (front door trim) Convenient storage • Glove box • Card holder (Glove box) • Seatback pocket [front seat (driver side)] • Floor console box • Door pocket (front door trim, rear door trim) • Tissue paper holder (floor console) Safety improvement • Front and rear collision protection seat mechanism (front seat) • ISO-FIX lower anchor (rear seat outside) • Upper tether anchor (rear shelf) • deiver’s and passenger’s (front) air bags • Knee air bag
• • • • • •
Side-airbag Curtain air bag ELR 3-point seat belt (driver side) ELR/ALR 3-point seat belt (front passenger side) ELR/ALR 3-point seat belt (rear) Seat belt retractor with a driver's side pretensioner and variable force limiter • Seat belt retractor with a passenger’s side pretensioner and force limiter • Headliner energy absorption rib Consideration for the optimum driving position • Seat height adjustment (driver’s seat) • Headrestraint with height adjustment (front, rear) • Seat slide adjustment (front) Measures for resource recycling • Aggressively use PP materials that are easy to recycle and easy to stamp material symbols on the plastic (resin) parts. • Reduction of chemical material (formaldehyde*, organic solvent) NOTE: *: Clear and colourless, toxic, irritating odour
00-5
GENERAL TECHNICAL FEATURES
BODY DIMENSIONS AND SPACIOUS CABIN
M2000019000285
9
8
10 5
2
3
7
4
1
6
AC609780 AB
No.
Item
Dimension
1
Overall length mm (in)
4,570 (180.0)
2
Front overhang mm (in)
955 (37.6)
3
Wheel base mm (in)
2,635 (103.7)
4
Rear overhang mm (in)
980 (38.7)
5
Overall height mm (in)
1,490 (58.7)
6
Overall width mm (in)
1,760 (69.4)
7
Tread mm (in)
1,530 (60.2)
8
Front head room mm (in)
1,005 (39.6)
9
Rear head room mm (in)
935 (36.9)
10
Interior width mm (in)
1,390 (54.7)
ENGINE
M2000020000717
The newly-developed 4B11 MIVEC engine has been adopted. For the 4B11 engine, the aluminum die-cast cylinder block has been adopted to achieve the top level of this class in high performance, good fuel efficiency, while being compact and lightweight. Technology and purpose for 4B11 engine adoption Item
High performance /good fuel efficiency
Compact and lightweight
Aluminum die-cast cylinder block
X
Cylinder head cover made of resin
X
Direct injection DOHC valve drive
X
Low exhaust gas
Low vibration
X
Intake/exhaust continuously variable valve X timing (MIVEC)
X X
Timing chain cam drive
X
Serpentine auxiliary drive
X
Reliability improvement
X X
00-6 Item
GENERAL TECHNICAL FEATURES High performance /good fuel efficiency
Compact and lightweight
Low exhaust gas
Isometric long port intake manifold made of X resin
X
Exhaust manifold made of stainless steel (double structure)
X
X
X
X
X
Rear exhaust engine layout Ultra fine injection
Low vibration
Reliability improvement
X
EGR system
X
Water pump with shroud-integrated resin impeller
X
X
Returnless fuel system
X
Iridium spark plug
X
TRANSAXLE MANUAL TRANSAXLE F5MBB type (5M/T) has been adopted.
CONTINUOUSLY VARIABLE TRANSAXLE (CVT) The new CVT has been developed to achieve excellent fuel economy, driving ease, and fun. This CVT achieves quick and smooth acceleration suitable for LANCER from any speeds. The CVT combines "torque converter" and "continuously variable tran-
X M2000021000732
saxle mechanism by steel belt & pulley" to achieve "high driving performance" and "better fuel economy." Depending on the driving conditions, the comfortable gear ratio is automatically and continuously selected from low to overdrive, ensuring driver-intended smooth driving without shift shocks related to acceleration pedal operation.
00-7
GENERAL TECHNICAL FEATURES
PADDLE SHIFT
Down shift lever
AC609992
Up shift lever Down shift
Up shift (operate it for 2 seconds or more to return to D range.)
AC611129AB
For some models, the paddle-shaped up shift/down shift lever has been fitted just behind the steering wheel to allow the driver to operate up shift or down shift with his/her hands kept on the steering wheel.
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GENERAL TECHNICAL FEATURES
SUSPENSION
M2000023000590
Shock absorber
Upper arm
Coil spring Stabilizer bar Coil spring
Stabilizer link Stabilizer bar
Toe control arm Rear crossmember Stay Front suspension strut
Trailing arm
Lower arm Front axle crossmember AC609418AD
• A MacPherson strut type suspension is adopted for the front suspension. • A trailing arm type multi-link suspension is adopted for the rear suspension.
• Flexible steering stability is achieved, along with comfortable driving, secure handling, and flat cornering.
The ABS that ensures directional stability and controllability during hard braking. ABS is standard equippment on the ES and GTS models but is optional. This ABS uses a 4-sensor system that controls all four wheels independently of each other, and has the following features: • EBD *1 (Electronic Brake-force Distribution system) control that can obtain ideal rear wheel brake force has been employed.
Wheel speed sensor Magnetic encoder for Wheel speed sensor wheel speed detection AC608518AC
• The magnetic encoder for detecting the wheel speed has been installed instead of the rotor as the wheel speed sensor. • For wiring harness simplification and secure data communication, CAN *2 bus has been adopted as a tool of communication with another ECU. NOTE: . • *1: EBD (Electronic Brake-force Distribution) • *2: For more information about CAN (Controller Area Network), refer to GROUP 54C P.54C-2.
00-10
GENERAL TECHNICAL FEATURES
PASSIVE SAFETY
M2000032000769
SRS AIR BAGS Driver's air bag module Seat belt with pre-tensioner
Passenger's (front) air bag module
Side-airbag module
Curtain air bag module
Knee air bag module
AC609360 AB
• Driver's and passenger's (front) air bags, side-air bags, knee air bag, curtain air bags and seat belts with pre-tensioner are installed on all the vehicles as standard. • The SRS is a system that is effective with the seat belt fastened, and it is designed as a supplemental system of the seat belt. • The advanced air bag system is adopted to the driver's and passenger's (front) sides. When a frontal impact exceeds the threshold upon a frontal collision, or depending on the seat position (driver's seat side), the air bag inflates the cushion air bag in two stages, improving the protection for the front seat passengers. When a frontal impact exceeds the threshold, the knee air bag is instantaneously inflated to protect the passenger's feet (knee and leg). • The side-air bag is activated when an impact exceeds the threshold upon a side collision, and the cushion air bag is instantaneously inflated to protect the chest area of the front seat passengers.
• The curtain air bag is activated simultaneously with the side-air bag upon a side collision to protect the heads of the front seat and second seat passengers. • All the air bag modules are equipped with the inflator that does not contain toxic sodium azide. • The seat belt pre-tensioner is activated simultaneously with the deployment of driver's and passenger's (front) air bags in case of a frontal collision. Seat belts are pulled in to eliminate the slack upon a collision, thus improving the initial occupant restraint, and reducing the travel distance of the occupants. For the driver's seat, in addition to the seat belt pre-tensioner for the shoulder side, the lap pre-tensioner has been installed on the outer seat belt lower anchor side in order to improve the restraining performance in the waist and the chest areas.
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GENERAL TECHNICAL FEATURES
BODY CONSTRUCTION 4
Section A - A
6 5
Crush box
A
A
2 3
1
AB609784AB
The front and rear structures to absorb high energy, and the strong and sturdy cabin structure is adopted to reduce the risk of passenger injuries at front-, rear-, and side-impact collisions, secure the space for life protection, and facilitate rescuing passengers. The structures also have the following features: 1. The crush box structure is adopted for the front end of the sidemember to reduce the vehicle repair cost in a low speed collision. 2. An annular construction is used for the side structure reinforcement to improve collision safety and vehicle body rigidity. 3. The front frame structure is supported in three directions by the dash crossmember center, dash crossmember lower, and front sidemember rear in order to improve the frontal collision characteristics, and increase the vehicle body rigidity. 4. The crush box structure has been changed to straight type with an octagon cross-section so that the structure can effectively absorb energy from the impact at the time of collision. 5. The closed section structure has been adopted for the roof bow and roof rail to improve driving stability and reduce vibration and noise.
6. The roof bow and roof rail and the side outer panel have been jointed by the brace to improve driving stability.
SAFETY-ENHANCED FRONT SEATS The front seats are designed to minimize the risk of whiplash in a collision from the rear. The head restraints have been ideally angled forward, while the seat frame was moved toward the rear.
OTHER SAFETY FEATURES • • • • • •
Brake pedal recede-control device Collapsible steering column Child-protection rear door locks Front fog lamps Passenger’s seat weight sensor system 3-point ELR seat belts • 3-point ELR/ALR seat belts • Tire pressure monitoring system (TPMS)
00-12
GENERAL TECHNICAL FEATURES
ENVIRONMENTAL PROTECTION
M2000027000473
Mitsubishi has given careful consideration to protection of natural resources and the environment in the vehicle. Environmentally friendly features are shown below.
Items Dealing with Environmental Protection Prevention of atmospheric pollution
Parts name
Features
Adoption of easy recycling material
Bumper, Instrument panel, Door trim, Interior trim and soon
Adoption of thermoplastic resin
Expansion of recycled material
Bumper, Instrument panel, Door trim, Radiator Re-use of material discarded in plant grille Sound absorbing material in dash panel and roof, Oil level gauge
Reduction of hazardous substances
Re-use of discarded material in other industry
Fuel tank, Radiator, Heater core, Battery cable Adoption of lead free material terminal, Balance weight for wheel, Pressure hose for power steering, Glass ceramics print, Harness, Electrostatic coating, Intake valve sheet, Crank bearing metal, Connecting rod bearing metal, Connecting rod
SERVICEABILITY AND RELIABILITY ENHANCED DIAGNOSIS SYSTEM Diagnosis functions have been included for the following systems, so that it is possible to use the scan tool to read the diagnosis codes and service data and to carry out actuator tests. In addition, it is also possible to read the diagnosis codes by the flashing of the warning light in some systems. • MFI • Auto-cruise control system • CVT • ABS • Power window • Keyless operation system (KOS) NOTE: In this manual, F.A.S.T.-key (Free-hand Advanced Security Transmitter) is described as Keyless Operation System (KOS). • SRS air bag • Immobilizer • Combination meter • Headlight auto leveling device
M2000028000647
• ETACS • Radio and CD player and visual information equipment etc. • Heater and air conditioning
ADAPTATION OF BOLTS AND NUTS WITH STABILIZER FOR COEFFICIENT OF FRICTION * The bolts and nuts with stabilizer for coefficient of friction are used for the connections such as the suspension arm and crossmember in order to stabilize the axial force and to ensure the high axial force at bolt/nut connections, resulting in improved reliability. NOTE: *: The bolts and nuts with stabilizer for coefficient of friction mean that the bolts and nuts with surface treatment to stabilize and reduce the coefficient of friction, allowing to achieve the stable axial force and to secure the high axial force with low tightening torque.
00-13
GENERAL VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION
M2000001002662
.
VEHICLE IDENTIFICATION NUMBER LOCATION The vehicle identification number (VIN) is located on a plate attached to the left top side of the instrument panel.
AC611242
VEHICLE IDENTIFICATION CODE CHART PLATE All vehicle identification numbers contain 17 digits. The vehicle number is a code which tells country, make, vehicle type, etc.
J A 3 AU 2 6 U _ 8 U 0 0 0 0 0 1 12 1 2 3 4 5 6 7 8 9 10 11
No.
Item
Content
1
Country
J: Japan
2
Make
A: Mitsubishi
3
Vehicle type
3: Passenger car
4
Others
Restraint system A: Driver and passenger air bags
5
Line
U: LANCER
6
Price class
1: Economy
AC609472AB
2: Low 8: Sports 7
Body
6: 4-door sedan
8
Engine
U: 2.0 L (4B11) MIVEC
9
Check digits*
0, 1, 2, 3, -----------9, X
10
Model year
8: 2008 year
11
Plant
U: Mizushima
12
Serial number
000001 to 999999
NOTE: *: Check digit means a single number, or letter X, used to verify the accuracy of transcription of vehicle identification number.
00-14
GENERAL VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER LIST .
VEHICLES FOR USA (VEHICLES FOR FEDERAL EMISSION REGULATION) VIN Brand Engine (Except sequence number) displacement
Model code
JA3AU16U_8U
CY4ASNLHL2M
MITSUBISHI LANCER
2.0L
CY4ASTLHL2M
JA3AU26U_8U
CY4ASNSHL2M CY4ASTSHL2M
JA3AU86U_8U
CY4ASNXHL2M CY4ASTXHL2M
(VEHICLES FOR CALIFORNIA EMISSION REGULATION) VIN (Except sequence number)
Brand
Engine displacement
Model code
JA3AU16U_8U
MITSUBISHI LANCER
2.0L
CY4ASNLHL7M CY4ASTLHL7M
JA3AU26U_8U
CY4ASNSHL7M CY4ASTSHL7M
JA3AU86U_8U
CY4ASNXHL7M CY4ASTXHL7M
.
VEHICLES FOR PUERTO RICO VIN (Except sequence number)
Brand
Engine displacement
Model code
JA3AU16U_8U
MITSUBISHI LANCER
2.0L
CY4ASNLHL2M CY4ASTLHL2M
JA3AU26U_8U
CY4ASNSHL2M CY4ASTSHL2M
JA3AU86U_8U
CY4ASNXHL2M CY4ASTXHL2M
.
VEHICLES FOR CANADA VIN (Except sequence number)
Brand
Engine displacement
Model code
JA3AU16U_8U
MITSUBISHI LANCER
2.0L
CY4ASNLHL3M
JA3AU26U_8U
CY4ASTLHL3M CY4ASNSHL3M CY4ASTSHL3M
JA3AU86U_8U
CY4ASNXHL3M CY4ASTXHL3M
00-15
GENERAL GENERAL DATA AND SPECIFICATIONS
GENERAL DATA AND SPECIFICATIONS
M2000030001034
.
GENERAL SPECIFICATIONS
8
2
4
7
1
5
6
9
3
AC608677AB
Item
CY4ASNLHL2M/ CY4ASTLHL2M/ 3M/7M 3M/7M
CY4ASNSHL2M/ 3M/7M
1
1,760 (69.4)
1,760 (69.4)
1,760 (69.4)
2
1,530 (60.2)
1,530 (60.2)
1,530 (60.2)
3
4,570 (180.0)
4,570 (180.0)
4,570 (180.0)
Overhang-front
4
955 (37.6)
955 (37.6)
955 (37.6)
Wheelbase
5
2,635 (103.7)
2,635 (103.7)
2,635 (103.7)
Overhang-rear
6
980 (38.7)
980 (38.7)
980 (38.7)
Ground clearance
7
147 (5.8)
147 (5.8)
147 (5.8)
Overall height (unladen)
8
1,490 (58.7)
1,490 (58.7)
1,490 (58.7)
Tread-rear
9
1,530 (60.2)
1,530 (60.2)
1,530 (60.2)
1,325 (2,922)
1,360 (2,999)
1,335 (2,944)
1,850 (4,079)
1,850 (4,079)
1,850 (4,079)
Gross axle weight rating-front
1,010 (2,227)
1,010 (2,227)
1,010 (2,227)
Gross axle weight rating-rear
910 (2,007)
910 (2,007)
910 (2,007)
Seating capacity
5
5
5
Engine
Model No.
4B11
4B11
4B11
Piston displacement cm3 (cu in)
1,998 (121.9)
1,998 (121.9)
1,998 (121.9)
Maximum output kW/r/min (HP/r/min)
113/6,000 (152/6,000) , 107/6,000 (143/6,000)
Maximum torque N⋅ m/r/min (ft-lb/r/min)
198/4,250 (146/4,250) , 194/4,250 (143/4,250)
Fuel system
Fuel supply system
Electronic controlled multiport fuel injection
Transaxle
Model No.
F5MBB
F1CJA
F5MBB
Type
5-speed manual
CVT
5-speed manual
5.0 (16.4)
5.0 (16.4)
5.0 (16.4)
Vehicle Overall width dimension mm Tread-front (in) Overall length
Vehicle weight Curb weight kg (lb) Gross vehicle weight rating
CONNECTOR CONTINUITY AND VOLTAGE TEST Required Special Tools: •MB991219: Test Harness Set •MD998459: Test Harness Follow the steps below to avoid causing poor connector contact and/or reduced waterproof performance of connectors when checking continuity and/or voltage at waterproof connectors.
CAUTION Never backprobe a waterproof connector. Backprobing a connector may cause the terminals to corrode, deteriorating circuit performance. 1. If the circuit to be checked is a closed state, use a special tool like MD998459.
MD998459
AC000014 AB
CAUTION Forcing the probe into the terminal may open the terminal, causing intermittent or poor contact and creating an open circuit. 2. If the connector is disconnected for checking and the facing part is the female pin side, use an appropriate male terminal for checking the contact pressure of connector pins (like MB991219).
MB991219
AC000015 AB
CAUTION Do not simultaneously contact more than one terminal with the probe. Contacting two or more terminals at the same time may damage a circuit, possibly to the point of starting an electrical fire. 3. If the facing part is the male pin side, either carefully touch the probe to the pin so it does not accidently contact other pins, or use an appropriate female terminal.
IMPROPER TERMINAL ENGAGEMENT CHECK Terminals inside a connector may not engage properly even if the connectors engage. Make sure that each terminal does not come out of the connector when gently pulling each harness wire. If it does, repair or replace the terminal and/or connector.
AC000016
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GENERAL HARNESS CONNECTOR INSPECTION
00E-3
CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT Loosely engaged terminals can be repaired by removing the female terminal from the connector housing and raising its lance to establish better engagement. Removal of the connector terminal used for MFI and INVECS-II A/T control circuit can be done in the following manner. .
COMPUTER CONNECTOR 1. Insert a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure, disengage the front holder, and remove it.
FRONT HOLDER
FRONT HOLDER ACX00904AB
2. Push the harness wire of the terminal to be repaired deep into the connector from the harness side and hold it there.
ACX00905
3. Insert the tip of the screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, gently push the housing lance down with the tip, and pull out the terminal.
HOUSING LANCE
AC310118AB
4. Insert a needle through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom.
NEEDLE
NEEDLE ACX00907 AB .
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00E-4
GENERAL HARNESS CONNECTOR INSPECTION
ROUND WATERPROOF CONNECTOR 1. Remove the waterproof cap by using a screwdriver. 2. Insert the tip of the screwdriver [1.4 mm (0.06 inch) or 2.0 mm (0.08 inch) width] into the connector as shown in the figure, raise the housing lance slightly with the tip, and pull out the terminal.
HOUSING LANCE ACX00908 AB
3. Insert a screwdriver through the hole provided on the terminal and raise the contact point. Lightly squeeze the outer edge so the flats are parallel with the bottom.
ACX00909
.
RECTANGULAR WATERPROOF CONNECTOR 1. Disengage the front holder with a screwdriver and remove it.
FRONT HOLDER
FRONT HOLDER ACX00910AB
2. Insert the tip of a screwdriver [0.8 mm (0.03 inch) width] into the connector as shown in the figure, push it lightly to raise the housing lance, and pull out the terminal.
HOUSING LANCE ACX00911AB
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GENERAL HARNESS CONNECTOR INSPECTION
00E-5
3. Press the contact point to the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure. Lightly squeeze the outer edge so the flats are parallel with the bottom.
ACX00912
.
INJECTOR CONNECTOR 1. Remove the waterproof cap. WATERPROOF CAP
ACX00913AB
TERMINAL LANCE
AC310304AB
2. Insert the tip of a screwdriver [1.4 mm (0.06 inch) width] into the connector as shown in the figure, press in the terminal lance, and pull out the terminal.
CAUTION Make sure the lance is pressed in before the terminal is inserted into the connector. 3. Press the contact point to the male terminal down by holding a screwdriver [1.4 mm (0.06 inch) width] as shown in the figure.
AC310313
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00E-6
GENERAL HOW TO DIAGNOSE
HOW TO DIAGNOSE HOW TO DIAGNOSE The most important point in troubleshooting is to determine "Probable Cause." Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only.
TROUBLESHOOTING STEPS
M1001004300086
M1001004400049
If an attempt is made to solve a problem without going through correct steps for troubleshooting, the symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs. The four steps below should be followed in troubleshooting.
1 Observation of Problem Symptoms
2 Determination of Probable Causes
Checking of Parts Associated with 3 Probable Causes and Determination of Faulty Parts
Observe the symptom carefully. Check if there are also other problems.
In determining the probable causes, it is necessary to study the wiring diagram to understand the circuit as a system. Knowledge of switches, relays and other parts is necessary for accurate analysis. The causes of similar problems in the past must be taken into account.
Troubleshooting is carried out by making step-by-step checks until the cause is found.
After the problems are corrected, be sure to check that the system operates correctly. Also check that new problems have not been caused by the repair.
4 Repair and Confirmation
ACX00915 AC
INFORMATION FOR DIAGNOSIS
M1001004500132
This manual contains the harness diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component. The information is presented in the following manner: 1. Connector diagrams show the connector positions, etc., on the actual vehicle as well as the harness path. 2. Circuit diagrams show the configuration of the circuit with all switches in their normal positions.
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3. Operational explanations include circuit drawings of current flow when the switch is operated and how the component reacts.
GENERAL HOW TO DIAGNOSE
00E-7
4. Troubleshooting hints include numerous examples of problems which might occur, traced backward in a common-sense manner to the origin of the trouble. Problems whose origins may not be found in this manner are pursued through the various system circuits. NOTE: Components of MFI, ETACS, etc. with ECU do not include 3 and 4 above. For this information, refer to a relevant group which includes details of these components.
INSPECTION
M1001004600139
1. Sight and sound checks Check relay operation, blower motor rotation, light illumination, etc. Listen for a "click" when some relay covers are pushed down.
CLICK
ACX00936 AB
2. Simple checks For example, if a headlight does not come on and a faulty fuse or poor grounding is suspected, replace the fuse with a new one. Or use a jumper wire to ground the light to the body. Determine which part(s) is/are responsible for the problem.
ACX00937
POINTER
SELECTOR KNOB
3. Checking with instruments Use an appropriate instrument in an adequate range and read the indication correctly.
ACX00938AB
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00E-8
GENERAL HOW TO DIAGNOSE
INSPECTION INSTRUMENTS For inspection, use the following instruments:
M1001004700040
CAUTION Never use a test light for checking ECU-related circuits or ECUs. 1. Test light A test light consists of a 12V bulb and lead wires. It is used to check voltages or short circuits.
ACX00939
2. Self-powered test light A self-powered test light consists of a bulb, battery and lead wires connected in series. It is used to check continuity or grounding.
ACX00940
CAUTION Never use a jumper wire to connect a power supply directly to a load. 3. Jumper wire A jumper wire is used to close an open circuit.
ACX00941
POWER LINE BLACK LEAD WIRE
4. Voltmeter A voltmeter is used to measure the circuit voltage. Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground. Use a digital voltmeter to check for voltage drop before or after a component.
RED LEAD WIRE GROUND ACX00942AB
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GENERAL HOW TO DIAGNOSE
00E-9
5. Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or coil. If the measuring range has been changed, the zero point must be adjusted before measurement.
ACX00943
CHECKING FUSES
M1001005000141
A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live.
FUSE BLOCK
TEST TAPS ACX00951AB
CAUTIONS IN EVENT OF BLOWN FUSE
STATE OF FUSE BLOWN DUE TO OVERCURRENT
ACX00952 AB
When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity.
STATE OF FUSE BLOWN DUE TO THERMAL FATIGUE
ACX00953 AB
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00E-10
GENERAL HOW TO DIAGNOSE
CHECKING SWITCHES NORMALLY OPEN (NO) TYPE ON
OFF
CURRENT DOES NOT FLOW
M1001004800177
In a circuit diagram, a switch is shown in the idle state. 1. Normally open or normally closed switch Switches are classified into those which open the circuit and those which close the circuit when off. Switches are shown in their normal state unless specified otherwise.
CURRENT FLOWS
NORMALLY CLOSED (NC) TYPE OFF
ON
CURRENT FLOWS
CURRENT DOES NOT FLOW ACX00944AC
2. Switch connection This figure illustrates a complex switch. The continuity between terminals at each position is as indicated in the table below.
6
OFF
1ST 2ND 3RD 4TH STAGE
5
4
3
2
1
ACX00945 AB
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SWITCH POSITION
TESTER CONNECTION
SPECIFIED CONDITION
OFF
−
−
1st stage
1−5−6
Continuity
2nd stage
1−4−6
Continuity
3rd stage
1−3−6
Continuity
4th stage
1−2−6
Continuity
GENERAL HOW TO DIAGNOSE
CHECKING RELAYS
M1001004900152
1. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light.
POWER SUPPLY
RELAY OFF
00E-11
ON
FUSE SWITCH ON
LIGHT OFF
ACX00948 AB
NORMALLY OPEN (NO) TYPE ENERGIZED STATE
COVER SPRING
COIL
2. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece returns to its original position by a spring, opening the contact (OFF).
IRON CORE
IRON PIECE
CONTACT
AC308621 AB
NORMALLY OPEN (NO) TYPE DEENERGIZED STATE ENERGIZED STATE
3
1
2 4 CURRENT DOES NOT FLOW
3
1
2 4 CURRENT FLOWS AC310636AB
NORMALLY CLOSED (NC) TYPE DEENERGIZED STATE ENERGIZED STATE
3
1
4 2 CURRENT FLOWS
3
1
4 2 CURRENT DOES NOT FLOW AC310637 AB
3. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. NOTE: The deenergized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil. (1) The normally open-type When a normally open relay as illustrated here is checked, there should be no continuity between terminals 3 and 4 when the relay is deenergized. There should be continuity between terminals 3 and 4 when battery voltage and ground are applied to terminals 1 and 2. The relay condition is determined by this check. NOTE: Check the relay in both situation which is energized and is not energized. (2) The normally closed-type When a normally closed relay as illustrated here is checked, there should be continuity between terminals 3 and 4 when the relay is deenergized. There should be no continuity between terminals 3 and 4 when battery voltage and ground are applied to terminals 1 and 2. The relay condition is determined by this check. NOTE: Check the relay in both situation which is energized and is not energized.
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00E-12
GENERAL HOW TO DIAGNOSE
CABLES AND WIRES CHECK
ACX00954 AB
ACX00955AB
M1001005100041
1. Check connections for looseness, rust, and stains. 2. Check terminals and wires for corrosion. 3. Check terminals and wires for open circuit or impending open circuit. 4. Check wire insulation and coating for damage, cracks, and wear. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7. Check for incorrect wiring. 8. Check that harnesses are secured to prevent contact with sharp edges and corners or hot parts (exhaust manifold, pipe, etc.). 9. Check that harnesses are secured firmly to provide enough clearance from the fan pulley, fan belt, and other rotating or moving parts. 10.Check that the harnesses between fixed parts (such as the vehicle body) and vibrating parts (such as the engine) are long enough to allow for vibration and movement.
BATTERY HANDLING
M1001005200048
WARNING
Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING. When checking or servicing does not require power from the vehicle battery, be sure to disconnect the cable from the battery (−) terminal. This will prevent problems that could be caused by a short circuit. Disconnect the (−) battery terminal first and reconnect it last. AC000017
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GENERAL HOW TO DIAGNOSE
00E-13
GENERAL ELECTRICAL SYSTEM CHECK
M1001005300045
POWER SUPPLY
FUSE
ON (2) SWITCH
OFF
(3) MOTOR
(1)
TEST LIGHT (OR VOLTMETER) ACX00956AB
POWER SUPPLY FUSE BLOCK (REMOVE THE FUSE)
A circuit consists of the power supply, switch, relay, load, ground, etc. There are various methods to check a circuit including an overall check, voltage check, short-circuit check, and continuity check. Each of the methods briefly described below applies only to circuits similar to the illustration. 1. VOLTAGE CHECK (1) Ground one lead wire of the test light. If a voltmeter is used instead of the test light, ground the grounding side lead wire. (2) Connect the other lead wire of the test light to the power side terminal of the switch connector. The test light should come on or the voltmeter should indicate a voltage. (3) Then, connect the test light or voltmeter to the motor connector. The test light should not come on, or the voltmeter should indicate no voltage. When the switch is turned ON in this state, the test light should come on, or the voltmeter should indicate a voltage, with the motor starting to run. (4) The circuit illustrated here is normal. If there is any problem, such as the motor failing to run, check voltages beginning at the connector nearest to the motor until the faulty part is identified. 2. SHORT-CIRCUIT CHECK Because the fuse has blown, it is probable that there is a short circuit. Follow the procedures below to narrow down the short-circuit location. STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Circuit switch: OFF). Q: Does the test light illuminate? YES : Short-circuit exists between the fuse block and the switch. Repair the harness between the fuse block and the switch. NO : Go to Step 2.
SHORT-CIRCUIT LOCATION
TEST LIGHT
SWITCH OFF
ILLUMINATION LIGHT
ACX00957 AB
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00E-14
GENERAL HOW TO DIAGNOSE
POWER SUPPLY FUSE BLOCK (REMOVE THE FUSE) TEST LIGHT
STEP 2. Turn the switch ON and disconnect the illumination light connector. Q: Does the test light illuminate? YES : Short-circuit exists between the switch and the connector. Repair the harness between the switch and the connector. NO : Short-circuit exists between the connector and the illumination light. Repair the harness between the connector and the illumination light.
SWITCH ON SHORT-CIRCUIT LOCATION DISCONNECT THE LOAD
ILLUMINATION LIGHT
ACX00958AB
POWER SUPPLY FUSE BLOCK (REMOVE THE FUSE) TEST LIGHT SWITCH ON
DISCONNECT THE LOAD SHORT-CIRCUIT LOCATION ILLUMINATION LIGHT ACX00959AB
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GENERAL HOW TO DIAGNOSE
1 4
SELF-POWERED TEST LIGHT (OR OHMMETER) ON
ON OFF
OFF
2 3
00E-15
3. CONTINUITY CHECK (1) When the switch is in the "OFF" position and the contact points of terminals 1 and 2 are connected, the selfpowered test light should illuminate or the ohmmeter should read 0 ohm. (2) When the switch is the "ON" position and the contact points of terminals 3 and 4 are connected, the selfpowered test light should come on or the ohmmeter should read 0 ohm.
Front bumper back beam Front end crossmember Headlight support panel Front end upper bar Front sidemember inner Front sidemember rear Front sidemember outer Front sidemember outer front Front fender shield front Front wheel house panel inner Front end upper bar side Front fender bracket upper front Engine mounting gusset Front upper frame inner Front upper frame outer Dash panel crossmember upper Dash panel crossmember lower Dash panel Brake pedal support reinforcement Brake pedal support bracket Front deck Front deck crossmember Front pillar inner lower Front pillar inner center Hood inner panel Hood outer panel Front door inner panel Front door side door beam Front door outer panel Rear door side door beam Rear door outer panel Rear door inner panel Roof panel Roof center bow lower Roof center bow upper Rear shelf panel Trunk lid inner panel Trunk lid outer panel Curtain air bag bracket Quarter inner panel Quarter inner extension front Fuel filler door panel Rear end panel Rear floor sidemember extension Rear floor sidemember lower
Rear floor sidemember upper Front floor side sill inner Front fender Battery bracket front Battery bracket rear Backbone crossmember front Backbone crossmember rear Front floor pan Backbone reinforcement Front floor crossmember front Front floor crossmember rear Side sill inner support front Front pillar reinforcement lower Front pillar inner upper Roof side rail inner Center pillar inner upper Center pillar inner lower Rear wheel house panel inner Rear wheel house shield plate front Rear quarter inner panel lower (Left side) Roof side rail support Front pillar support Roof side rail reinforcement rear Roof side rail reinforcement front Rear door hinge reinforcement support Rear door hinge reinforcement Center pillar reinforcement Rear door catch reinforcement Rear pillar reinforcement lower Rear pillar reinforcement Side sill outer reinforcement rear Side sill outer reinforcement front Front upper frame outer rear Front fender bracket lower Rear floor crossmember rear Rear floor crossmember front Seat belt rear floor reinforcement (Right side) Seat belt rear floor reinforcement (Left side) Rear floor (rear seat) crossmember Front floor reinforcement lower Front floor sidemember front Rear floor extension Rear floor pan front Rear floor pan rear Side outer panel
1-3
1-4
BODY CONSTRUCTION BODY MAIN CROSS-SECTIONAL VIEWS
BODY MAIN CROSS-SECTIONAL VIEWS B
M4010002000785
C
F
D E
A AB601072AB
Front end crossmember upper
A
D
Front door hinge reinforcement lower
Front pillar inner lower
Front end crossmember lower
AB601099AB
Front pillar reinforcement lower
E
B Roof panel
Side outer panel AB601103AB
Side sill outer reinforcement front
Roof front rail upper Roof front rail lower
C
Front floor side sill inner AB601100AB
Side outer panel
Side outer panel AB601104AB
F
Side sill outer reinforcement rear
Center pillar reinforcement Roof side rail reinforcement front Roof side rail inner
Roof side rail support AB601101AB
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Front floor side sill inner
Side outer panel AB601105AB
1-5
BODY CONSTRUCTION BODY MAIN CROSS-SECTIONAL VIEWS
AB601073
G
I
H
J
K
L
AB601492AB
J
G
Rear shelf panel
Front pillar support
Roof side front reinforcement front
Front pillar inner upper
Side outer panel
Rear shelf reinforcement AB601108AB
AB601106AB
H
Center pillar inner upper
K
Rear door hinge reinforcement support
Rear pillar reinforcement lower
Side outer panel
Rear wheel house panel inner
Center pillar reinforcement
Rear door hinge reinforcement
I
Roof side rail inner
Side outer panel Quarter inner panel
AB601102AB
Roof side rail reinforcement rear
Side outer panel
AB601107AB
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Rear wheel house shield plate front AB601109AB
L
Rear end crossmember inner
Rear bumper center reinforcement
Rear end crossmember outer
AB601110AB
1-6
BODY CONSTRUCTION MAINTENANCE, SERVICEABILITY
MAINTENANCE, SERVICEABILITY
M4010003000670
FENDER SHIELD A positioning hole, lug, marking, and cut-out have been added on the front side member, front side member rear, and headlamp support panel to improve assembling workability during panel replacement.
AB601196AB
SIDE STRUCTURE A panel positioning notch has been added on the door opening to improve assembling workability when replacing the panel.
Panel positioning notch
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AB201388AB
1-7
BODY CONSTRUCTION MAINTENANCE, SERVICEABILITY
AB601194AB
SIDE OUTER PANEL The extra parts are supplied in 4 different cut forms as a result of employing the integrated side-frame side outer panel. Center pillar outer
Front pillar outer
Rear quarter outer panel
Floor side sill outer AB601082AB
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1-8
BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS
BODY CONSTRUCTION CHARACTERISTICS FRONT BODY
M4010010000810
HEADLIGHT SUPPORT • The crush box structure, which has an octagonal cross-section at the front end of the front sidemember, has been adopted. This structure can effectively absorb energy upon frontal impact and reduces the vehicle repair cost caused by a light collision.
• The bolt-on hood lock stay, and bolt-on front end upper bar are used to improve maintainability.
Front bumper back beam Bumper support bracket side Front end upper bar Radiator bracket upper Bumper support bracket center Front sensor reinforcement Hood lock stay Front end crossmember upper Front end crossmember gusset Radiator bracket lower A Radiator bracket lower B Front end crossmember lower Shipping reinforcement front Shipping hook front Front No. 2 crossmember pipe Front end crossmember bulkhead
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A
Crush box
AB601701AB
The crush box structure has been changed to straight type with an octagon cross-section so that the structure can effectively absorb energy from the impact at the time of collision.
1-9
BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS
FENDER SHIELD • The front frame structure is supported in three directions by the dash crossmember center, dash crossmember lower and front sidemember rear in order to improve the frontal collision characteristics, and increase the vehicle body rigidity.
• The padding structure of the fender has been adopted to efficiently absorb energy upon impact and improve the pedestrian protection capability.
Front sidemember Front fender gusset Front fender lower bracket front inner Upper side bar front Front end upper bar side Front fender bracket upper front Upper frame bulkhead front Upper frame bulkhead center Upper frame bulkhead rear Front upper frame outer Front upper frame inner Fender bracket upper center 2 Harness bracket Spring house bracket reinforcement Spring house bracket front
Spring house corner gusset Spring house panel rear Horn bracket Spring house harness bracket Suction hose bracket Engine mounting bracket upper Condense tank reinforcement Front fender shield Engine mounting gusset Spring house panel Power steering reservoir tank bracket Engine-ECU bracket Clutch tube bracket Relay box bracket Transmission mounting gusset
1-10
BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS
FRONT SIDEMEMBER REINFORCEMENT The 590-MPa class high tensile strength steel panels have been adopted for the front sidemember outer front, front sidemember reinforcement rear lower, front sidemember rear bulkhead, and front sidemember rear to improve the body rigidity. Right side
12* 11 4
8
7
10
6
14*
17
5
3*
13*
9
16 15
19 18
2
20
1
22
21
*: Indicates 590MPa-high-tensile steel panels.
AB600952AB
6
12
17 5
8
A
18
B
11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
14
Front sidemember plate rear Headlight bracket lower Front sidemember outer front Front sidemember outer Front sidemember bulkhead front Engine mounting bulkhead Front brake hose bracket Front suspension crossmember bulkhead Front sidemember brace upper Tie down reinforcement front Height sensor bracket
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
13
AB600954AB
Front sidemember reinforcement rear lower Front sidemember rear bulkhead Front sidemember rear Dash crossmember extension lower Front sidemember brace lower Front sidemember inner Front suspension crossmember bracket front Pipe nut Engine mount bracket Engine mount reinforcement Headlight support panel
B
A
20 4
4
5 17
9 17
8 AB601112AB
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AB601113AB
1-11
BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS
Headlight bracket lower Front sidemember plate rear Headlight support panel Front sidemember inner Connecter bracket Battery bracket front Battery bracket rear Pipe nut Transmission mounting bracket Front suspension crossmember bracket front Dash crossmember extension lower
AB600955AB
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Front sidemember brace lower Front sidemember rear Front sidemember reinforcement rear lower Front sidemember rear bulkhead Tie down reinforcement front Front sidemember brace upper Front suspension crossmember bulkhead Front sidemember outer Front brake hose bracket Transmission mounting bulkhead Front sidemember outer front
B
A
19
17 19
4
4
21 AB601225AB
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18
AB601115AB
1-12
BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS
FRONT DECK The impact absorbing opening on the cowl top outer reinforcement has been added to efficiently absorb energy upon impact and improve the pedestrian protection capability.
6
5 4 9
8
3
7 2
10
14 13
1
11
12 1. 2. 3. 4. 5. 6. 7.
Cowl top panel lower Wiper B bracket Cowl top stay bracket rear Cowl top outer reinforcement upper Cowl top panel inner Cowl top panel outer Clutch pedal support bracket
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8. 9. 10. 11. 12. 13. 14.
Brake pedal support bracket Deck crossmember stay bracket Fender bracket upper rear Upper frame to front pillar brace Upper frame extension inner Cowl top outer reinforcement lower Brake pedal support reinforcement
AB601010AB
1-13
BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS
DASH PANEL • The front frame structure is supported in three directions by the dash crossmember center, dash crossmember lower and front sidemember rear in order to improve the frontal collision characteristics and increase the vehicle body rigidity.
• The 590-MPa class high tensile strength steel panels have been adopted for the dash panel crossmember center to improve the body rigidity.
BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS
SIDE BODY
M4010011000705
SIDE STRUCTURE The 590-MPa class high tensile strength steel panels or 980-MPa class ultra high tensile strength steel panels have been adopted for the front pillar, center pillar, side sill, and roof side rail to improve the body rigidity.
Front pillar outer extension lower Front pillar outer extension upper Front door hinge reinforcement lower Front pillar reinforcement center bulkhead Front door hinge reinforcement upper Front pillar inner lower Harness bracket Deck crossmember bracket (Right side) Front pillar inner center Front pillar inner upper
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25
26
24
23** AB601011AB
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Roof side rail inner Bracket C Curtain air bag bracket Quarter inner panel Quarter inner extension front Roof side rail reinforcement rear Quarter outer upper extension Quarter outer upper side extension Rear combination light housing Quarter corner panel
Fuel filler neck bracket (Left side) Side sill outer reinforcement rear Side sill outer reinforcement front Side sill inner support front Front fender bracket lower Cowl side trim bracket Fender bracket Fender bracket Front upper frame outer rear Front pillar reinforcement lower Deck support pipe (Left side) Rear door hinge reinforcement Rear door hinge reinforcement support Roof side rail reinforcement front Front pillar support Cowl side trim bracket (Right side) Hood opener bracket Center inner pillar lower Roof rail front extension Roof rail center extension Center inner pillar upper Roof rail rear extension Center pillar seat belt reinforcement upper Center pillar seat belt reinforcement lower Rear wheel house shield plate front Rear quarter inner panel lower (Left side) Filler pipe MTG bracket (Left side) Head restraint bracket (Left side) Harness bracket (Right side) Rear wheel house panel inner Rear seat back brace front Rear seat back brace rear Harness bracket (Left side) Plate rear seat back reinforcement Rear seat hook A Rear shelf upper brace Brace rear seat back bulkhead Rear seat belt reinforcement Subwoofer upper bracket Roof side rail support Rear pillar reinforcement Nut plate Rear pillar reinforcement lower Rear door catch reinforcement Center pillar reinforcement Side outer panel
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1-15
1-16
BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS
SIDE STRUCTURE REINFORCEMENT The ring structure of the side structure reinforcement has been adopted to improve the collision characteristics and the rigidity of the whole vehicle. Side roof rail rear reinforcement
Roof side rail front reinforcement
Rear pillar reinforcement
Rear pillar reinforcement lower
Side sill outer reinforcement rear Center pillar reinforcement
Front pillar reinforcement lower
Side sill outer reinforcement front AB601202AB
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1-17
BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS
REAR BODY
M4010012000582
REAR DECK 4
5.0 ± 1.0 N·m 44 ± 9 in-lb
3 2 5
6 5.0 ± 1.0 N·m 44 ± 9 in-lb
1
AB601685AB
1. 2. 3.
4. 5. 6.
Seat belt reinforcement center Rear shelf extension Rear shelf reinforcement
Rear shelf panel Rear seat hook A Rear seat back reinforcement
REAR END CROSSMEMBER 5
4
5.0 ± 1.0 N·m 44 ± 9 in-lb
3
2
1 AB601686AB
1. 2. 3.
4. 5.
Rear bumper side bracket Rear end crossmember inner Trunk lid striker reinforcement
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Rear end crossmember outer Rear bumper center reinforcement
1-18
BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS
ROOF • The closed section structure has been adopted to the front roof rail, roof bow center and rear roof rail to reduce vibration and noise and to improve the rigidity.
M4010013000853
• The 590-MPa class high tensile strength steel panels have been adopted for the roof center bow lower to improve the body rigidity.
Without sunroof
6 5
7
4
9
3
8*
2 *: Indicates 590MPa-high-tensile steel panels.
1
AB601687AB
Sunroof
6
5
10 4 11
3 13 14
2 1 1. 2. 3. 4. 5. 6. 7.
AB601688AB
8. 9. 10. 11. 12. 13. 14.
Sunvisor bracket Maplamp bracket Roof front rail lower Roof front rail upper Roof panel Roof rear rail Roof center bow upper
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12
Roof center bow lower Room light bracket Roof panel reinforcement Bracket A Set rear bracket Bracket B Set front bracket
1-19
BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS
UNDER BODY
M4010014000812
FRONT FLOOR The 590-MPa class high tensile strength steel panels have been adopted for the front floor sidemember front and front floor crossmember front, and the 980-MPa class ultra high tensile strength steel panels for the front floor sidemember front, to improve the body rigidity.
Backbone crossmember front Front floor pan Parking brake lever reinforcement Backbone reinforcement Parking brake cable reinforcement Backbone crossmember rear Front floor sidemember front
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8. 9. 10. 11. 12. 13.
Front floor crossmember rear Seat belt reinforcement Front floor side sill inner reinforcement center Front floor side sill inner Front floor crossmember front Front floor reinforcement lower (Right side)
1-20
BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS
REAR FLOOR The 590-MPa class high tensile strength steel panels have been adopted for the rear floor extension, rear floor crossmember front, and rear seat crossmember to improve the body rigidity.
5 5.0 ± 1.0 N·m 44 ± 9 in-lb
6 7
4 6
3
10 8 9 21
11
12*
2*
13 14 5.0 ± 1.0 N·m 44 ± 9 in-lb
20 1
4 18
19* 15
*: Indicates 590MPa-high-tensile steel panels.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
16
17
Extension rear floor reinforcement side Rear floor extension Rear floor pan front Rear spring house reinforcement Rear floor pan rear Jack bracket Spare tire bracket Rear floor crossmember extension rear upper Rear floor crossmember extension rear Rear floor crossmember rear Rear floor sidemember
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AB601690AB
12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Rear floor crossmember front Rear floor crossmember extension Fuel tank rear bracket Rear spring house panel Rear spring house bracket Sidemember front floor extension Rear seat crossmember bulkhead inner Rear seat crossmember Seat belt rear floor reinforcement (Left side) Seat belt rear floor reinforcement (Right side)
1-21
BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS
REAR FLOOR SIDEMEMBER REINFORCEMENT The 590-MPa class high tensile strength steel panels have been adopted for the rear floor side sill inner, rear floor sidemember reinforcement, rear floor sidemember extension, and rear floor sidemember bulkhead to improve the body rigidity.
8* 6
10 11* 9 12 7
17 18
5
24
16
19
4
13
3
20
25 2
26*
21
22
23
14 15
1* *: Indicates 590MPa-high-tensile steel panels.
AB601581AB
22
8
1
17
6
12
26
B
2 3
25
23
16
11
5
A AB601691AB
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Rear floor side sill inner Rear floor sidemember extension front Rear tie down plate Front No. 2 crossmember pipe Trailing arm bracket Rear floor sidemember upper Canister bracket Rear floor sidemember reinforcement Pipe nut Muffler hanger rear Rear floor sidemember extension Rear floor sidemember extension bulkhead Rear bumper support Rear shipping hook reinforcement
BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS
6
B
6
2 22
1
26
23
25
3
AB601116AB
AB601117AB
DOOR An uneven thickness steel sheet* has been used for the front and rear door inner panels to make the forward part of the vehicle thicker for reduction in vehicle weight and higher rigidity.
Front door
M4010015000633
NOTE: *: A steel sheet of varying thickness that is welded into one steel sheet.
6
5
8 9 7
10 11
4
12
3
2 1
14
13 AB601048AB
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1-23
BODY CONSTRUCTION BODY CONSTRUCTION CHARACTERISTICS
22
Rear door
23 21
24
19
15
20
25 26
17
27
18 16
28
14
AB601049AB
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Front door checker reinforcement Front door mirror reinforcement Front door window sash front Front door outer panel Front door window sash upper Front door window sash rear Front door inside handle bracket Front door beltline outer reinforcement Front door beltline inner reinforcement Front door latch reinforcement Front door outer stiffner Front door side door beam Front door inner panel Nut plate
Rear door inside handle bracket Rear door side door beam Rear door beltline inner reinforcement Rear door latch reinforcement Rear door beltline bracket Rear door window sash front Rear door outer panel Rear door window sash upper Rear door beltline outer reinforcement Rear door stat corner bracket Rear door sash reinforcement Rear door window sash lower bracket Nut plate Rear door inner panel
1-24
BODY CONSTRUCTION SILENCER APPLICATION LOCATIONS
SILENCER APPLICATION LOCATIONS A silencer (MD-12) has been affixed on the upper surface of the floor for vibration damping.
: 3.2 mm thick MD-12 [Place two 1.6 mm melting sheet one on top of another.]
NOTE: ( ) indicates the number of melting sheets that are used for repair.
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M4010005000836
NOTE: MD-12 is a high-performance sheet made of asphalt, to which mica, heat cured resin, and so on are added to improve damping performance.
AB601192AB
1-25
BODY CONSTRUCTION FOAMING MATERIAL USAGE LOCATIONS
FOAMING MATERIAL USAGE LOCATIONS The sound dampening foam material have been adopted to the upper and lower sections of the front pillar, center pillar lower section, side roof rail and wheel house arch inside to shield from external noise.
M4010006000099
CAUTION The sound dampening foam material may burn when heated. Always observe the following instructions: • Never use a gas burner to burn the areas where sound dampening foam material are used. • When cutting the parts which are provided with sound dampening foam material, ensure to use tools (air saw, etc.) that do not generate fire. • If there are residual sound dampening foam material remaining on the cut section (body side), remove the sound dampening foam material from periphery of the welding area before welding work. AB601548
Sound dampening foam material
Sound dampening foam material
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AB601682AB
NOTES
2-1
GROUP 2
BODY DIMENSIONS CONTENTS BODY DIMENSIONS AND MEASUREMENT METHODS . . . . . . . . . . . . . . . . . . . . . 2-2
BODY DIMENSIONS BODY DIMENSIONS AND MEASUREMENT METHODS
BODY DIMENSIONS AND MEASUREMENT METHODS
M4020001000448
• Type A (projected dimensions) is the dimension when a measurement location is projected onto the plane. NOTE: The height indicates a distance from the assumed standard line established 100 mm below the lowest measurement point.
Projected dimension
Height Probe
AB302138AE
• Type B (actual-measurement dimensions) is the actual distance between the measurement points.Measure using a tracking gauge or a measuring tape, etc. NOTE: . • Make the lengths of the tracking gauge probes the same (A=A’). • Do not bend or twist the measuring tape.
Ac dim tual en -me sio as n ur
ed
A A'
AB302139AE
Center of hole
• Insert the tracking gauge probes securely into the measurement holes. • When the standard dimensions in the illustration are enclosed by rectangle, this indicates that the symmetrical left and right positions have the same dimensions.
AB302140AF
• When using a notch for dimension measurement, set the measuring point at the center of the notch.
AB302141AD
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BODY DIMENSIONS BODY DIMENSIONS AND MEASUREMENT METHODS
2-3
• When measuring the suspension mounting arm, or link mounting position, use the suspension mounting bolt, etc. (Type B only) • The body center points are shown for the purpose of checking the position of the left and right symmetry location.
WELDED PANEL REPLACEMENT ULTRA HIGH STRENGTH STEEL PLATE
ULTRA HIGH STRENGTH STEEL PLATE ADVANTAGES OF ULTRA HIGH STRENGTH STEEL PLATE The ultra high strength steel plate has the following advantages as compared with conventional high strength steel plate. • It has tensile strength approximately 1.7 times higher than the conventional high strength steel sheet. • It has a higher yielding point and yielding ratio (yielding point/tensile strength). These advantages allow thinner and lighter plates and better fuel efficiency than the high strength steel plate.
PRECAUTION UPON MAINTENANCE OF ULTRA HIGH STRENGTH STEEL PLATE • Use a spot cutter for ultra high strength steel plate to ensure that the spot-welded area is cut off.
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M4030002800073
• For the part in which the ultra high strength steel plate is used, do not repair it by cutting and bonding to avoid the reduction in strength by heat. Instead, replace the whole assembly including the part. • Be careful with rough extending work, because the ultra high strength steel plate has higher tensile strength and a higher yielding point than high strength steel plate and general steel plate. Careless work will cause symptom such as over-pulling and springback. Do not extend it completely at a time. Do it gradually while removing the distortion by sheet metal processing with a hammer. • Plug welding of φ 8 mm (0.31 inch) diameter plug for repair ensures the strength equivalent to spot welding for 2 steel sheets. For 3 sheets, weld 2 sheets each time instead of welding from one side to give sufficient welding strength.
NOTE: Refer to the Front End Crossmember section on P.3-3 for the welding point with front end crossmember.
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3-5
WELDED PANEL REPLACEMENT FENDER SHIELD
B
E B
F J
G
I C
D
H
C AB601428AC
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3-6
WELDED PANEL REPLACEMENT FENDER SHIELD
D (With the front upper frame outer removed)
E
G
3 points on left side only
F
I
H
J AB601429AB
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WELDED PANEL REPLACEMENT FENDER SHIELD
3-7
NOTE: Partial replacement of the front upper frame is possible depending on the range of damage. When performing partial replacement, cut the front upper frame outer front 152 mm (6.0 inches) forward of the positioning hole center, and cut the front upper frame inner 25 mm (1.0 inches) forward of the positioning hole center.
Front upper frame inner 25 mm (1.0 in)
152 mm (6.0 in) Front upper frame outer front
AB601431AB
NOTE ON REPAIR WORK .
REMOVAL Front sidemember inner
Turn up the front sidemember outer as shown to cut off the welded point between the front sidemember inner and the front sidemember brace lower.
Front sidemember outer Front sidemember brace lower
AB601422 AB .
INSTALLATION 1. When installing the new front sidemember, align the hole of the front sidemember brace lower with the front sidemember outer to make a hole because the front sidemember outer prevents the front sidemember inner and front sidemember brace lower from being welded.Then, weld the front sidemember outer, front sidemember inner, and front sidemember brace lower.
Front sidemember outer
Front sidemember inner AB601423AB
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3-8
WELDED PANEL REPLACEMENT FRONT SIDEMEMBER (PARTIAL REPLACEMENT)
FRONT SIDEMEMBER (PARTIAL REPLACEMENT) M4030000100454
Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
REPAIR WELDS Left side
Right side
A B
275 mm (10.8 in)
315 mm (12.4 in)
135 mm (5.3 in)
210 mm (8.3 in) B
A
AB601532AB
NOTE: . • Refer to the Front End Crossmember section on P.3-3 for the welding point with front end crossmember. • Refer to the Fender Shield section on P.3-4 for the welding points with the front fender Shield front.
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WELDED PANEL REPLACEMENT FRONT SIDEMEMBER (PARTIAL REPLACEMENT)
CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn. NOTE: Refer to the Fender Shield section on P.3-4 for the welding points with the front upper frame outer rear.
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)
3-11
WELDED PANEL REPLACEMENT FRONT PILLAR
Cutting position
F
Cutting position
D
F
E
Sound dampening foam material
H
(With the side outer panel removed) Sound dampening foam material
Cutting position
G I
(With the side outer panel removed) AB601388AB
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3-12
WELDED PANEL REPLACEMENT FRONT PILLAR
NOTE ON REPAIR WORK .
REMOVAL After removing the front pillar, cut the side outer panel 140 mm (5.5 inches) behind the positioning notch to remove the side sill reinforcement outer front, side sill inner support front, and front inner pillar lower remaining on the body side.
140 mm (5.5 in)
Front inner pillar lower
Side sill inner support front
Side outer panel Side sill reinforcement outer front
AB601206AB .
INSTALLATION Side outer panel
Front pillar inner upper
100 mm (3.9 in)
1. To reinforce the strength in the front pillar cut area, cut the side outer panel 100 mm (3.9 inches) above the cut area and cut the front inner pillar upper 50 mm (1.97 inches) above the cut area. 2. Assemble the new front pillar inner lower parts. 3. Assemble the new front pillar inner upper part.
50 mm (1.97 in)
Roof side rail front reinforcement AB601213AB
Side sill reinforcement front
Aluminum tape
4. Assemble the new side sill reinforcement front parts. After that, cover the hole with aluminum tape to prevent the sound dampening foam material from dropping when the material is filled into the front pillar in the next process.
AB601208AB
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WELDED PANEL REPLACEMENT FRONT PILLAR
3-13
5. Align the new roof side rail reinforcement to the body side to cut and install.After that, machine the body loose panel cushion (MR535301 or MR435765) as shown and apply it to the body side to prevent the sound dampening foam material from dropping when the material is filled into the front pillar in the next process.
A
50 mm (2.0 in)
20 mm (0.8 in) 40 mm (1.6 in)
Front pillar reinforcement lower
A : Body loose panel cushion
Front pillar inner upper AB601297AB AB601297
6. When installing the new front pillar lower reinforcement is installed, remove the front pillar outer lower extension and front pillar outer upper extension in advance, and install the front pillar lower reinforcement because there are some points which cannot be welded on the body side.After that, install the front pillar outer lower extension and front pillar outer upper extension.
Front pillar outer upper extension
Front pillar outer lower extension AB601220AB
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3-14
WELDED PANEL REPLACEMENT FRONT PILLAR 65 mm (2.6 in)
20 mm (0.8 in) 25 mm (1.0 in)
35 mm (1.4 in)
7. When installing the new front pillar outer, machine the body loose panel cushion (MR535301 or MR435765) as shown and apply it to the body side to prevent the sound dampening foam material from dropping when the material is filled into the front pillar upper in the next process (for front pillar upper).
15 mm (0.6 in) A
Side outer panel
Front pillar reinforcement lower A
10 mm (0.4 in)
30 mm (1.2 in)
80 mm (3.1 in)
AB601733AB
35 mm (1.4 in) 90 mm (3.5 in)
8. When installing the new front pillar outer, machine the body loose panel cushion (MR535301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material is filled into the front pillar (for front pillar lower).
B
110 mm (4.3 in)
Front pillar reinforcement lower
B
: Body loose panel cushion
Side outer panel AB601245AB
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WELDED PANEL REPLACEMENT FRONT PILLAR
3-15
9. When installing the new front pillar outer, apply the body sealant to the areas as shown in advance.
: Body sealant
AB601221AB
10.Assemble the front pillar outer, bolt and tape the hole and flange with aluminum tape, then fill the hole with sound dampening foam material as shown in the figure of the instructions. SOUND DAMPENING FOAM MATERIAL: 3M™ AAD ULTRAPRO Panel foam-Yellow
A AB601214
Front pillar reinforcement lower
Front inner pillar lower
A : Sound dampening foam material
AB601246AB
11.Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminum tape, then melt the sound dampening foam material with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with sound dampening foam material.
AB100787
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3-16
WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT)
CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn. NOTE: Refer to the Fender Shield section on P.3-4 for the welding points with the front upper frame outer rear.
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3-17
WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT)
Cutting position
F
D E
Cutting position F
G
(With the side outer panel removed) AB601448AB
NOTE ON REPAIR WORK .
REMOVAL Front inner pillar lower
After removing the front pillar, cut the side outer panel 140 mm (5.5 inches) behind the positioning notch to remove the side sill reinforcement outer front, side sill inner support front, and front inner pillar lower remaining on the body side.
140 mm (5.5 in)
Side sill inner support front
Side outer panel Side sill reinforcement outer front
AB601206AB .
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3-18
WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT)
INSTALLATION Side outer panel
1. To reinforce the strength in the front pillar cut area, cut the side outer panel 50 mm (1.97 inches) above the cut area. 2. Assemble the new front pillar inner lower parts.
50 mm (1.97 in)
AB601207AB
Side sill reinforcement front
Aluminum tape
3. Assemble the new side sill reinforcement front parts. After that, cover the hole with aluminum tape to prevent the sound dampening foam material from dropping when the material is filled into the front pillar in the next process.
AB601208AB
4. When installing the new front pillar lower reinforcement is installed, remove the front pillar outer lower extension and front pillar outer upper extension in advance, and install the front pillar lower reinforcement because there are some points which cannot be welded on the body side.After that, install the front pillar outer lower extension and front pillar outer upper extension.
Front pillar outer upper extension
Front pillar outer lower extension AB601220AB
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WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT)
10 mm (0.4 in)
30 mm (1.2 in)
80 mm (3.1 in)
35 mm (1.4 in) 90 mm (3.5 in)
3-19
5. When installing the new front pillar outer, machine the body loose panel cushion (MR535301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the front pillar.
A
110 mm A (4.3 in)
Front pillar reinforcement lower
A
: Body loose panel cushion
Side outer panel AB601226AB
6. When installing the new front pillar outer, apply the body sealant to the areas as shown in advance.
: Body sealant
AB601450AB
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3-20
WELDED PANEL REPLACEMENT FRONT PILLAR (PARTIAL REPLACEMENT)
7. Assemble the front pillar outer, bolt and tape the hole and flange with aluminum tape, then fill the hole with sound dampening foam material as shown in the figure of the instructions. SOUND DAMPENING FOAM MATERIAL: 3M™ AAD ULTRAPRO Panel foam-Yellow A
Front pillar reinforcement lower
Front inner pillar lower : Sound dampening foam material A
AB601590AB
8. Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminum tape, then melt the sound dampening foam material with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with sound dampening foam material.
Anti-corrosion agent application locations (Use access holes to apply liberally to butt-welded joints.)
REPAIR WELDS 190 mm (7.5 in)
A
Cutting position Sound dampening foam material
A
B
B The same position as the new center outer part
The same position as the new center outer part
C
Sound dampening foam material
C
D
D
AB601417AB
CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn.
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3-22
WELDED PANEL REPLACEMENT CENTER PILLAR
NOTE ON REPAIR WORK .
REMOVAL Side outer panel Center pillar reinforcement
Side sill reinforcement outer rear
1. To cut the welding points between the side sill center pillar reinforcement and side sill reinforcement outer rear, cut the side outer panel as shown.
AB601418AB
2. After removing the center pillar, remove the center pillar inner upper left on the body side.
Center pillar inner upper AB601247AB .
INSTALLATION
Center pillar reinforcement 50 mm (1.97 in)
Side outer panel
1. To reinforce the strength in the center pillar cut area, cut the side outer panel 100 mm (3.9 inches) above the cut area and cut the center pillar reinforcement 50 mm (1.97 inches) above the cut area.
100 mm (3.9 in)
AB601248 AB
2. Remove the center pillar inner lower from the new center inner pillar, and install the center inner pillar to the body. Center pillar inner lower
AB601249AB
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WELDED PANEL REPLACEMENT CENTER PILLAR
Rear door hinge reinforcement 50 mm (1.97 in)
100 mm (3.9 in)
Center pillar reinforcement
3-23
CAUTION Weld and repair if the rear door hinge reinforcement is damaged. 3. Cut the new center pillar reinforcement parts by aligning them with the cut area of center pillar reinforcement in the body-side. Then, cut only the center pillar reinforcement 100 mm (3.9 inches) below from the cut area to create a cover, and then cut the rear door hinge reinforcement 50 mm (1.97 inches) below from the cut area.
AB601250 AB
4. Weld the rear door hinge reinforcement then weld the cover of the center pillar reinforcement. Cover
Rear door hinge reinforcement
Center pillar reinforcement AB601251AB
50 mm (2.0 in) 50 mm (2.0 in)
35 mm (1.4 in) 20 mm (0.8 in)
50 mm (2.0 in)
75 mm (3.0 in)
5. When installing the new center pillar outer, machine the body loose panel cushion (MR535301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the front pillar.
75 mm (3.0 in) 40 mm (1.6 in)
450 mm (17.7 in)
A
Center pillar reinforcement
A
Side outer panel : Body loose panel cushion AB601254AB
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3-24
WELDED PANEL REPLACEMENT CENTER PILLAR
6. Assemble the center pillar outer, bolt and tape the hole and flange with aluminum tape, then fill the hole with sound dampening foam material as shown in the figure of the instructions. SOUND DAMPENING FOAM MATERIAL: 3M™ AAD ULTRAPRO Panel foam-Yellow A
Center pillar reinforcement
A
Side sill reinforcement outer rear : Sound dampening foam material
AB601255AB
7. Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminum tape, then melt the sound dampening foam material with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with sound dampening foam material.
CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn.
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WELDED PANEL REPLACEMENT SIDE SILL
D
3-27
Sound dampening foam material
(With the side outer panel removed)
D
NOTE: Partial replacement is possible depending on the range of damage. Cut the side sill reinforcement outer rear 50 mm (1.97 inches) away from the cut area of the side outer panel.
Side sill reinforcement outer rear
(With the side outer panel removed) : Cuttable range
AB601517AB
AB601311AB
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3-28
WELDED PANEL REPLACEMENT SIDE SILL
NOTE ON REPAIR WORK .
REMOVAL 1. When installing the side sill reinforcement outer rear, cut the center pillar reinforcement 80 mm (3.15 inches) downward from the installation hole of the rear door hinge because the center pillar reinforcement interferes with it.For the rear wheel house, remove the rear wheel house shield plate front and quarter inner extension front because the quarter inner extension front interferes with the rear wheel house shield plate front.
80 mm (3.15 in)
Center pillar reinforcement
Rear wheel house shield plate front
Quarter inner extension front
AB601298AB
2. After removing the side sill reinforcement outer rear, remove the center pillar inner lower.
Center pillar inner lower
AB601307 AB
.
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WELDED PANEL REPLACEMENT SIDE SILL
3-29
INSTALLATION 1. Remove the center pillar inner upper from the new center inner pillar, and install the center inner pillar to the body.
Center pillar inner upper AB601249 AC
2. Remove the side sill reinforcement outer front from the new side sill reinforcement, and install the side sill reinforcement to the body.
Side sill reinforcement outer front
AB601309AB
10 mm (0.4 in)
30 mm (1.2 in)
80 mm (3.1 in)
35 mm (1.4 in) 90 mm (3.5 in)
110 mm (4.3 in)
3. When installing the new floor side sill outer, machine the body loose panel cushion (MR535301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the front pillar.
A
Front pillar reinforcement lower
A
: Body loose panel cushion
Side outer panel AB601737AB
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3-30
WELDED PANEL REPLACEMENT SIDE SILL 50 mm (2.0 in) 50 mm (2.0 in)
75 mm (3.0 in)
35 mm (1.4 in) 20 mm (0.8 in)
50 mm (2.0 in)
4. When installing the new floor side sill outer, machine the body loose panel cushion (MR535301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the center pillar.
75 mm (3.0 in) 40 mm (1.6 in)
450 mm (17.7 in)
A
Center pillar reinforcement
A
: Body loose panel cushion
Side outer panel AB601310AB
5. Assemble the floor side sill outer, bolt and tape the hole and flange with aluminum tape, then fill the hole with sound dampening foam material as shown in the figure of the instructions. SOUND DAMPENING FOAM MATERIAL: 3M™ AAD ULTRAPRO Panel foam-Yellow A
Center pillar reinforcement
A
Side sill reinforcement outer rear : Sound dampening foam material
AB601255AB
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WELDED PANEL REPLACEMENT SIDE SILL
3-31
6. Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminum tape, then melt the sound dampening foam material with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with sound dampening foam material.
CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn.
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3-33
WELDED PANEL REPLACEMENT QUARTER OUTER
D
E AB601477AB
NOTE ON REPAIR WORK .
INSTALLATION 40 mm (1.6 in) 175 mm (6.9 in) 25 mm (1.0 in)
1. When installing the new rear quarter outer panel, machine the body loose panel cushion (MR535301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the wheel arch.
A
Side outer panel
Roof side rail reinforcement rear A
: Body loose panel cushion
AB601738AB
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3-34
WELDED PANEL REPLACEMENT QUARTER OUTER
185 mm (7.3 in) 40 mm (1.6 in)
30 mm (1.2 in)
2. When installing the new rear quarter outer panel, machine the body loose panel cushion (MR535301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the wheel arch.
A
Rear pillar reinforcement lower
Quarter inner panel
Side outer panel A : Body loose panel cushion
AB601328AB
3. When installing the new rear quarter outer panel, apply the body sealant in advance to the areas as shown. Left side only
: Body sealant
AB601325AB .
NOTE: Partial replacement is possible depending on the range of damage.
CAUTION When repairing the area using sound dampening foam material do not use firing tools since the sound dampening foam material may burn. NOTE: Refer to the Quarter Outer section on P.3-32 for the welding points with the quarter outer.
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3-41
WELDED PANEL REPLACEMENT QUARTER INNER
Right side only
E
Right side only Right side Right side only C D
Right side
Right side
Left side only
(With the rear pillar reinforcement and the rear pillar reinforcement lower removed)
E
Left side only C
D
Left side only AB601519AB
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3-42
WELDED PANEL REPLACEMENT QUARTER INNER
Right side only
H Left side only
F
G
Right side only
H
(With the rear wheel house shield plate front removed) AB601591AB
NOTE ON REPAIR WORK .
INSTALLATION
A
125 mm (4.9 in)
1. When installing the new rear quarter inner panel, machine the body loose panel cushion (MR535301 or MR435765) as shown and apply it to the body side to prevent the sound dampening foam material from dropping when the material is filled into the rear pillar in the next process.
70 mm (2.8 in) 20 mm (0.8 in) Roof side rail reinforcement rear
Quarter inner panel
A
: Body loose panel cushion
AB601339AB
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WELDED PANEL REPLACEMENT QUARTER INNER
2. When installing the new rear pillar reinforcement lower, machine the body loose panel cushion (MR535301 or MR435765) for replacement as shown and apply it to the body side because the sound dampening foam material cannot be filled into the rear pillar reinforcement lower.
85 mm (3.3 in)
20 mm (0.8 in)
3-43
40 mm (1.6 in)
A
Quarter inner panel
Rear pillar reinforcement lower A
: Body loose panel cushion
AB601327AB
3. Assemble the rear quarter inner panel, bolt and tape the hole and flange with aluminum tape, then fill the hole with sound dampening foam material as shown in the figure of the instructions. SOUND DAMPENING FOAM MATERIAL: 3M™ AAD ULTRAPRO Panel foam-Yellow
AB601338AB
4. Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminum tape, then melt the sound dampening foam material with a soldering gun so a clip, etc. can thoroughly be inserted in the hole filled with sound dampening foam material.
(With the rear pillar reinforcement and the rear pillar reinforcement lower removed)
Rear wheel house shield plate front
B
C
C (With the rear wheel house shield plate front removed)
AB601487AB
NOTE: . • Refer to the Quarter Outer Section on P.3-32 for the welding points with the quarter outer. • Refer to the Quarter Inner Section on P.3-40 for the welding points with the rear pillar reinforcement and the rear pillar reinforcement lower.
REMOVAL 1. Adhere tape along the wheel arch of the quarter inner panel as shown in the figure of the instructions, use the tape as a guide so about 20 mm (0.79 inch) of the flange remains, then cut and remove.
Tape AB601343 AB .
INSTALLATION 1. For the new rear quarter inner panel parts, cut the wheel arch end are so that it overlaps with the flange on the body-side.
AB601344
2. Overlap, assemble and weld the rear quarter inner panel with the body-side flange. Weld at a pitch of 40 mm (1.57 inches).
40 mm (1.57 in)
AB601342AB
3. Weld the rear quarter inner panel then apply a body sealing in the area shown in the figure of the instructions.
Body sealing AB601426AB
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3-46
WELDED PANEL REPLACEMENT FRONT DOOR OUTER PANEL (WELDED TYPE)
BRAND: 3M™ AAD Part No.8542 or equivalent NOTE: After hemming the front door outer panel, MIG spot weld the flange overlap section at a pitch of 50 mm (1.97 inches).
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)
3-47
WELDED PANEL REPLACEMENT FRONT DOOR OUTER PANEL (ADHESION TYPE)
• ADHESIVE 1: Urethane body sealer BRAND: 3M™ AAD Part No.8542 or equivalent • ADHESIVE 2: Epoxyayresin adhesive BRAND: 3M™ AAD Part No.8115 or equivalent
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NOTE ON REPAIR WORK .
INSTALLATION 1. When installing the front door outer panel, grind the bonding surface and remove the paint to improve adhesion. Then, degrease the front door outer panel. 2. Install the front door outer panel and hem it. Then, wipe off the adhesive that squeezed out.
3-48
WELDED PANEL REPLACEMENT REAR DOOR OUTER PANEL (WELDED TYPE)
ADHESIVE: Urethane body sealer BRAND: 3M ATD Part No.8542 or equivalent NOTE: After hemming the rear door outer panel, MIG spot weld the flange overlap section at a pitch of 50 mm (1.97 inches).
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3-49
WELDED PANEL REPLACEMENT REAR DOOR OUTER PANEL (ADHESION TYPE)
ADHESIVE 1: Urethane body sealer BRAND: 3M ATD Part No.8542 or equivalent ADHESIVE 2: Epoxyayresin adhesive BRAND: 3M ATD Part No.8115 or equivalent
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NOTE ON REPAIR WORK .
INSTALLATION 1. When installing the rear door outer panel, grind and remove the paint, etc. from the bonded surface of the outer panel to ensure the bonding strength. After the removal, degrease it. 2. Install the outer panel and hem it. Wipe off the excessive adhesive and finish it.
SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS
LOCATION OF SYNTHETIC-RESIN PARTS
M4050001000980
The location and material of each of the principal synthetic-resin parts are shown below.
4 3
41 2, 5
12
6
13
32
7 1
27 8 26
9
25 24
29
28
23
AB601424AB
15
35
31 16
36
17
30 14 34 33
18 10
19
21 20 11
37 22 40
39
38 AB601425AB
5-3
SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS NO.
PART NAME
NAME OF RESIN
ABBREVIATION HEATRESISTANT TEMP [° C (° F)]
1
Radiator grille
Acrylonitrile butadiene styrene
ABS
80 (176)
2
Door mirror cover (colour)
3
Rear spoiler
4
Roof antenna base
Acrylonitrile ethylene styrene
AES
80 (176)
5
Door mirror cover (black)
Acrylonitrile styrene acrylate
ASA(AAS)
80 (176)
6
Door mirror
7
Headlight
Polycarbonate
PC
120 (248)
8
Rear door outside handle
PC+PET
120 (248)
9
Front door outside handle
Polycarbonate+Polyethylene terephthalate
10
Rear splash shield
High density polyethylene
11
Front splash shield
PE-HD (HDPE)
70 −90 (158 −194)
12
High-mounted stoplight
Polymethyl methacrylate
PMMA
80 (176)
13
Trunk lid light
14
Front door trim lower
Polypropylene
PP
80 (176)
15
Inside rear view mirror
16
Rear door trim
17
Rear shelf trim
18
Rear end trim
19
Rear scuff plate
20
Front scuff plate
21
Cowl side trim
22
Fender protector
23
Fog light bezel
Rubber denatured polypropylene
PP+E/P
80 (176)
24
Air intake bezel
25
Front bumper face
26
Under grille
27
Rear bumper face
28
Front air dam
29
Side air dam
Talc filled rubber modified polypropylene (20%)
PP+E/P-TD20 110 (230)
30
Front door trim upper
Talc filled polypropylene (10%)
31
Center pillar trim lower
PP-TD10 (PPF)
110 −120 (230 −248)
5-4
SYNTHETIC-RESIN PARTS LOCATION OF SYNTHETIC-RESIN PARTS
NO.
PART NAME
NAME OF RESIN
ABBREVIATION HEATRESISTANT TEMP [° C (° F)]
32
Front deck garnish
Talc filled polypropylene (20%)
33
Instrument panel
PP-TD20 (PPF)
120 −130 (248 −266)
34
Front pillar trim
35
Center pillar trim upper
36
Rear pillar trim
37
Cup holder
38
Floor console
39
Floor console panel
40
Console side cover
41
Roof drip molding
Polyvinyl chloride
PVC
80 (176)
NOTE: . • If the material symbols designated by the ISO differ from the old symbols, both are given, with the old symboling enclosed in brackets. ISO: International Standardization Organization. • A slash (/) in the material symbol indicates that two different materials make two-layer construction. A plus sign (+) indicates that the two different materials mix each other. • The indicated heat-resistant temperature for parts which are composed of two or more types of material is the value for the material with the lowest heat-resistant temperature. • The material symbols for synthetic-resin parts are embossed on the parts in hidden places.
6-1
GROUP 6
BODY COLOR CONTENTS BODY COLOR CODE . . . . . . . . . . . .
Body color code is stamped on the name plate, which is attached on the underside of the center pillar (Right side).
Body color code AB601277AB
BODY COLOR CHARTS
M4060002001396
Check the vehicle’s body color code, and then use this body color chart to determine the refinishing paint supplier from which the color can be purchased. Color Color code Color number Color name (Previous name)
Composition of film
SILVER
A31
CMA10031
Cool Silver Metallic
Metallic
MEDIUM A39 PURPLISH GRAY
CMA10039
Medium Purplish Gray Mica
Metallic + Interferenced Pearl
GREENISH SILVER
A86
CMA10086
Greenish Silver Metallic
Metallic + Interferenced Pearl
BLUE
T70
CMT10070
Blue Mica
Pearl
BEIGE
S18
CMS10018
Platinum Beige Metallic
Metallic + Interferenced Pearl
BLACK
X42
AC11342
Black Mica (Amethyst Black)
Interferenced Pearl
WHITE
W37
CMW10037
White Solid
Solid
RED
P26
CMP10026
Red Metallic
Metallic
NOTE: . • It is a solid, but clear coating is applied. • For painting, inner panel colors should be similar to the outer panel colors.
6-3
BODY COLOR BODY COLORING
BODY COLORING RADIATOR GRILLE
M4060007000592
1
2 ES, GTS
DE
1 Chrome plating
Dark gray (CMH18031)
2 Material color
Material color
WHEELHOUSE
: Black (AC10657)
AB601174AB
M4060012000327
AB601150AB AB601150
NOTES
9-1
GROUP 9
BASE OF BODY REPAIR CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . .
Welding is the partial joining of two or more metals by deposition; the welding methods used for body maintenance and repair can be classified into the following methods. Fusion methods Temperature: 1,130 – 1,550˚C (2,066 – 2,822˚F) Welding methods
Shielded arc welding CO2 gas arc welding Gas welding
Electric resistance spot welding Pressure methods [Temperature approximatery 1,500˚C (2,732˚F) or higher at weld area] Brazing methods
Fusion welding is a method of welding in which the weld connection is made by forming or supplying the weld metal at the part where the weld is to be made.
Brazing is a method of welding in which the weld connection is made by supplying a filler metal (which is molten at a temperature lower than the melting temperature of the base metal) at the place where the joining is to be made without melting the base metal itself.
PRESSURE WELDING Pressure welding is a method of welding in which the weld connection is made by applying external pressure while the part where the weld is to be made is in a molten or semi-molten condition.
ELECTRIC RESISTANCE SPOT WELDING Electric resistance spot welding is a method for fusing metal parts together. Two or three metal sheets are positioned between two copper-alloy electrode tips, and pressure and a large current are then applied, thus causing the contacting surfaces to heat up and fuse together because of the electric contact resistance.
.
ADVANTAGES OF ELECTRIC RESISTANCE SPOT WELDING
M4090002000039
• Because the time required for welding at each point is brief, the work can be done quickly and at reduced cost. • Because both metals are fused and pressure applied to make the weld, the strength and reliability are both high. • Because the time required to make the welds is short, there is little occurrence of distortion of the panel due to heat.
BASE OF BODY REPAIR WELDING
9-3
PROCEDURE There are three basic stages in electric resistance spot welding. 1. Initial pressure application stage This stage precedes the current application. Applying pressure to the steel panels through the electrode tips ensures a uniform contact resistance and a smoother current flow.
AB200026
2. Current application stage While an ample amount of pressure is being applied, the current is sent through the electrode tips. The contact resistance causes the contact surfaces of the steel panels to heat up and fuse together.
AB200027
3. Holding stage When the current application is finished and a nugget (a solidified piece of molten metal) forms at the weld, the pressure application is continued in order to strengthen the weld. This is the most important stage of electric resistance spot welding in ensuring the strength of the weld.
AB200028
.
9-4
BASE OF BODY REPAIR WELDING
NUGGET FORMATION
Weak ← Shear strength per point → Strong
Cooling water
More than 1.6 mm (0.06 in)
C D
Melting point C' D'
B' B
A' A
Electrode
1.6 mm (0.06 in) or less
C is the scatter point
Steel panel
Nugget
Electrode
Small ← Welding current → Large
Water 540 1,095 1,650˚C Cooling water temperrature (1,000) (2,000) (3,000)˚F Max. Heating temperature AB301468 AC
Generally speaking, the size of the nugget will increase as the welding current increases, and as the size of the nugget increases, the strength of the weld will also increase. Nugget formation will not begin until the current level reaches a certain point; however, once this welding current level is passed, the strength will increase rapidly (between points A and B).
As the current level increases further, the weld strength for thick panels [more than 1.6 mm (0.06 inch)] continues to increase proportionately (between points B and C); however, for thin panels [1.6 mm (0.06 inch) or less], the weld strength reaches a peak very quickly and will increase only slightly, even if the current level increases (between points B' and C'). Then, for both thick panels and thin panels, the molten metal will scatter if the current level increases past a certain point. .
9-5
BASE OF BODY REPAIR WELDING
NOTES REGARDING WELDING
D
t
90 – 120˚ D : Diameter of the electrode tip t : Thickness of the panel
AB301455AC
1. Selection of the electrode tips • Select the electrode tips according to the thickness of the panels to be welded. D = 2t + 3 mm (D = 2t + 0.1 inch) • The angle of the tip should be between 90 degree angle and 120 degree angle. • To always keep the end of tip in the correct shape, use a tip cutter, file or similar tool to shape it if it becomes worn. 2. Alignment of the electrode tips • Adjust the arms so that the upper and lower electrode tips are in a straight line. 3. Alignment and length of the arms • Adjust the electrode tips so that the upper and lower arms are parallel. • Select an appropriate arm length. Note, however, that the arm length should not be more than 350 mm (13.8 inches) in order to ensure nugget strength. 4. The weld points • The overall strength will increase as the pitch decreases; however, if the pitch decreases too much, the current will be short-circuit diverted to the previous weld point and the strength of the individual nuggets will be insufficient.
• Make the spot welds at the center of the flanges to provide sufficient adhesion. When welding at an edge, make the spot welds at least 5 mm (0.2 inch) from the edge of the flange. • The number of spot weld points should be the same as, or slightly more than the number of original repair welds. • When spot welding three or more panels together, if painted surfaces cause a loss of conductivity, make the welds at the same places as the factory welds. If this is done, extra welds will not be necessary, but if extra welds are necessary, switch to plug welding. .
WELDING REQUIREMENTS Standard steel plate (SPCC, etc.)
CAUTION If the total thickness of the plates at the weld places is 3 mm (0.12 inch) or more, use plug welding, because spot welding will not provide sufficient welded strength. Example • Center pillar (outer): plate thickness 1.4 mm (0.06 inch), material SPCC • Center pillar (inner): plate thickness 1.5 mm (0.06 inch), material SPCC The number of weld points are as below when the outer and inner center pillars are repaired by welding.
9-6
BASE OF BODY REPAIR WELDING
Factory welds (F)
8 Points
8 Points
Repair welds (R)
11 Points
11 Points
As shown by the Welding Requirements table, the number of repair welds is as follows. 8 (points) × 130 (%) = 10.4 (points) The number of weld points should, therefore, be ten or eleven. If, however, a pitch of 26 mm (1.0 inch) or more cannot be maintained, the plug welding method (eight weld points) should be used. AB200031AC
PANEL THICKNESS* [mm (in)]
NUMBER OF REPAIR WELD (PERCENTAGE OF FACTORY WELD)
SAFETY EQUIPM ENT AREA
1.0 (0.04) or less
100% Same number as factory welds
1.2 (0.05)
150% Maintain pitch of at least 22 mm (0.9 inch); if not possible, plug weld.
1.4 (0.06) or more
100% Same number as factory welds; plug welding
OTHER AREA
1.2 (0.05) or less
100% Same number as factory welds
1.4 (0.06)
130% Maintain pitch of at least 26 mm (1.0 inch); if not possible, plug weld.
1.6 (0.06) or more
100% Same number as factory welds; plug welding
NOTE: *: For welding steel plates of different thickness, conform to the welding conditions for the thinner plate. .
BASE OF BODY REPAIR WELDING
9-7
Galvanized steel plate (SECC) CAUTION If the total thickness of the plates at the weld places is 3 mm (0.1 inch) or more, use plug welding, because spot welding will not provide sufficient welded strength. PANEL THICKNESS* [mm (in)]
NUMBER OF REPAIR WELD (PERCENTAGE OF FACTORY WELD)
SAFETY EQUIPM ENT AREA
0.9 (0.04) or less
100% Same number as factory welds
1.0 (0.04)
200% Maintain pitch of at least 18 mm (0.7 inch); if not possible, plug weld.
1.2 (0.05) or more
100% Same number as factory welds; plug welding
OTHER AREA
0.9 (0.04) or less
100% Same number as factory welds
1.0 (0.04)
140% Maintain pitch of at least 18 mm (0.7 inch); if not possible, plug weld.
1.2 (0.05) or more
100% Same number as factory welds; plug welding
NOTE: *: For welding steel plates of different thicknesses, conform to the welding conditions for the thinner plate. .
USING A TEST PIECE TO CHECK NUGGET FORMATION
Weld point
1
2
3 AB200032AC
Weld a test piece of the same type of steel plate as the panels to be welded. Try to twist the piece, and also check the nugget diameter. Using the weld point as an axis, apply force in the direction indicated by the arrows in the illustration, and determine the strength of the weld. 1. Good (The welded part remains at one side). 2. and 3. The weld conditions are unsatisfactory; adjust the welding current, the current application time, and/or the applied pressure. .
9-8
BASE OF BODY REPAIR WELDING
CHECKING NUGGET STRENGTH FOLLOWING SPOT WELDING
3 mm (0.1 in)
AB200033AB
CAUTION • Stop wedging the tip or the chisel or flat-tipped screwdriver as soon as the size of the nuggets can be determined; do not wedge it in more than 30 mm (1.2 inches). • After checking the nugget diameter, correct the place where the checking was done. Wedge the tip of a chisel or flat-tipped (-) screwdriver into the space between two weld points. • The nuggets should not break apart. • The nugget diameter should be 3 mm (0.1 inch) or more.
GAS SHIELD ARC WELDING
M4090003000032
Wire Nozzle Contact tip Metal vapor
Shield gas
AB301456 AC
Gas shielded arc welding is one method of arc welding. In this method, while the area to be welded is shielded from the air by a layer of inert gas (such as argon) or carbon dioxide gas, the filler metal (wire) is fed from the torch nozzle at a constant rate and an electric arc is generated between the tip of the wire and the area being welded, thus generating heat to
fuse the area. There are two types of gas shielded arc welding, classified according to the gas they use as the shield gas: carbon dioxide (CO2) gas shielded arc welding, and MIG welding, which uses an inert gas (such as argon). However, herein we will refer to all gas shielded arc welding as MIG welding.
MIG SPOT WELDING Wire Gas cup
Gas outlet
AB200036 AD
BASE OF BODY REPAIR WELDING
This welding method is used in areas where regular spot welding cannot be done. The two panels are stacked together, the tip of the torch (one designed for use in MIG spot welding) is positioned on one side, an arc is generated for a short time, and a partial melting is done to obtain a spot weld.
9-9
2. Being sure that the two prongs are not leaning to either side, set them in direct contact with the panel to the welded. 3. Welding will begin when the torch trigger is squeezed, and will stop automatically when the weld is complete.
.
Procedure
.
CAUTION • Make sure that the area to be welded is perfectly clean; remove oxidation film, scales, rust, dirt, etc. • The two panels to be welded must be in perfect contact with each other. • The number and pitch of the weld points should be approximately the same as for the factory welds. 1. Position the tip of the nozzle at a right angle to the surface to be welded.
FEATURES OF MIG SPOT WELDING In comparison to resistance spot welding, MIG spot welding has the following advantages and disadvantages. ITEM MIG SPOT WELDING
ELECTRIC RESISTANCE SPOT WELDING
Working characteristics
• Light weight • Welding possible at various positions (no limit upon welding positions)
• Although the torch with separate transformer is lightweight, the torch combined with transformer type is heavy. • The arm must be exchanged to conform to the weld location.
Weld time/point
Slow (0.5 second or more)
Fast (0.5 second or less)
Treatment after welding
Necessary (grinding by grinder, etc.)
Unnecessary
Power
High voltage, low current (15 −30 V, 50 −200 A)
Low voltage, high current (2 −4 V, 4 −10 kA)
Flux material
• CO2 (carbonic acid gas) • Weld wire
Unnecessary
Weld points/10 minutes (rate of use)
• 25 points or less • Arc instability and contact tip burn if rate of use is exceeded.
• 50 −60 points • Welding rod deformation and transformer overheating if rate of use is exceeded.
Distortion caused by welding
Occurs easily
Rare
9-10
BASE OF BODY REPAIR WELDING
ITEM
MIG SPOT WELDING
ELECTRIC RESISTANCE SPOT WELDING
Welding strength
Depends on strength of welding wire itself.
• Same as base material • Little oxidation • Uniform welding quality
Weld traces
Button head (slightly convex)
Slight concave (Almost no indentation if swivel tip used.)
Swivel tip
AB200037AC
Re-repairability (cutting away welded area)
Difficult Easy (Much welding trace High hardness (Can be separated by spot cutter.) of weld points) .
The MIG welding done around the doors, wheelhouse arches, etc., to prevent the flanges from coming undone after hemming work is also called MIG spot welding.
AB200038 AB
PLUG WELDING
Torch
5 – 6 mm (0.2 in) Diameter hole
Perfect contact
AB301460AC
CAUTION In order to prevent the formation of blowholes, fill in each hole completely in one pass.Be sure that the two panels are in perfect contact.Be sure that the penetration goes all the way to the bottom panel. Plug welding is done by making holes 5 −6 mm (0.2 inch) in diameter in one of the panels to be welded together, positioning the torch at a right angle to the holes and then filling in the holes one at a time.
BASE OF BODY REPAIR WELDING
9-11
CONTINUOUS WELDING There are several types of continuous welding: fillet (lap joint) welding, butt welding, T joint welding, gap welding, etc.; these are called short-circuit arc welding, and provide a stable arc at a relatively low current.
AB200041 .
Torch angle and welding technique
15 – 30˚
There are two welding techniques: forehand welding and backhand welding. Forehand welding: Penetration is shallow and the bead is flat. Backhand welding: Penetration is deep and the bead has a convex shape. The angle of the torch should be 15 −30 degree angle for either technique, and the tip should be maintained at a distance of 6 − 10 mm (0.2 −0.4 inch) from the surface being welded.
1. Backhand technique Because the direction for each weld pass and that for the fusion progression are opposite, the residual stress is evenly distributed. 2. Symmetrical technique Because the welds are made in symmetrical positions in relation to the center of the joint, the residual stress is also symmetrical. 3. "Stepping stone" technique Because the welds are made at random positions, the residual stress is the most evenly distributed; however, the possibility of flaws at the starting and stopping points is relatively high.
9-12
BASE OF BODY REPAIR WELDING
NOTES REGARDING MIG WELDING Note the following notes regarding MIG welding. 1. The surface to be welded must be perfectly clean; be sure to remove any non-conductive paint. 2. If the end of the wire forms into a ball, it will adversely affect the formation of the arc; cut the end off with a pair of wire snips or a similar tool.
3. Select a welding current to match the thickness of the panels being welded. 4. For continuous welding, maintain a constant weld speed and keep both the height and the width of the bead constant. In addition, the tack welding pitch and the welding bead should be shorter as the thickness of the panels being welded decreases.
OTHER TYPES OF WELDING
M4090004000035
BRAZING In brazing, a filler metal is melted into the joint of the panels to be welded at a comparatively low temperature to fuse them together without melting the panels themselves. In other words, through the aid of a flux and because of the capillarity phenomenon, the molten filler metal will flow into the joint between the two panels which are in contact with each other and spread along the metal surfaces. When this molten filler metal cools and solidifies, it will from a strong joint of the two panels. Note that, if two panels of different kinds of metal are brazed, the electrolysis generated between the two metals will cause moisture to from, which will result in corrosion. Panels should not be connected together by brazing at any place except those places indicated. The following materials (filler metals) are usually used for brazing.
1. Brass filler metal (brass solder) Brass filler metal is an alloy consisting of 60% copper and 40% zinc with a melting temperature of approximately 850 −1,050° C (1,562 − 1,922° F), and it is the most commonly used brazing filler metal used for body repair. The filler metal itself is coated with flux to facilitate penetration between the panels to be joined. 2. Silver alloy filler metal (silver solder) Silver alloy filler metal consists of silver, copper, zinc or cadmium, nickel, and tin, or other metals. This filler metal is most applicable for the brazing of steel and non-ferrous alloy other than aluminum, magnesium, and others with low melting points.
Notes with regard to brazing work
Examples of brazed joints
• Use a wire brush, sandpaper, file etc., to remove any oxide film grease, dirt, etc., from the surfaces of the panels to be brazed.
AB200044 AD
• When doing brass brazing, if the panels and the filler metal are heated excessively, a weak iron-copper alloy will form, which could crack easily. Be careful not to apply excessive heat. • The joint of the panels must overlap as indicated in the illustration.
9-13
BASE OF BODY REPAIR WELDING
GAS WELDING Oxy-acetylene flame
Welding rod Deposite
Base metal
Gas welding is a method in which a high temperature flame is used to melt both a welding rod and the base metal (panels) to make a fused joint. Oxy-acetylene is the most common type of gas welding. However, because of the extremely high temperature of the fused joint, the strength of the steel plate deteriorates, and there is a higher possibility of warping. This method, therefore, is not very suitable for body repair.
AB200049 AC
.
The flame in gas welding can be classified according to the ratio of acetylene and oxygen.
Flame core
Acetylene core
3. Peroxide flame
2. Standard flame
1. Carburizing flame
Flame core
Outer flame
Outer flame
Flame core
Outer flame AB200050 AD
1. Carburizing flame (acetylene-rich flame) This flame has an excess of acetylene or a deficiency of oxygen. The incomplete combustion gives off a black smoke, and two flame cores can be seen inside the deformed yellow flame. The flame itself is large, but the temperature is relatively low, making this flame unsuitable for welding. 2. Standard flame (neutral-mixture flame) This flame has approximately equal amounts of acetylene and oxygen. The length is shorter than that of the carburizing flame; the flame core is rounded; and it is clear and bright. The carbon in the acetylene is burned completely, resulting in the maximum obtainable temperature. This is the flame most commonly used for welding. 3. Peroxide flame (oxygen-rich flame) This flame has an excess of oxygen or a deficiency of acetylene. The flame core is shorter and sharper, and the entire flame has a blackish-purplish color. The combustion is unstable, and the flame flickers continuously.
.
Notes with regard to gas welding 1. Handle the oxygen and acetylene tanks carefully. 2. Adjust the flame in accordance with the type of metal being welded. 3. Select a nozzle to match the work to be done. Avoid overheating and adhesion of foreign matter (dirt, etc.) 4. The following points are particularly important when welding mild steel plate. • Melt a sufficient amount of welding rod, but be careful not to melt the base metal. Use the same amount of welding rod on both sides. • Use the correct amount of welding rod in accordance with the melting point of the base metal. • Avoid welding over places which have been welded before. • In order to avoid warping, do only the amount of tack welding that is absolutely required.
9-14
BASE OF BODY REPAIR BODY REPAIR
BODY REPAIR STANDARD BODY REPAIR PROCEDURES The following is an explanation of the standard repair procedures for the monocoque body and the frame-type body. Furthermore, please refer to the replacement of welded panels for the applicable model for information concerning the procedures for replacement of panels (as classified by position) for the various models. NOTE: That reference should be made to page P.9-27 concerning repair procedures for the frame of frame-type vehicles.
M4090006000064
STANDARD PROCEDURES FOR REPLACEMENT OF WELDED PANELS
In order to maintain the proper levels of strength, rigidity, and precision when making welded panel replacements, it is essential to first gain a thorough understanding of the body structure, and then to perform all repair operations carefully and correctly. In addition, when performing the operations, be sure to use the proper protective equipment for each operation.
.
AB200051
CAUTION • Select an appropriate location for the cutting operation, and perform the work carefully, so as not to cut into the reinforcements located inside the pillars, panels which are not be replaced, or any other such parts. • There are harnesses, hoses, and other such parts routed inside the front pillar, the rear pillar, the fender shield, the side sill, etc.; perform the repair work only after any such material has been removed. • For overlap cutting, allow an overlap of approximately 30 −50 mm (1.2 −2.0 inches) when performing the cutting operation. 1. Rough cutting of panels First make a rough cutting of a portion of the panel to be replaced, and then remove that portion, thus making it easier to break the spot welds. 2. Removal of the paint coat from spot-welded points In order to clearly identify the spot-welded points, remove the paint coat from areas where it is difficult to determine the spot welds.
AB200052
AB200053
3. Cutting and separation of spot-welded points In order to perform cutting and separation of spot-welded points, use a spot weld cutter which is larger than the size of the nugget to make a hole only in the panels to be replaced. When cutting and separating spot-welded points in places where the surrounding panel or other parts interfere with the spot weld cutter, or if the operation is hampered by a lack of space, bend back the flanges in order to make the work easier. If a spot-weld cutter cannot be used at all, cut and separate the spot welds by using a chisel or similar tool.
BASE OF BODY REPAIR BODY REPAIR
9-15
NOTE: If a replacement panel is to be mounted by doing plug welding from the side of the panel remaining on the body, either a hole can be made in the panel on the body, or a hole can be made right through both the panel which is to remain on the body and the panel to be replaced.
CAUTION When performing this operation, warping of the surrounding panels may occur if an excessive amount of heat is applied; therefore, be careful to avoid doing this. 4. Breaking of brazing and arc welds Heat only the brazed or arc welded portion (such as the upper portion of pillars, etc.), and then separate by using a screwdriver while melting occurs.
AB200054
5. Finishing work of spot welding Grind and smooth any weld traces which might be left on the body surface by using an air grinder or similar tool, being careful not to damage any of the panels which is not to be replaced. When performing this operation, be sure to wear safety goggles (dust proof glasses).
AB200055
6. Making of holes in new parts for MIG plug welding Make holes approximately 5 −6 mm (0.2 inch) in diameter at points where plug welding is to be performed because spot welding is not possible.
AB200056
AB200057
9-16
BASE OF BODY REPAIR BODY REPAIR
7. Flange correction for spot weld traces Correct any flanges that become bent or deformed when spot welds are broken or during other work.
AB200058
CAUTION Do not use a flame for paint coat removal because doing so might damage the paint coat of panels which are not to be replaced, thus causing corrosion. 8. Removal of the paint coat from new parts and from the vehicle body In order to provide for the proper flow of electric current during spot welding operations, remove the paint coat from both sides of the new part and the body by using a polisher wheel or similar tool. AB200059
9. Rough cutting of new parts Cut off the unnecessary portions of new parts. Allow an overlap of approximately 30 −50 mm (1.2 −2.0 inches) when performing overlap cutting of the pillars, side sills, or other locations.
AB200060
Edge of the new part Edge of the panel on the body
AB200061AC
CAUTION Carefully select the location for cutting, taking care not to cut a reinforcement at the inner side of a pillar, etc. or a panel that is not to be replaced. 10.Overlap cutting of new parts For locations in which butt welding is to be done, first temporarily attach the new parts to the body, and then cut the two panels simultaneously. NOTE: If a reinforcement or a panel which is not to be replaced is cut accidentally, first repair the mistake by welding before proceeding with the rest of the work. CAUTION Perform the operations carefully so that the cut ends fit together properly. 11.Cutting of new parts by using a measurement marking
BASE OF BODY REPAIR BODY REPAIR
Two-layer construction
Outer panel Approx. 50 mm (2.0 in) Inner panel
9-17
If overlap cutting is not possible in a place where butt welding is to be done, make a measurement marking on the new part at the exact same measurement which was used for the cutting of the body panel, and then cut the new part by using this measurement marking. • Two-layer construction When cutting a front pillar or center pillar which has a two-layer construction but no reinforcement, make the cutting of the inner panel and that of the outer panel approximately 50 mm (2.0 inches) apart in order to obtain maximum strength.
AB200062AC
Three-layer coustruction
Inner panel cut line
Outer panel and reinforcemant Inner panel cut line cut line
Inner panel
• Three-layer construction When cutting a front pillar or center pillar which has a three-layer (including a reinforcement) construction (double-box construction), cut the outer panel and the reinforcement at the same position, and don't forget to butt weld the reinforcement. If the inner panel is an assembly replacement part, cut it at two places in order to provide ample working space for the butt welding of the reinforcement.
AB200063AC
12.Application of spot sealer to spot-welded points Apply an electro-conductive spot sealer to the connecting surfaces of both the new parts and the vehicle body in order to provide corrosion protection.
AB200064
9-18
BASE OF BODY REPAIR BODY REPAIR
AB200065
CAUTION During temporary mounting, it is extremely important to obtain accurate measurements for each component. The mounting positions for the front and rear suspensions are especially crucial with regard to safety; therefore, it is necessary that all work concerning these areas be done carefully and correctly. 13.Temporary mounting of new parts (1) In order to bring the new parts into the proper mounting position, measure each part carefully and make any corrections necessary in order to obtain agreement with the measurements. (2) In addition, make temporary welds, and then check to confirm that the closing and fit of the doors, fenders, etc., are correct. For parts which should be symmetrical to the body center, measure the distances from the body center point to both the left part and the right part, and confirm that the distances are the same.
AB200066
CAUTION Weld completely so that there are no pinholes. 14.Butt welding For burr welding, make a 10 −15 mm (0.4 −0.6 inch) MIG spot weld, and then, in order to prevent warping which might be caused by the welding heat, complete the welding by making welds of the specified width at alternate positions.
AB200067
AB200068
BASE OF BODY REPAIR BODY REPAIR
9-19
AB200070
15.Spot welding When doing spot welding, it is not only important to correctly position the electrode tips, but also to hold the two panels securely together with vise-grip pliers or some other type of clamps, being sure that they are in perfect contact with each other. • Be sure that the force applied by the arm is sufficient. • Use a test piece to check the secondary current and the current application time of the spot welder, and adjust the values as appropriate.
AB200070
16.Plug welding If spot welds cannot be made, make holes for plug welding in the new parts, and then MIG weld. Because the quality of the fusion varies according to the size of the holes, they should be about 5 −6 mm (0.2 inch) in diameter. In addition, be sure the two surfaces are in complete contact with each other by using vise-grip pliers to securely hold them. NOTE: Depending on the working conditions, it might also be necessary to make holes in the panel remaining on the body 17.Hemming (Adhesion type) (1) Apply an adhesive to the area to be hemmed of the door outer panel.
Section A–A A AB401282
A AB500010 AC
(2) For the area to be hemmed of the door outer panel, apply an adhesive and smooth the panel with a hammer and a dolly. Then, hem the panel with a hemming tool.
Hemming tool AB200072 AC
9-20
BASE OF BODY REPAIR BODY REPAIR
18.Hemming (Welded type) (1) For the area to be hemmed of the door outer panel, etc., smooth the panel with a hammer and a dolly, and hem it with a hemming tool.
Hemming tool AB200072 AC
(2) After completing the hemming work, make MIG spot welds at 50 −60 mm (2.0 −2.4 inches) intervals on the inside.
AB200073
CAUTION Be sure not to grind the panel down too much. Before welding the outer panel, be sure to apply an anticorrosion agent. 19.Finishing work for butt welding and plug welding Do the finishing work to smooth the protruding weld traces. However, the butt joints of reinforcements and other internal parts will be stronger if the weld traces are not finished.
AB200074
20.Application of body sealant Apply a coating of sealant carefully, without breaks, as described in the section (of the manual corresponding to that model). NOTE: After application has been made to any external surfaces, perform smooth-finishing work.
AB200076
BASE OF BODY REPAIR BODY REPAIR
AB200077
9-21
CAUTION Wipe off any anticorrosion agent which oozes out onto surfaces to be painted later; the presence of such anticorrosion agent would prevent correct adhesion of the paint coat. 21.Application of an anticorrosion agent Apply an ample amount of anticorrosion agent to any welded areas and to all surfaces from which the paint coat was removed. The paint coat of welded areas will have been damaged by the heat; be sure to apply an anticorrosion agent to surfaces to be repaired. Use an aerosol-type anticorrosion agent for application to the side sills, the pillars, and other similar parts which have a hollow construction, by utilizing the trim mounting holes, etc.
AB200078
22.Application of undercoating If the underbody is repaired or replaced, carefully apply a coating of undercoating as described in the section (of the manual corresponding to that model).
AB200079
CAUTIONS REGARDING BODY REPAIR
At the time of repair, it is particularly necessary to take measurements at the components noted below, and to make all welds and installations with special care. • Front sidemember • Rear floor sidemember • Front wheelhouse (inner) • Rear wheelhouse (inner) (Independent rear suspension type) 2. Because the places where the floor panel and sidemember parts are joined have an important effect upon the rigidity of the entire body, welds in these places must be done with particular care. 3. After repairs have been completed, the wheel alignment, wheel base, tread, etc., must be carefully checked to be sure that there is no deviation.
Because each component part of a single-unit construction body makes some contribution, more or less, to the overall strength of that body, it is necessary to sufficiently understand the actual function of any part to be repaired before attempting any repair or welding procedure. .
STRENGTH AND RIGIDITY 1. The suspension installation part plays an important role, determining the wheel alignment. Wheel misalignment is of course potentially very dangerous because it can lead to driving instability, one-sided braking, abnormal tire wear, abnormal vibration, etc. .
9-22
BASE OF BODY REPAIR BODY REPAIR
SAFETY 1. Procedures related to the installation of any component related to safety must be done with particular care in order to assure full maintenance of safety. • Suspension installation parts • Fuel pipe • Brakes • Fuel tank installation parts, etc. 2. Because seat belts are directly related to driver and passenger safety, any welds of seat belt anchor points or reinforcements must be done with particular care in order to maintain strength.
3. 4. 5. 6. 7. .
VIBRATION AND NOISE 1. Prevent any decrease of tensional rigidity caused by welding distortion. 2. Carefully apply body sealant to panel connection joints and other fitting places. 3. Tape over any unused holes in the panel inner side by using sealing tape.
.
PREVENTION OF CORROSION AND OF WATER OR DUST ENTRY 1. After any work is completed, it is important to completely remove any welding residue, particles or residue from cutting, and any other dirt, etc. 2. Corrosion-prevention material must without fail be applied at the following places: • At any place where paint has flaked off or peeled away. • At any surfaces that have been cut. • At the outer and inner side of every welded place. • Within any semi-enclosed structure or component (aerosol-type rust inhibitors are effective for difficult-to-reach places).
• At the outer and inner side of any place subjected to heat. Apply a coating of undercoating if the underbody is repaired. Use spot sealer if spot welds are made. Repair any scratches to panels made by moldings, sashes, etc. Carefully apply body sealant to panel connection joints and other fitting places. Tape over any unused holes in the panel inner side by using sealing tape.
.
CONTACT AND ALIGNMENT 1. In order to maintain the precision of openings, make careful measurements as repairs are being made. 2. Make contact/alignment adjustments of door hinge, lid, and hood hinge installation parts.
THEFT PROTECTION
M4090007000056
In order to prevent theft, following Vehicle Identification Number (VIN) has been engraved and attached, in the form of a label to the engine, transaxle, and main of the outer body: Engine cylinder block, Transaxle housing, Fender, Doors, Quarter panel, Hood, Liftgate, Trunk lid, Bumpers Furthermore, supplementary parts for the main portions of the outer body have theft protection labels attached and the supplementary parts for the engine and the transaxle are engraved with the same details.
Theft protection label For original parts
For replacement parts
AC211646 AC
BASE OF BODY REPAIR BODY REPAIR
9-23
PANEL REPAIR CAUTION 1. Take care when respraying the original part to cover the theft protection label with masking tape prior to respraying. In addition, remember to peel off the masking tape after completion of the respray. 2. Because theft protection labels on the supplementary parts are covered with masking tape already, they can be resprayed just as they are. 3. Take care not to peel off the theft protection labels from either the original or the supplementary parts.
HOW TO PEEL OFF THE SURFACE MASKING FILM FROM THE THEFT-PROTECTION LABEL
Knife
Masking film
AB200080AC
CAUTION Be careful not to damage the paint surface or the label itself. 1. Using a sharp knife at the corner of the label surface, lift up the masking film only. 2. Grasp the masking film and peel it all off. NOTE: If the masking film tears, repeat from step 1. Use the knife, however, to lift the opposite corner of the label, rather than trying to continue peeling from the place where it tore.
9-24
BASE OF BODY REPAIR BODY REPAIR
ATTACHMENT OF SILENCERS
M4090009000041
Dash panel interior side
: Thickness: 1.6 mm (0.06 in) : Thickness: 3.2 mm (0.13 in) (two 1.6 mm (0.06 in) silencers overlapped)
AB200097AC
Silencers (petroleum-asphalt sheets) are attached to welded panel, cut and attach replacement material the upper surface of the floor and at the interior side (in the shape shown in the figure). For detailed inforof the dash panel in order to absorb vibrations and mation concerning the locations where silencers are shut out exhaust gas heat. If these silencers are to be attached for individual models, refer to the peeled off in the course of replacement or repair of a manual for that model. 1. Heat the "silencer layer" (petroleum-asphalt sheet) with a blow drier to soften it.
AB200098
BASE OF BODY REPAIR BODY REPAIR
9-25
2. Align the silencer layer in the position where it is to be installed, and then press it down with a roller or a block of wood so that it adheres well. NOTE: An infrared light can also be used to heat both the silencer layer and the body panels (be sure to wear gloves).
AB200099
POSITIONING DIMENSIONS FOR OPENINGS
M4090010000034
Porta power
AB200100 AC
When replacing the panel of the opening of the front pillar, center pillar and other openings, make a point to securely bite the poltapower, etc. so the position of the opening is not off-center. Upon assembling, adjust the opening dimensions to the standard specifications and then weld.
9-26
BASE OF BODY REPAIR BODY REPAIR
STANDARD PROCEDURES FOR SHEET METAL WORK
M4090012000029
REPAIRS USING A HAMMER AND DOLLY It a damaged external panel, etc., can be reused, the usual way to repair it is by using a hammer and dolly to hammer out the damaged area. The following describes these repair procedures. .
1. Check whether or not there is foreign material (mud, etc.) on the panel surface. If so, clean it away.
CAUTION The surface of the hammer and dolly must be free of scars, etc. 2. Select the appropriate hammer and dolly to be used according CAUTIONto the panel shape. Care should be taken, as far as possible, not to permit the panel plates to become elongated. 3. Use the hammer and dolly to repair the dents and other uneven surfaces of the panel. (1) First repair the larger areas of damage so that they are as close as possible to the original condition before the damage occurred. (2) Next repair the areas of moderate damage. (3) Finally, smooth the surface out.
(1)
(2)
(3)
AB200101
BASE OF BODY REPAIR BODY REPAIR
• • 4.
5.
AB200102
6. 7.
9-27
CAUTION Be careful not to file too much; this will reduce the strength and rigidity of the panel. Do not use the file in one direction only; alternate use in two directions diagonally opposite each other. Next, file the area so that convex and concave parts are no longer clearly visible, and at the same time remove small projections. After once again smoothing the clearly visible dents and projections by using the hammer and dolly, follow step 4 above. Alternately repeat hammering and filing until there are file traces over the entire repair area. Make a solder build-up at the repair. Finally, finish up the solder build-up using a body file.
USING A FRAME STRAIGHTENER For serious and extensive damage, when for example the damage extends to the frame of members, it is necessary to first use a frame straightener to make a rough, overall repair of the body, and then to proceed to careful repairs of each individual area of damage. When a frame straightener is used for body repairs, it is a fundamental principle that the pulling should be in the direction from which the impact was sustained, and from the opposite direction. If this is, in error, not done, previously undamaged components will be deformed, and repair may become impossible. It is for that reason that it is important to decide upon the method of repair, especially regarding the initial overall repair, by following the steps below.
OVERALL ROUGH REPAIRS 1. First, analyze the impact. This means analysis and consideration of the point of collision, the speed at the time of collision, and the strength, weight and shape of the object hit. 2. Then get a complete understanding of the condition of the existing damage. In particular, if the damage extends to the suspension installation components, an inspection must be made to determine whether or not there is any deviation of the frame or body alignment.
M4090013000033
3. Finally, determine what repair methods should be used. • To what extent will frame straightening and other overall repairs be necessary in order to restore the damaged areas to the way they were? • At what stage of the repairs should panels adjoining the components to be frame straightened, etc., be removed? • Decide upon the work steps and restoration methods to be followed after the rough, overall repairs are completed. Select the frame straightener based upon the results of above, and use it to pull in the appropriate direction. More than one direction may be appropriate, depending upon the damage. If the damage is of a moderate degree or less, it may be possible to do all that is necessary in one pull. If, however, the damage is major, that is to say if repairs must be made to components of the passenger compartment such as the dash panel, etc., it may be necessary, after completing the first pull, to set up the frame straightener at a different position and use it again at that position.
9-28
BASE OF BODY REPAIR BODY REPAIR
FRAME STRAIGHTENING NOTES Wires for protection
AB200103AC
• For safety, no one must be standing in the direction of the pull. • Wires or chains should be used for protection in the event of an accident. • For frame straightening of body with frame, care should be taken regarding the position (body mount) of installation to the frame. The reason for this is that usually mounting rubber pieces are used at the installation part in order to improve vibration prevention, and these mounting rubber pieces might be deformed if there is a deviation of the installation position. • If the part to be pulled is made of high-tensile steel (which has a higher tensional strength and yield point than ordinary steel), the pulling must be done with care in order to avoid "over pull" and "spring back". It is particularly important for the pulling of sidemembers and other reinforcement components made of high-tensile steel that the pulling not be all done at one time; pull gradually while using a hammer to repair distorted areas as the pulling is done.
FRAME REPAIR PROCEDURES The frame is subjected to the following types of loads. • Vertical loads: Vertical loads may occur either while stopped or during travel. • Lateral (horizontal) loads: This type of loads occurs during turning, start-off and braking. • Torsional loads: Torsional loads occur while traveling on roads with poor surface conditions.
M4090014000036
These various types of loads are compounded under various conditions, and are applied to the frame. As a result, it is important, before attempting to repair the frame, to carefully observe the shape of the damaged part and to in that way fully understand the cause of the damage.
CHECKING FOR FRAME CRACKING OR FLAKING Check, by using a test hammer, for flaking or cracking of the welded surface of the sidemembers, crossmembers and brackets. Test hammer
Sidemember
AB200127AC
BASE OF BODY REPAIR BODY REPAIR
9-29
REPAIRING CRACKS If the check reveals a crack(s) in the frame, repair as described bellow. 1. Remove the components near the crack. 2. Make φ 6 −8 mm (0.2 −0.3 inch) holes (to prevent further cracking), by using a drill, at points 7 −8 mm (0.3 inch) from the crack ends.
Crack-stop hole A A Crack Ø6 – 8 mm (0.2 – 0.3 in) A : 7 – 8 mm (0.3 in)
AB301469 AC Ø10 – 12 mm (0.4 – 0.5 in)
3. Use a φ 10 −12 mm (0.4 −0.5 inch) drill to bevel the hole openings.
Ø6 – 8 mm (0.2 – 0.3 in)
Ø10 – 12 mm (0.4 – 0.5 in)
AB301470 AB
Crack Crack-stop hole
Approx. Approx.90˚ 1 mm (00.4 in)
A
Approx. 8 mm (0.3 in)
4. Use a chisel or gouging tool to open up the crack and holes, and then fill the crack and holes by MIG welding.
Approx. 1 mm (0.04 in)
If a chisel is used
If a gouge is used
A
A
AB301471AC
AB200131AB
CAUTION • Gas welding should be avoided because it causes thermal distortion of the frame. • When using a grinder for finishing, be careful not to grind the frame excessively. 5. Using a grinder for finishing after welding.
9-30
BASE OF BODY REPAIR BODY REPAIR
CAUTION • The reinforcement plate should completely cover the cracked part. • The reinforcement plate should be the same thickness and material as the frame. 6. To avoid a concentration of stress, prepare a reinforcement plate that has been cut to 30 −45 degree angle at both ends. A
A
A : 30 – 45˚
AB301461AB
10 mm (0.4 in)
CAUTION Be sure that the edges of the reinforcement plate are not near any place where a concentration of stress of the crossmember or spring hanger installation part, etc. could easily occur. 7. Attach the reinforcement plate to the repaired crack area by MIG welding. In order to avoid a concentration of stress at the time, weld the reinforcement plate at points about 10 mm (0.4 inch) from its edges.
Welded point AB200133 AC
(1)
(2)
AB200134 AB
NOTE: If the crack is at the upper side of the frame, attach the reinforcement plate facing downward, as shown in (1). If the crack is at the lower side, attach the reinforcement plate to face upward, as shown in (2). 8. Finally, apply a coating of chassis black to the repaired area and to any places where the coating has flaked off.
BASE OF BODY REPAIR BODY REPAIR
NOTES REGARDING REPAIR WORK
9-31 M4090015000028
SAFETY MEASURES .
PROTECTIVE GEAR
1
2
3
4 5
6
8
7
9
10
11
During body repair work, a work suit, a work cap, and safety shoes should be worn at all times. Depending on the work being done, safety glasses, gloves, ear protectors, a dustproof mask, etc., should also be worn as needed. 1. Safety glasses 2. Work cap 3. Ear protectors 4. Head protector 5. Work suit 6. Dustproof mask 7. Work apron 8. Welding gloves 9. Foot and ankle protectors 10. Safety shoes 11. Work gloves
AB200104
.
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 1. Items to review when servicing SRS (1) Be sure to read Service Manual GROUP 52B, Supplemental Restraint System (SRS). For safe operation, please follow the directions and heed all warnings. (2) Wait at least 60 seconds after disconnecting the battery cable before doing any further work. The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected. Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected. (3) Warning labels must be heeded when servicing or handling SRS components. (4) Always use the designated special tools and test equipment. (5) Store components removed from the SRS in a clean and dry place. The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward. .
(6) Never attempt to disassemble or repair the SRS components (SRS-ECU, air bag module and clock spring). If there is a defect, replace the defective part. (7) Whenever you finish servicing the SRS, check the SRS warning light operation to make sure that the system functions properly. (8) Be sure to deploy the air bag before disposing of the air bag module or disposing of a vehicle equipped with an air bag. 2. Observe the following when carrying out operations on places where SRS components are installed, including operations not directly related to the SRS air bag. (1) When removing or installing parts, do not allow any impact or shock to occur to the SRS components. (2) If heat damage may occur during paint work, remove the SRS-ECU, the air bag module, clock spring, the front impact sensor, the side impact sensor, and the seat belt pre-tensioner. • SRS-ECU, air bag module, clock spring, front impact sensor, the side impact sensor: 93 ° C (200 ° F) or more • Seat belt pre-tensioner: 90 ° C (194 ° F) or more
9-32
BASE OF BODY REPAIR BODY REPAIR
SECURING THE VEHICLE If the vehicle is raised on a jack, be sure to always support it with jack stands positioned at the specified points. .
CLEARING THE AREA OF FLAMMABLE MATERIALS Because of the presence of many various kinds of flammable materials, organic solvents, etc., in the work area, there is always the possibility of a fire or explosion. It is, therefore, important to keep the work area as clear as possible of such dangerous materials. .
HANDLING ELECTRONIC PARTS AND SEMICONDUCTORS WARNING
Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING. When the body is used as the ground during welding for body repairs, be absolutely sure to first disconnect the battery's positive (+) cable.
AB200105
CAUTION • Be sure that both the ignition and lighting switches are "LOCK" (OFF) position before either disconnecting or reconnecting a battery cable. (If this is not done, equipment containing semiconductors could be damaged). • Note that the memory of electronic equipment having a memory function will be cleared when the battery cable is disconnected. NOTE: Vehicles today include a great many electronic parts and components, and these are in general very susceptible to adverse effects caused by overcurrent, reverse current, electromagnetic waves, high temperature, high humidity, impacts, etc. In particular, such electronic components can be damaged if there is a large current flow during welding from the body side, etc. This is because, for electronic components that incorporate a back-up circuit (for memory retention) that functions (by a trickle current) even when the ignition switch is at OFF, an electronic circuit is formed even when the switch is at OFF. .
BASE OF BODY REPAIR BODY REPAIR
9-33
HANDLING COMBUSTIBLE MATERIALS If welding work is to be done in the area of the fuel tank, the fuel tank must be removed to prevent the generation of flammable gases. Also be sure to cap the inlet port and the pipes of the fuel tank after removal to prevent the escape of any fuel or flammable gases. Wipe up any fuel, oil, etc., spilled in the work area as soon as possible. Only the amounts of paint to be used for the day's work should be in the work area; do not keep excessive amounts of paint, or paint which is not going to be used, in the work area.
HEALTH AND SANITATION PROCEDURES The following points should be noted for employee health and sanitation. • The work area should be well ventilated in order to prevent the inhalation of dust, organic solvent vapors, etc. • All unused paint cans must be securely covered. • Care should be taken to avoid exposure to the skin of adhesives, organic solvents, etc. If an unavoidable exposure occurs, the exposed area should be immediately washed with clean water.
VEHICLE PROTECTION • Vehicle covers (fender covers, seat covers, etc.) and tape (if there is the possibility of damage by tools, equipment, etc.) should be used to protect painted surfaces, interior/exterior parts and components, etc., from staining and damage.
AB200106
• For welding operations, a heat-resistant protective cover should be used to protect glass, seats, instrument panel, carpeting, etc.
AB200107
9-34
BASE OF BODY REPAIR BODY REPAIR
HEAT-WITHSTAND TEMPERATURES OF RESIN-PLASTIC PARTS Because resin-plastic parts are deformed by heat, they should be removed if the heat to be applied is high enough to cause deformation, as shown by the table below. MATERIAL NAME ABBREVIATION HEAT-DEFORMATION WHERE MAINLY USED TEMPERATURE ° C (° F)
M4090016000032
Acrylonitrile styrene acrylate
ASA
80 (176)
Door mirror, Pillar garnish, License garnish, Radiator grille
Acrylonitrile butadiene styrene
ABS
80 (176)
Air spoiler, Console box, Radiator grille, Rear garnish, Headlight bezel
NOTE: . • A slash (/) in the abbreviation indicates that two different materials make two-layer construction. A plus sign (+) indicates that the two different materials mix each other. • If the new material symbols designated by the ISO differ form the old symbols, both are given, with the old symbol being enclosed in brackets. ISO: International Organization for Standardization • *1: Temperature differs depending on the ratio of the materials included. • *2: Impossible to fix the temperature due to the multi-layer and foam material structure. • If an infra-red lamp is used for drying, use a heat-resistant cover, etc., to protect parts.
HOW TO DISTINGUISH TYPES OF PLASTICS
M4090017000024
There are various methods that can be employed to determine types of plastics, among them (1) using a chemical solvent, etc., to check it chemically, (2) scratching the material to determine its make-up, (3) cutting of a small piece (where the scar can't be seen) and burning it to judge by the way it burns, etc. The following is an outline of the burning method, which is a relatively simple method. PLASTIC NAME
ABBREVIATION
FLAME COLOR
COMBUSTION CONDITIONS
Polyvinyl chloride
PVC
Yellow flame top Blue flame bottom
Burns to black residue Yes
Irritating acid odor
Polyethylene
PE
Yellow flame top Blue flame bottom
Burns cleanly while melting
No
Candle-like odor
Polypropylene PP
Yellow flame top Blue flame bottom
• Burns briskly and No drips • Slight white smoke
Petroleumlike odor
Polyurethane
PUR
Orange
No
Rubber odor
TRUR
Orange
Crackles as burns; drips
Polycarbonate PC
Yellow
Cinders remain
To some extent Sweet odor
Polyamide (nylon)
Yellow flame top Blue flame bottom
Melts and drips
Yes
Strong formic acid odor
Polyester resin UP
Yellow
Ashes remain
No
Styrene odor
Glass-fiberreinforced plastic
FRP
Yellow
Ashes with glass-fiber No remnants remain
Differs according to plastic type
Phenol resin
PF
Yellow
Ashes remain
Formalin odor
ABS resin
ABS
Orange
Burns accompanied No by foaming and black smoke
PA
SELFODOR EXTINGUISHING
Yes
Rubber odor
BASE OF BODY REPAIR CORROSION PROTECTION
9-37
CORROSION PROTECTION ANTICORROSION TREATMENT AT THE FACTORY Anticorrosion treatment at the time of production includes the following measures.
M4090019000053
THE USE OF GALVANIZED STEEL PLATE
: locations where galvanized steel plate is used. AB200136 AB
Because galvanized steel plate has excellent corrosion resistance, it is used in areas which have a high possibility of painting deficiency.
ZINC PHOSPHATE COATING 1 2 3 4 5 6
AB200109
In order to improve the adhesive properties of the paint coat on the steel plate, and also to improve the finish of the paint coat, the entire body is coated with a film of zinc phosphate prior to undergoing the electrodeposition undercoating process. 1. Final coat 2. Intermediate coat 3. Anticorrosion primer 4. Undercoat 5. Zinc phosphate film 6. Steel plate
9-38
BASE OF BODY REPAIR CORROSION PROTECTION
CATIONIC ELECTRODEPOSITION UNDERCOATING
Cationic coating
Anionic coating
Counteragent
Counteragent
Anionic electrodeposition
Alkali solution
Cationic electrodeposition
AB200110AC
In the cationic electrodeposition method, the car body is the negative pole, thus preventing damage to the zinc plating of the galvanized body panels or to the chemically formed phosphate crystals. This method, therefore, maximizes the corrosion resistance and the results obtained are much better than those from conventional anionic electrodeposition.
BODY SEALING Sealant has been applied to all body panel joints and seams in order to provide resistance to water, dust, and corrosion.
A
A
Section A – A
AB301462 AC
UNDERBODY COATING An underbody coating has been applied to the underside of the floor pans, the inside of the doors, etc., in order to provide resistance to vibration, corrosion, and wear.
AB200112
9-39
BASE OF BODY REPAIR CORROSION PROTECTION
WAX INJECTION Wax injection is used at the lower part of the frame, side sill and hollow panels, etc., in order to obtain a better anticorrosion effect.
AB200113
ANTICORROSION PRIMER
A
1 1
A 1. Rocker panel primer application
AB200114 AC
Anticorrosion primer is used at the side sill outer panels in order to prevent corrosion and to suppress vibration.
SEALING TAPE Sealing tape is attached at unused holes, at the inner side of the panel, for waterproofing and anticorrosion protection.
: Locations for attachment of sealing tape
AB301463AE AB301463
9-40
BASE OF BODY REPAIR CORROSION PROTECTION
ANTICORROSION TREATMENT AT THE TIME OF BODY REPAIR WORK
M4090020000035
The following procedures should be followed for anticorrosion protection when making repairs.
AB200116
CORROSION PROTECTION FOR HOLLOW PARTS
AB200117
CAUTION • Wipe away any excess anticorrosion agent on the coated surface, because it can adversely affect the coating. • When spraying the anticorrosion agent, use holes in different areas to ensure that all weld surfaces of the hollow structure are well coated. The insides of hollow parts (such as the side sill, pillars, etc.) which have been welded are more susceptible to corrosion. Spray an aerosol-type anticorrosion agent into these parts by using the trim mounting holes and other openings.
ANTICORROSION TREATMENT OF ROUGH CUTS An anticorrosion agent should be applied to rough cuts made in the course of welding, because the surface film has been damaged by the heat of welding.
SPOT SEALER In order to prevent corrosion from occurring at the contact surfaces of panels which are spot welded, apply an electroconductive spot sealer. .
SPOT SEALER APPLICATION STEPS 1. Remove all paint, etc., from the areas to be spot welded by using sandpaper or a pneumatic belt sander.
AB200118
BASE OF BODY REPAIR CORROSION PROTECTION
9-41
2. Use a brush to apply spot sealer to the contact surfaces of the panels (both the new panel and the panel remaining on the body) to be spot welded.
AB200119
3. Do not spot welding. NOTE: The spot welding can be done as the spot sealer is dry to the touch. Dry to the touch: 30 minutes or less at 20° C (68° F)
AB200120
BODY SEALING Even if a car body is restored to the exact specified dimensions, the body repair work cannot be considered to be complete if an ample amount of sealant is not applied to each of the panel joints and seams. Insufficient sealant will result in water leakage, corrosion, etc. NOTE: Use a piece of clean cloth dampened in lead-free gasoline or a similar material to clean parts and areas where sealant is applied. • When applying sealant to areas at which the external appearance is important (areas which can be seen or where the condition of the paint coat is important), be sure to apply the sealant so that it is perfectly level with the surrounding panels.
Clean away any excess
AB301490AC
• Apply the sealant at the fuel port so that it is perfectly level with the surrounding panel so that drops of fuel will not collect.
AB200122
9-42
BASE OF BODY REPAIR CORROSION PROTECTION
• After applying sealant to the door-stop, etc., clean away any excess so as to be sure that there is no interference with installed parts, etc.
AB200123
UNDERCOATING
: Undercoating application locations
• Be sure to mask any parts installation holes, and the area around the place where undercoating is to be applied, before applying it. • Be sure not to apply the undercoating to tires or to the drive shaft and other drive components.
AB301464 AC
If the undercoating application inside the wheel housing, on the under body, etc., is insufficient, it can result in corrosion. Be sure, therefore, to apply a good coating of undercoating to such parts after repairs are completed.
BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS
9-43
REPAIR OF SYNTHETIC-RESIN PARTS SYNTHETIC-RESIN PARTS REPAIR PROCEDURES
M4090000300078
Bumper is taken as a repair work example for explanation.
FLOWCHART
Hole (Diameter 50 mm (1.97 in) or smaller)
Crack, tear (Length 200 mm (7.8 in) or smaller)
Scratch (Length 200 mm X width 120 mm (7.8 X 4.7 in) or smaller)
1. Cleaning
2. Reshaping of damaged area
3. Fixing of glass cloth (backing)
4. Adhesive application
5. Base surface preparation (surface grinding)
6. Rough grinding
7. Filling (putty application)
8. Surface grinding
9. Surface preparation for primer-surfacer
10. Cleaning and degreasing
11. Masking
12. Primer-surfacer coating
13. Primer-surfacer grinding
14. Coating
AB401319 AD
9-44
BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS
REPAIR JUDGMENT .
REPAIRABLE AREA • In case of a hole, the damaged area is reshaped to be a circle or ellipse for easier filling of the repair agent. The diameter or major diameter should be 50 mm (1.97 inches) or smaller. • In case of a crack or tear, if the both ends of the crack or tear are not separated from the body, the length of the area should be 200 mm (7.8 inches) or smaller. If one of the ends reaches the bumper edge, the length of the damaged area should be 200 mm (7.8 inches) or smaller, and also the width should be a half or less of the bumper width. • In case of a scratch, the area should be 200 x 120 mm (7.8 x 4.7 inches) or smaller. .
UNREPAIRABLE COMPONENTS Black-base area is raw urethane base and repairable, however, its color does not match in color of the repair agent (ash gray). In this case, the replacement of the bumper is preferable. .
BUMPER REMOVAL AND CLEANING • The damage of holes, cracks, and tears requires a repair work from the rear surface. Remove the bumper to clean the whole surface, degrease the front and rear surfaces of the repair area using SU Silicone Off, and then repair, holding the bumper to avoid twisting. • In case of a scratch, a softener is applied to the bumper as repair paint. The repair area cannot be polished after painting, and surface/gloss matching is difficult. Therefore, do not apply gradated topcoat painting, and paint the whole surface as a rule.
REPAIR PROCEDURE .
1. CLEANING Using SU Silicone Off, degrease the repair area, and then remove the wax and oil completely. .
AB401311AB
BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS
9-45
2. RESHAPING OF DAMAGED AREA CAUTION The grind surface area should be larger than the resin putty application area. Remove burrs on the rear surface reinforcement point, and grind with a sandpaper #60 to #80, as a surface preparation for painting. When using a sander #80, grind at a low speed 6000 r/min. For PP, apply PP primer after grinding. PRIMER : PP PRIMER BRAND : 3M™ Automix Polyolefin Adhesion Promoter 5907 or equivalent AB401317AB
.
3. FIXING OF GLASS CLOTH (BACKING) CAUTION • After applying the instant adhesive, fix the repair area. • For PP, apply PP primer. Apply the adhesive to the glass cloth fixing area of the repair part in order to adhere the glass cloth. • TAPE: Glass cloth tape BRAND: 3M™ Glass Cloth Tape 6400 or equivalent • ADHESIVE: Urethane adhesive BRAND: 3M™ Duramix Plastic Repair Semi-rigid 4040 or equivalent AB401293AB AB .
4. Adhesive application Apply a resin adhesive to cover the fixing glass cloth and its surrounding area. Then smooth it, using a spatula, and dry.
AB401312AB .
5. BASE SURFACE PREPARATION (SURFACE GRINDING) Remove burrs on the surface, and grind with a sandpaper #120 to make the repair area surface lower than the surrounding area. When using a sander #120, grind at a low speed 6000 r/min.
Background
.
Old paint layer AB401316AC
9-46
BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS
6. ROUGH GRINDING Grind the base surface area with a sandpaper #80 as a surface preparation for painting.
AB401315AB .
7. FILLING (PUTTY APPLICATION)
AB401291AB
CAUTION When mixing the two kinds of liquid, be sure that the air is not mixed in. 1. Using SU Silicone Off, degrease the repair area, and then remove the wax and oil completely. 2. For scrape, apply putty to the repair area. • PUTTY: Epoxy resin putty BRAND: 3M™ Automix EZ Sond Flexble Parts 5887 or equivalent • PUTTY: Epoxy resin putty BRAND: 3M™ Resin Putty No.1, 8120 or equivalent NOTE: . • The amount to be applied at a time is approximately 1.5 mm (0.06 inches). Therefore, recoat it as needed. • For tear and scratch, apply putty after sanding the surface.
AB401296AB
.
8. SURFACE GRINDING After drying, grind with a sandpaper #120. .
AB401297AB
BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS
9-47
9. SURFACE PREPARATION FOR PRIMER-SURFACER Grind with a sandpaper #180 to #240. Grind the primer-surfacer application area as a surface preparation for painting. In addition, remove the grind mark.
AB401297AB .
10. CLEANING AND DEGREASING Using SU Silicone Off, degrease and wipe off completely. .
11. MASKING To avoid splashing of primer-surfacer during the coating, apply masking. MASKING: Masking paper tape BRAND: 3M™ Scotch Block Masking Paper or equivalent AB401318AB
.
12. PRIMER-SURFACER COATING CAUTION • If an excessive amount is applied at a time, or force-dried in a short time, the coating film may crack. • For color separation, use masking tape. While taking flash off time, apply 1 to 3 times of double coating, using a spray gun.
AB401298AB .
13. PRIMER-SURFACER GRINDING 1. Grind the base surface with a sandpaper #240 to #320.
AB401299AB
9-48
BASE OF BODY REPAIR REPAIR OF SYNTHETIC-RESIN PARTS
2. Apply the putty to cover pinholes, grind marks, and slight distortion. Do not apply an excessive amount at a time. Repeat application of small amount, taking a drying time.
AB401300AB
3. Grind with a sandpaper #240 to #320. If the PP base surface is exposed, apply PP primer. PRIMER : PP PRIMER BRAND : 3M™ Automix Polyolefin Adhesion Promoter 5907 or equivalent
AB401299AB
CAUTION If an excessive amount is applied at a time, or force-dried in a short time, the coating film may crack. 4. While taking flash off time, apply 1 to 3 times of double coating, using a spray gun.
AB401302AB
5. Dry sand with a sandpaper #240 to #300 or finer. Then, as a surface preparation for painting, grind lightly so as not to expose the base surface. Finally, use a sandpaper #600 (#800 for dark color coating) or finer to remove grind marks.
GENERAL INFORMATION The 4B11 (2.0 L) engine is an in-line four-cylinder engine. The cylinder numbers are assigned as 1-2-3-4 from the front of the engine (timing belt side). The firing order is 1-3-4-2. ITEMS
SPECIFICATIONS
Type
In-line DOHC
Number of cylinders
4
Bore mm (in)
86 (3.39)
Stroke mm (in)
86 (3.39)
Total displacement cm3 (cu. in)
1,998 (121.9)
Compression ratio
10.0
Firing order
1-3-4-2
Valve timing
Intake valve
Opens (BTDC)
0° −25° 3° −28°
Closes (ABDC)
48° −23° 45° −20°
Exhaust valve
Opens (BBDC)
44° −24° 41° −21°
Closes (ATDC)
0° −20° 3° −23°
Lubrication system
Pressure feed, full-flow filtration
Oil pump type
Trochoid type
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M1111000101111
11A-3
ENGINE MECHANICAL ENGINE DIAGNOSIS
ENGINE DIAGNOSIS
M1111000700370
SYMPTOMS
PROBABLE CAUSE
REMEDY
Compression is too low
Blown cylinder head gasket
Replace the gasket.
Worn or damaged piston rings
Replace the rings.
Worn piston or cylinder
Repair or replace the piston and/or the cylinder block.
Worn or damaged valve seat
Repair or replace the valve and/or the seat ring
Engine oil level is too low
Check the engine oil level.
Malfunction of engine oil pressure switch
Replace the engine oil pressure switch.
Clogged oil filter
Install a new filter.
Worn oil pump gears or cover
Replace the gears and/or the cover.
Thin or diluted engine oil
Change the engine oil to the correct viscosity.
Stuck (opened) oil relief valve
Repair the relief valve.
Excessive bearing clearance
Replace the bearings.
Engine oil pressure too high
Stuck (closed) oil relief valve
Repair the relief valve.
Noisy valves
Incorrect valve clearance
Adjust valve clearance
Thin or diluted engine oil (low engine oil pressure)
Change the engine oil.
Worn or damaged valve stem or valve guide
Replace the valve and/or the guide.
Insufficient oil supply
Check the engine oil level.
Thin or diluted engine oil
Change the engine oil.
Excessive bearing clearance
Replace the bearings.
Drop in engine oil pressure
Connecting rod noise/main bearing noise
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11A-4
ENGINE MECHANICAL SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS Item Drive belt tension
Vibration frequency Hz (Reference)
M1111000301278
Standard value
Limit
102 −129
−
Tension N (lb) (Reference) 248 −400 (56 − 90)
−
Intake valve
0.20 ± 0.03 (0.008 ± 0.0012)
−
Exhaust valve
0.03 ± 0.03 (0.012 ± 0.0012)
−
Basic ignition timing at idle
5° BTDC ± 3°
−
Actual ignition timing at curb idle
Approximately 10° BTDC
−
CO contents %
0.5 or less
−
HC contents ppm
100 or less
−
Curb idle speed r/min
700 ± 100
−
Compression pressure (200 r/min) kPa (psi)
1,470 (213)
Minimum 1,050 (152)
Compression pressure difference of all cylinder kPa (psi)
−
98 (14)
Intake manifold vacuum at curb idle kPa (in Hg)
−
Minimum 60 (18)
Auto-tensioner rod protrusion amount mm (in)
9.1 −13.4 (0.36 − − 0.52)
Valve clearance (at cold) mm (in)
SEALANTS
M1111000500536
Item
Specified sealant
Flywheel bolt
LOCTITE 262, Three bond 1324 Semi-drying or equivalent sealant
Cylinder head cover
Three bond 1227D, 1217G or equivalent
Cylinder block
Three bond 1227D, 1217G, LOCTITE 5970, 5971, 5900 or equivalent
Engine oil pan Timing chain case assembly
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Remark
11A-5
ENGINE MECHANICAL SPECIAL TOOLS
SPECIAL TOOLS Tool A
B B992080
a
MB991824
b
MB991827
c
MB991910
d
DO NOT USE MB991911
e
M1111000601570
Tool number and name
Supersession
Application
MB992080 Belt tension meter set A: MB9912081 Belt tension meter B: MB992082 Mic assembly
Tool not available
Drive belt tension check
MB991958 Scan tool (M.U.T.-III sub assembly) A: MB991824 Vehicle communication interface (V.C.I.) B: MB991827 M.U.T.-III USB cable C: MB991910 M.U.T.-III main harness A (Vehicles with CAN communication system) D: MB991911 M.U.T.-III main harness B (Vehicles without CAN communication system) E: MB991914 M.U.T.-III main harness C (for Daimler Chrysler models only) F: MB991825 M.U.T.-III adapter harness G: MB991826 M.U.T.-III trigger harness
MB991824-KIT NOTE: MB991826 M.U.T.-III Trigger Harness is not necessary when pushing V.C.I. ENTER key.
DO NOT USE MB991914
f
MB991825
g
MB991826 MB991958
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CAUTION For vehicles with CAN communication, use M.U.T.-III main harness A to send simulated vehicle speed. If you connect M.U.T.-III main harness B instead, the CAN communication does not function correctly. • Drive belt tension check • Ignition timing check • Curb idle speed check • Idle mixture check • Erasing the diagnostic trouble code
11A-6
ENGINE MECHANICAL SPECIAL TOOLS
Tool
Tool number and name
Supersession
Application
MB990767 Front hub and flange yoke holder
MB990767-01
Holding the camshaft sprocket
MD998719 Pin
MIT308239
MB992103 Chain tension release bar
−
Camshaft and camshaft sprocket assembly (exhaust side) removal
MD998772 Valve spring compressor
General service tool
Valve spring compression
MB992090 Retainer holder attachment
−
MB992089 Retainer holder C
−
MB992085 Valve stem seal pliers
−
Valve stem seal removal
MD998737 Valve stem seal installer
MD998737-01
Valve stem seal press-fitting
B990767
D998719
B992103
MD998772
B992090
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11A-7
ENGINE MECHANICAL SPECIAL TOOLS
Tool
Tool number and name
Supersession
Application
MD998727 Oil pan FIPG cutter
MD998727-01
Oil pan removal
MB991883 Flywheel stopper
General service tool
Supporting the drive plate or flywheel
MD998718 Crankshaft rear oil seal installer
MD998718-01
Press-fitting the crankshaft rear oil seal
MB991448 Bush remover and installer base
MB991448-01
Press-fitting the crankshaft front oil seal
MB991346 Top Cover Wrench
−
Holding the oil pump sprocket
D998727
MB991883
B991346
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11A-8
ENGINE MECHANICAL SPECIAL TOOLS
Tool
Tool number and name
Supersession
Application
MB991454 Engine hanger balancer
MZ203827-01
MB991895 Engine hanger
Tool not available
When the engine hanger is used: Supporting the engine assembly during removal and installation of the transaxle assembly NOTE: Special tool MB991454 is a part of engine hanger attachment set MB991453.
B991454
MB991895
MB991928 Slide bracket (HI) Engine hanger A: MB991929 Joint (50) × 2 E B: MB991930 Joint (90) × 2 F A C: MB991931 D Joint (140) × 2 B D: MB991932 C Foot (standard) × 4 B991928 E: MB991933 Foot (short) × 2 F: MB991934 Chain and hook assembly MB992201 Engine hanger plate
B992201
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Tool not available
−
Transaxle removal
ENGINE MECHANICAL ON-VEHICLE SERVICE
11A-9
ON-VEHICLE SERVICE DRIVE BELT TENSION CHECK
M1111003101596
1. Remove the radiator condenser tank mounting bolts. 2. Move the radiator condenser tank to a place where it will not be a hindrance when checking the drive belt tension.
Auto-tensioner
A
Indicator mark AC506730 AC
CAUTION Check the drive belt tension after turning the crankshaft clockwise one turn or more. 3. Make sure that the indicator mark on the auto-tensioner is within the area marked with A in the illustration. 4. If the mark is out of the area A, replace the drive belt (Refer to P.11A-19). NOTE: The drive belt tension check is not necessary as the auto-tensioner is adopted. 5. Tighten the radiator condenser tank mounting bolts to the specified torque. Tightening torque: 12 ± 2 N⋅ m (102 ± 22 in-lb)
AUTO-TENSIONER CHECK
M1111003000972
OPERATION CHECK 1. Turn off the engine from the idle state then check to see that the drive belt is not protruding from the pulley width of the auto-tensioner. 2. Remove the drive belt (Refer to P.11A-19). 3. Rotate the pulley bolt of the auto-tensioner clockwise and counterclockwise with an offset wrench [45° , a long offset wrench (5/8 x 11/16 inches) recommended] to check for binding. 4. If there are any problems in the procedure 1 or 3, replace the auto-tensioner (Refer to P.11A-63). 5. Install the drive belt (Refer to P.11A-19).
Auto-tensioner
AC506731 AD
FUNCTION CHECK The auto-tensioner can be checked whether it is in good condition by checking its tension. .
Required Special Tools: • MB992080: Belt Tension Meter Set • MB992081: Belt Tension Meter • MB992082: Mic Assembly 1. Check the tension of the drive belt (Refer to P.11A-9).
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11A-10
ENGINE MECHANICAL ON-VEHICLE SERVICE
Belt tension meter set (MB992080) MB992081
MB992082 AC507219AD
Power steering oil pump pulley
10 – 15 mm (0.4 – 0.59 inch)
Idler pulley
Gently tap with your finger 15˚ 15˚ MB992080
Idler pulley Crankshaft pulley
Alternator pulley
2. Check the tension of the drive belt in the following procedures. (1) Connect special tool microphone assembly (MB992082) to special tool belt tension meter (MB992081) of special tool belt tension meter set (MB992080). (2) Press the "POWER" button to turn on the power supply. (3) Press the numeral key of "1" and check that "No. 1" appears on the upper left of the display. NOTE: This operation is to temporarily set the preset data such as the belt specifications, because if the measurement is taken without input of the belt specifications, conversion to tension value (N) cannot be made, resulting in judgement of error. (4) Press "Hz" button twice to change the display to the frequency display (Hz).
CAUTION • The temperature of the surface of the belt should be as close to normal temperature as possible. • Do not allow any contaminants such as water or oil to get onto the microphone. • If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values. • If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values. • Do not take the measurement while the vehicle's engine is running. (5) Hold special tool MB992080 to the middle of the belt between the pulleys (at the place indicated by arrow) where it does not contact the belt (approximately 10 −15 mm (0.4 −0.59 inch) away from the rear surface of the belt) so that it is perpendicular to the belt (within an angle of ± 15 degree). (6) Press the "MEASURE" button. (7) Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value. Standard value: 102 −129 Hz NOTE: To take the measurement repeatedly, tap the belt again. (8) Press and hold the "POWER" button to turn off the power supply. 3. If not within the standard value, replace the auto-tensioner (Refer to P.11A-63).
AC607321AC
.
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ENGINE MECHANICAL ON-VEHICLE SERVICE
11A-11
1. Check the tension of the drive belt (Refer to P.11A-9). 2. Use a belt tension gauge in the middle of the belt between the pulleys shown in the figure (at the place indicated by the arrow) to check that the belt tension is within the standard value. Standard value: 248 −400 N (56 −90 lb)
Power steering oil pump pulley
Idler pulley
3. If not within the standard value, replace the auto-tensioner (Refer to P.11A-63).
Belt tension gauge Idler pulley Crankshaft pulley
Alternator pulley AC506733 AC
VALVE CLEARANCE CHECK AND ADJUSTMENT
M1111001500681
Refer to GROUP00, General −Maintenance service −Intake And Exhaust Valve Clearance (Inspect And Adjust)
IGNITION TIMING CHECK
M1111001701699
Required Special Tool: MB991958: Scan Tool (M.U.T.-III Sub Assembly) • MB991824: V.C.I. • MB991827: M.U.T.-III USB Cable • MB991910: M.U.T.-III Main Harness A 1. Before inspection, set the vehicle in the following condition: • Engine coolant temperature: 80 −95° C (176 −203° F) • Lights and all accessories: OFF • Transaxle: Neutral (P range on vehicles with CVT) NOTE: On vehicles for Canada, the headlight, taillight, etc. remain lit even when the lighting switch is in "OFF" position but this is no problem for checks.
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11A-12
ENGINE MECHANICAL ON-VEHICLE SERVICE
CAUTION To prevent damage to scan tool MB991958, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958. 2. Connect scan tool MB991958 to the data link connector.
Data link connector
MB991910 MB991824
MB991827
AC608435 AB
Equipment side connector No. 1 ignition coil
1 2 3 Power supply line (terminal No. 3)
AK604618 AB
3. Set the timing light to the power supply line (terminal No. 3) of the ignition coil No. 1. 4. Start the engine and run it at idle. 5. Check that the idle speed is approximately 700 r/min. 6. Select scan tool MB991958 actuator test "item number 11". 7. Check that basic ignition timing is within the standard value. Standard value: 5° BTDC ± 3° 8. If the basic ignition timing is not within the standard value, check the following items: • Diagnostic output • Timing belt cover and crankshaft position sensor installation conditions • Crankshaft sensing blade condition
CAUTION If the actuator test is not canceled, the forced drive will continue for 27 minutes. Driving in this state could lead to engine failure. 9. Cancel the setting mode of the scan tool MB991958. 10.Check that the actual ignition timing is at the standard value. Standard value: Approximately 10° BTDC NOTE: Ignition timing fluctuates about ± 7° Before Top Dead Center, even under normal operating condition. NOTE: It is automatically further advanced by about 5° to 10° Before Top Dead Center at higher altitudes. 11.Remove the timing light.
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ENGINE MECHANICAL ON-VEHICLE SERVICE
11A-13
CAUTION To prevent damage to scan tool MB991958, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958. 12.Disconnect scan tool MB991958 from the data link connector.
CURB IDLE SPEED CHECK
M1111003501561
Required Special Tool: MB991958: Scan Tool (M.U.T.-III Sub Assembly) • MB991824: V.C.I. • MB991827: M.U.T.-III USB Cable • MB991910: M.U.T.-III Main Harness A 1. Before inspection, set the vehicle in the following condition: • Engine coolant temperature: 80 −95° C (176 −203° F) • Lights and all accessories: OFF • Transaxle: Neutral (P range on vehicles with CVT) NOTE: On vehicles for Canada, the headlight, taillight, etc. remain lit even when the lighting switch is in "OFF" position but this is no problem for checks.
CAUTION To prevent damage to scan tool MB991958, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958. 2. Connect scan tool MB991958 to the data link connector.
Data link connector
MB991910 MB991824
MB991827
AC608435 AB
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11A-14
ENGINE MECHANICAL ON-VEHICLE SERVICE Equipment side connector
No. 1 ignition coil
1 2 3 Power supply line (terminal No. 3)
AK604618 AB
3. Set the timing light to the power supply line (terminal No. 3) of the ignition coil No. 1. 4. Start the engine. 5. Run the engine at idle for 2 minutes. 6. Check the actual ignition timing is at the standard value. Standard value: Approximately 10° BTDC 7. Check the idle speed. Select item number 2 and take a reading of the idle speed. Curb idle speed: 700 ± 100 r/min NOTE: The idle speed is controlled automatically by the idle air control system. 8. If the idle speed is outside the standard value, refer to GROUP 13A, Multiport Fuel Injection (MFI) −Multiport Fuel Injection (MFI) Diagnosis −Symptom Chart P.13A-51. NOTE: Ignition timing fluctuates about ±7° Before Top Dead Center, even under normal operating condition. NOTE: It is automatically further advanced by about 5° to 10° Before Top Dead Center at higher altitudes. 9. Remove the timing light.
CAUTION To prevent damage to scan tool MB991958, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958. 10.Disconnect scan tool MB991958 from the data link connector.
IDLE MIXTURE CHECK
M1111002101087
Required Special Tool: MB991958: Scan Tool (M.U.T.-III Sub Assembly) • MB991824: V.C.I. • MB991827: M.U.T.-III USB Cable • MB991910: M.U.T.-III Main Harness A 1. Before inspection, set the vehicle in the following condition: • Engine coolant temperature: 80 −95° C (176 −203° F) • Lights and all accessories: OFF • Transaxie: Neutral (P range on vehicles with CVT) NOTE: On vehicles for Canada, the headlight, taillight, etc. remain lit even when the lighting switch is in "OFF" position but this is no problem for checks.
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ENGINE MECHANICAL ON-VEHICLE SERVICE
11A-15
CAUTION To prevent damage to scan tool MB991958, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958. 2. Connect scan tool MB991958 to the data link connector.
Data link connector
MB991910 MB991824
MB991827
AC608435 AB
Equipment side connector No. 1 ignition coil
1 2 3 Power supply line (terminal No. 3)
AK604618 AB
3. Set the timing light to the power supply line (terminal No. 3) of the ignition coil No. 1. 4. Start the engine and let it run at idle. 5. Check that the actual ignition timing is at the standard value. Standard value: Approximately 10° BTDC NOTE: Ignition timing fluctuates about ±7° Before Top Dead Center, even under normal operating condition. NOTE: It is automatically further advanced by about 5° to 10° Before Top Dead Center at higher altitudes. 6. Run the engine and increase the engine speed to 2,500 r/min for 2 minutes. 7. Set the CO, HC tester. 8. Check the CO contents and the HC contents at idle. Standard value: CO contents: 0.5% or less HC contents: 100 ppm or less 9. If there is a deviation from the standard value, inspect the MFI system (Refer to GROUP 13A −Multiport Fuel Injection (MFI) −Multiport Fuel Injection (MFI) Diagnosis −Symptom Chart P.13A-51) 10.Remove the timing light.
CAUTION To prevent damage to scan tool MB991958, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958. 11.Disconnect scan tool MB991958 from the data link connector.
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11A-16
ENGINE MECHANICAL ON-VEHICLE SERVICE
COMPRESSION PRESSURE CHECK
M1111002601747
Required Special Tool: MB991958: Scan Tool (M.U.T.-III Sub Assembly) • MB991824: V.C.I. • MB991827: M.U.T.-III USB Cable • MB991910: M.U.T.-III Main Harness A 1. Before inspection, check that the engine oil, starter and battery are normal. Also, set the vehicle in the following condition: • Engine coolant temperature: 80 −95° C (176 −203° F) • Lights and all accessories: OFF • Transaxle: Neutral (P range on vehicles with CVT) 2. Remove all of the ignition coils and spark plugs. 3. Disconnect the all of the injector connectors. NOTE: Doing this will prevent the engine control module from carrying out ignition and fuel injection.
Injector connectors
WARNING
Keep your distance from the spark plug hole when cranking. Oil, fuel, etc., may spray out from the spark plug hole and may cause serious injury. AK502603AE
Compression gauge
AK502604AE
4. Cover the spark plug hole with a shop towel etc., after the engine has been cranked, check that no foreign material is adhering to the shop towel. 5. Set compression gauge to one of the spark plug holes. 6. Crank the engine with the throttle valve fully open and measure the compression pressure. Standard value (at engine speed of 200 r/min): 1,470 kPa (213 psi) Limit (at engine speed of 200 r/min): Minimum 1,050 kPa (152 psi) 7. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: Maximum 98 kPa (14 psi) 8. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps from 5 to 7. (1) If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface. (2) If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket. 9. Connect the all of the injector connector. 10.Install the spark plugs and ignition coils.
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ENGINE MECHANICAL ON-VEHICLE SERVICE
11A-17
11.Use the scan tool MB991958 to erase the diagnosis codes. NOTE: This will erase the diagnosis code resulting from the injector connectors being disconnected.
Data link connector
MB991910 MB991824
MB991827
AC608435 AB
MANIFOLD VACUUM CHECK
M1111002701313
Required Special Tool: MB991958: Scan Tool (M.U.T.-III Sub Assembly) • MB991824: V.C.I. • MB991827: M.U.T.-III USB Cable • MB991910: M.U.T.-III Main Harness A 1. Before inspection, set the vehicle in the following condition: • Engine coolant temperature: 80 −95° C (176 −203° F) • Lights and all accessories: OFF • Transaxle: Neutral (P range on vehicles with CVT) NOTE: On vehicles for Canada, the headlight, taillight, etc. remain lit even when the lighting switch is in "OFF" position but this is no problem for checks.
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11A-18
ENGINE MECHANICAL ON-VEHICLE SERVICE
CAUTION To prevent damage to scan tool MB991958, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958. 2. Connect scan tool MB991958 to the data link connector.
Data link connector
MB991910 MB991824
MB991827
AC608435 AB
Vacuum gauge
PCV valve
Plug AK502601AE
3. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve, and then connect a vacuum gauge to the ventilation hose. Plug the PCV valve. 4. Start the engine and check that idle speed is approximately 700 r/min. 5. Check the intake manifold vacuum. Limit: Minimum 60 kPa (18 in Hg) 6. Turn off the ignition switch. 7. Remove the vacuum gauge and then connect the ventilation hose to the PCV valve.
CAUTION To prevent damage to scan tool MB991958, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991958. 8. Disconnect scan tool MB991958 from the data link connector.
TSB Revision
11A-19
ENGINE MECHANICAL CRANKSHAFT PULLEY
CRANKSHAFT PULLEY REMOVAL AND INSTALLATION
M1112001601402
Pre-removal operation • Engine Room Under Cover Front Removal (Refer to GROUP 51 −Under Cover P.51-16). • Engine Room Side Cover (RH) Removal (Refer to GROUP 51−Under Cover P.51-16). • Radiator Condenser Tank Removal (Refer to GROUP 14 − Radiator P.14-26).
Post-installation operation • Radiator Condenser Tank Installation (Refer to GROUP 14 −Radiator P.14-26). • Drive Belt Tension Check (Refer to P.11A-9). • Engine Room Side Cover (RH) Installation (Refer to GROUP 51 −Under Cover P.51-16). • Engine Room Under Cover Front Installation (Refer to GROUP 51 −Under Cover P.51-16).
