A-Pillar Outer Panel, Front Door Hinge Reinforcement and Dash Side Panel Removal and Installation

Precautions: Precautions for Body Structure · Precautions for Body, Cab and Accessories · General safety (00)

NOTE:

The figure below shows condition where the following parts are removed.

•Front fender

•Hood lock member and lamp support brace

•Cowl side outer member

•Dash side front panel

•Fuel filler door panel

General Notes

•Welding method and number of welding points are the same on both sides. This repair instruction shows procedure for left side.
•Part filled with foamed material is included in parts of this repair. Therefore, repair referring to Foamed Material Filling Area Repair for precautions and repair procedure.
•The dimensions shown in the figure are reference values when cutting replacement part placed on top of existing part. Determine the most appropriate cutting (or joint) line considering both size of replacement part and condition of existing part.

Removal

1)Mark at the shown position and cut A-pillar outer panel.

NOTICE:

You may accidentally cut the parts under the A-pillar outer panel or the parts under the side sill outer panel when cutting the A-pillar outer panel.

Take sufficient care not to damage the parts under the A-pillar outer panel or the parts under the side sill outer panel when cutting the A-pillar outer panel.

2)Drill out welding spots.

3)Bend open metal tab (arrow) and remove A-pillar outer panel.

:	When heating around foamed material application portion to detach foamed material, be sure that temperature of said portion does not reach 170 °C (338 °F).

4)Drill out welding spots and remove front door hinge reinforcement, door hinge retainer and front door hinge upper reinforcement.

:	When heating around foamed material application portion to detach foamed material, be sure that temperature of said portion does not reach 170 °C (338 °F).

5)Drill out welding spots.

6)Unscrew bolt and remove dash panel side reinforcement.

[A]:

Driver side

[B]:

Passenger side

7)Drill out welding spots.

8)Unscrew 2 bolts and remove dash side panel.

[A]:	Vehicle left side
[B]:	Vehicle right side
1:	Grind welding spots using belt sander, if necessary.
2:	When heating around sealer application portion to detach body sealer, be sure that temperature of said portion does not reach 170 °C (338 °F).
3:	This symbol indicates that dash side front panel, fender apron panel and fender apron extension are replaced at the same time.

Installation

NOTE:

•Before conducting any weld, check installation position and condition for installation part(s).

—Side body outside:

—Side body inside:

•Perform repair while taking into consideration installation of parts that affect appearance.

1)Install dash side front panel and dash side panel.

2)Conduct resistance spot weld and plug weld.

3)Tighten 2 bolts to specified torque.

4)Apply anti-corrosion wax to back side of continuous weld part.

[A]:	Vehicle left side	:	This symbol indicates that dash side front panel, fender apron panel and fender apron extension are replaced at the same time.
[B]:	Vehicle right side	:	10 N·m (1.0 kgf-m, 7.5 lbf-ft)
1.	Applied part of body sealer.

5)Install dash panel side reinforcement.

6)Conduct resistance spot weld and plug weld.

7)Tighten bolt to specified torque.

[A]:

Driver side

[B]:

Passenger side

:

10 N·m (1.0 kgf-m, 7.5 lbf-ft)

8)Repair foamed material.

1.	Foamed material	3.	Dash side panel
2.	Front door hinge reinforcement	4.	Baffle plate

9)Install front door hinge reinforcement.

10)Conduct plug weld.

11)Install new A-pillar outer panel to vehicle body and cut in stacked condition.

12)Install A-pillar outer panel.

13)Conduct resistance spot weld and plug weld.

14)Conduct continuous weld.

15)Apply anti-corrosion wax to back side of continuous weld part.

16)Bend in metal tab (arrow) of A-pillar outer panel.

Applied part of body sealer.

:

Conduct resistance spot weld as three panel thickness.

17)Install front fender bracket and front fender lower bracket.

18)Conduct plug weld.