Quarter-Pillar Outer Panel and Side Body Outer Lower Extension 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

•Fuel filler door panel

Precautions

•Welding method and number of welding points are the same on both sides. This repair instruction shows procedure for left side.
•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 quarter-pillar outer panel.

NOTICE:

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

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

2)Drill out welding spots.

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

[A]:	Vehicle left side
1:	When heating around sealer application portion to detach body sealer, be sure that temperature of said portion does not reach 170 °C (338 °F).
2:	This symbol indicates that quarter-pillar outer panel, rear wheel house outer panel and back panel are replaced at the same time.
3:	This symbol indicates that quarter-pillar outer panel, rear wheel house outer panel and rear wheel house outer extension are replaced at the same time.

4)Drill out welding spots.

5)Remove side body outer lower extension, if necessary.

Installation

NOTE:

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

—Rear end door:

—Side body outside:

—Side body inside:

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

1)Apply body sealer to fuel filler box.

2)Install fuel filler box.

3)Conduct resistance spot weld.

1.	Applied part of body sealer.

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

5)Remove quarter-pillar outer panel and apply body sealer.

6)Install side body outer lower extension, if removed.

7)Conduct resistance spot weld.

8)Reinstall quarter-pillar outer panel to vehicle body.

9)Conduct resistance spot weld or plug weld.

10)Conduct continuous weld.

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

12)Bend in metal tab (arrow) of quarter-pillar outer panel.

[A]:	Vehicle left side
1.	Applied part of body sealer.
2:	This symbol indicates that quarter-pillar outer panel, rear wheel house outer panel and back panel are replaced at the same time.
3:	This symbol indicates that quarter-pillar outer panel, rear wheel house outer panel and rear wheel house outer extension are replaced at the same time.

13)After installation of quarter-pillar outer panel, affix fuel lid cushion films (1) and side body outer seat (2) as shown in figure.

[A]:	Vehicle outside