Side Sill Outer Panel Replacement

NOTE:

High-strength steel is defined as any steel with a tensile strength of 340 MPa or higher. If a part is constructed of, or includes high-strength steel observe the important guidelines.

Welding symbols (The welding symbols with dashed lines have a meaning of the spot welding of the part which is not visible)

( ): The number of welds

The figure shows the size of side sill outer panel repair part.

1.	Mass Production Body Welding Positions and Numbers - Remove

Side Sill Outer Panel

2.	Construction - Remove

Side Sill Outer Panel

NOTE:

This section explains the procedures after removal of all related parts. For the related parts' removal procedure, refer to the appropriate Service Manual.

The component replacement procedure described here is only for new genuine supplied parts, as needed, according to the area and the degree of damage on the body.

Cut and pry off the side sill outer panel, and replace it.

NOTE: Select the sectioning location in consideration of the side sill outer panel repair part.

Replace the center pillar outer separator.

NOTE:

Position the replacement parts.
Before doing the main welding, check the body dimensions:

Front wheelhouse lower member position

Door hinge positions

Windshield and door openings

Temporarily install the related parts, then check for differences in level and clearance.
Check the external parts fitting positions. Make sure the body lines flow smoothly.

Confirm the sheet thickness, tensile strength, and existence of the zinc treatment of both sides, and set the welder to conform to the welding conditions by referring to Front Body Construction, Roof and Side Panel Construction, and Floor and Rear Body Construction.

Welding symbols (The welding symbols with dashed lines have a meaning of the spot welding of the part which is not visible)

( ) and ( )*: The number of welds

1.	Outer Panel Repair Part - Weld

Install the new center pillar outer separator (A) on the center pillar stiffener (B). Apply the sealer (C) without gaps all the way around the separator and inside the outer panel repair part (D).

Apply the adhesive (A) to areas around holes on the inside of the outer panel repair part (B) and the outside of the front pillar lower stiffener (C) as shown.

Adhesive: 3M AUTO MIX Panel Bonding 8115, or equivalent, commercially available

NOTE: See the adhesive manufacture's instructions for details.

Weld the outer panel repair part (A).

(?)*: Welding positions with the side sill reinforcement (B), include ultra high-strength steel (1500 MPa) parts. Perform the spot welding on the conditions of No. 26, 30, and 31 in the table shown below.

Spot welding conditions

No. 26	8000 A	800 ms	3432 N (350 kgf)
No. 30	8500 A	1200 ms	3432 N (350 kgf)
No. 31	9000 A	1200 ms	3432 N (350 kgf)