Service Procedure

^ The following explanation describes the procedure for removal of the rear side member on the left side.

^ The procedure for the right side is the same as that of the left side.

1. Remove the fusible insulator on rear floor front.





^ Remove the shaded portion as shown.

2. Remove the fusible insulator in the trunk room.





^ Remove the shaded portion as shown.

3. Remove the rear floor heat insulator.





^ Grind the rivets with a belt sander or a similar tool, and remove the rear floor heat insulator.

CAUTION:
The removed rear floor heat insulator is to be reinstalled on the vehicle.

4. Remove the rear seatback support assembly.





^ Drill spot weld through one panel of 3-layered parts at portion (h).

^ Drill spot weld through only two panels of 3-layered parts at portions (bc) and (be).





^ Drill spot weld through only one panel of 2-layered parts at portions (c), (e), (f), (g), (ba), (bb) and (bd).

^ Drill spot weld through one panel of 3-layered parts at portion (d).





^ Drill spot weld through only one panel of 2-layered parts at portions (ap), (aq), (ar) and (at).

^ Drill spot weld through one panel of 3-layered parts at portion (as).

CAUTION:
^ The removed rear seatback support assembly is to be reinstalled on the vehicle.

^ Drilled holes are used as holes for plug welding.





5. Remove the center rear crossmember assembly.

^ Drill spot weld through one panel of 3-layered parts at portion (ak).





^ Drill spot weld through one panel of 3-layered parts at portion (ah).





^ Drill spot weld through only one panel of 2-layered parts at portion (j).

^ Drill spot weld through one panel of 3-layered parts at portions (i) and (k).

CAUTION:
As portions (i), (j) and (k) are symmetric, the procedure for the right side is the same.

^ Drill spot weld through only one panel of 2-layered parts at portion (a).

^ Drill spot weld through one panel of 3-layered parts at portion (b).

CAUTION:
^ As portions (a) and (b) are symmetric, the procedure for the right side is the same.

^ The removed center rear crossmember assembly is to be reinstalled on the vehicle.

^ Drilled holes are used as holes for plug welding.

6. Cut off the rear floor front from the vehicle.





^ Drill spot weld through only one panel of 2-layered parts at portions (u), (v), (x) and (y).

^ Drill spot weld through one panel of 3-layered parts at portions (t), (w) and (z).

^ Cut off the portion along the cut lines with an air saw or a similar tool, and remove it.

CAUTION:
Do not damage the rear floor rear when cutting the rear floor front.





^ Drill spot weld through only one panel of 2-layered parts at portions (av) and (ax).

^ Drill spot weld through one panel of 3-layered parts at portion (aw).

^ Drill spot weld through only two panels of 3-layered parts at portion (ay).





7. Remove the rear side member.

CAUTION:
Never remove the rear side member extension and the inner sill extension from the vehicle.

^ Drill spot weld through only one panel of 2-layered parts at portion (au).

^ Drill spot weld through one panel of 3-layered parts at portion (ae).

^ Drill spot weld through only two panels of 3-layered parts at portion (ag).

^ Drill through weld portion (af) from the top.





^ Drill spot weld through only one panel of 2-layered parts at portions (I), (m), (o), (q), (r) and (s).

^ Drill spot weld through one panel of 3-layered parts at portion (p).





^ Drill spot weld through one panel of 3-layered parts at portions (am) and (ao).





^ Drill spot weld through only one panel of 2-layered parts at portion (ad).

^ Drill through weld portion (ac) from the outside.





^ Drill through weld portions (ai) and (aj) from the outside.





^ Roughly cut off the rear side member as shown in order to facilitate removal portions (az) [and (bj) California spec only].








^ For California spec only, Drill spot weld through only one panel of 2-layered parts at portion (bj).

CAUTION:
Perform work from the roughly cut opening.





^ Drill spot weld through only one panel of 2-layered parts at portion (az).

INSTALLATION

CAUTION:
Before installing, dress the welded parts or rust may form.





Remove the rear side member extension and inner sill extension from the rear side member service part.





1. Remove the rear side member brace and inner sill extension from the rear side member service part.

^ For California spec only, drill through weld portion (bj) from the outside in order to disassemble the rear side member, inner sill extension and rear side member brace.

CAUTION:
Drilled rear side member and rear side member brace holes are used as holes for plug weld of portion (bj).





^ For California spec only, drill spot weld through only two panels of 3-layered parts at portions (al), (bf) and (bh).

^ For California spec only, drill spot weld through one panel of 3-layered parts at portion (bg).

^ After removing rear side member brace, drill through weld portion (az) from the outside, and remove inner sill extension.

CAUTION:
Drilled rear side member holes are used as holes for plug weld of portions (al), (bf), (bg), (bh) and (az).





2. Remove the rear side member extension from the rear side member service part.

^ Drill spot weld through only one panel of 2-layered parts at portions (ac), (ad), (ai) and (aj).





3. Install the rear side member, and measure the various dimensions as specified in "BODY ALIGNMENT" drawing.

4. Weld the rear side member.





^ MIG plug weld portion (az) from the inside of compartment.

^ After welding, dress the welded portions, and apply anti-corrosive wax to the inside of rear side member.





^ For California spec only, install the rear side member brace that was removed from the rear side member service part.





^ For California spec only, MIG plug weld the portion (bj) using spot cut holes.

^ After welding, dress the welded portions, and apply anti-corrosive wax to the inside of rear side member.





^ For California spec only, MIG plug weld the portions (al), (bf), (bg) and (bh), using spot cut holes.

^ After welding, dress the welded portions, and apply anti-corrosive wax to the inside of rear side member.

^ After drilling, MIG plug weld holes in portions (I), (m), (o), (p), (q), (r) and (s) of service part.

^ After welding, dress the welded portions, and apply anti-corrosive wax.





^ MIG plug weld the portions (ac), (ad), (ai) and (aj), using spot cut holes.

^ After welding, dress the welded portions, and apply anti-corrosive wax to the inside of rear side member, using rear side member holes.





^ MIG plug weld the portions (am) and (ao), using spot cut holes.

^ After welding, dress the welded portions, and apply anti-corrosive wax to the inside of rear side member.





^ MIG plug weld the portions (ae), (af) and (au), using spot cut holes.

^ Drill MIG plug weld holes in the new rear side member with a flat drill, in portion (ag) using spot cut holes in mating panel, and MIG plug weld them.





5. Cut off the rear floor front service part.

^ Put rear floor front removed part upon rear floor front service part, and cut rear floor front service part, leaving 20 mm (0.8 in) lap allowance with mating part.





^ After drilling MIG plug weld hole in portions (t), (u), (v), (w), (x), (y), (z) and (aa) of service part, MIG plug weld them.

^ Drill MIG plug weld holes with a flat drill, in portion (ab) using drilled holes in matinq panel, and MIG plug weld them.





^ MIG plug weld the portions (aw) and (ax), using spot cut holes.

^ Drill MIG plug weld holes in new rear side member, with a flat drill, in portions (av) and (ay) using spot cut holes in mating panel, and MIG plug weld them.

6. Install the center rear crossmember assembly removal part.





^ MIG plug weld the portions (a) and (j), using spot cut holes.

^ Drill MIG plug weld holes with a flat drill in portions (b), (i), and (k) using spot cut holes in mating panel, and MIG plug weld them.

CAUTION:
^ As portions (a), (b), (i), (k) and (j) are symmetric, the procedure for the right side is the same.

^ Drill one panel of service part of portions (b), (i) and (k).





^ MIG plug weld the portions (ah) and (ak), using spot cut holes.





7. Weld the lower rear seatback support back using the spot cut holes created during removal.

^ MIG plug weld the portions (c), (d), (e), (f), (g), (ap), (aq), (ar), (as), (at), (ba), (bb) and (bd), using spot cut holes.





^ MIG plug weld the portions (h) and (be), using spot cut holes.

^ Drill MIG plug weld hole with a flat drill, in portion (bc) using spot cut hole in mating panel, and MIG plug weld them.





8. After welding, dress the welded portions, and apply anti-corrosive wax to rear floor front of overlapped portion, using center rear crossmember and lower rear seatback support holes.





^ After repair of rear floor front, apply sealant to the flange end portion from both sides (floor topside and underside).

9. Apply sealant to the other parts.

10. Install the fusible insulator in trunk room.

11. Install the fusible insulator on rear floor rear.

12. Apply undercoating to underbody.

13. Install the rear floor heat insulator using rivets.

BODY ALIGNMENT

Description

^ All dimensions indicated in the figures are actual.

^ When using a tracking gauge, adjust both pointers to equal length. Then check the pointers and gauge itself to make sure there is no free play.

^ When a measuring tape is used, check to be sure there is no elongation, twisting or bending.

^ Measurements should be taken at the center of the mounting holes.

^ An asterisk (*) following the value at the measuring point indicates that the measuring point on the other side is symmetrically the same.





^ The coordinates of the measurement points are the distances measured from the standard line of "X", "Y", and "Z".





UNDERBODY MEASUREMENT L31 (ALTIMA)





MEASUREMENT POINTS L31 (ALTIMA)





UNDERBODY MEASUREMENT A34 (MAXIMA)





MEASUREMENT POINTS A34 (MAXIMA)

Body Sealing L31 (ALTIMA) DESCRIPTION











The figure show the areas which are sealed at the factory. Sealant which has been applied to these areas should be smooth and free from cuts or gaps. Care should be taken not to apply an excessive amount of sealant and not to allow other unaffected parts to come into contact with the sealant.

Body Sealing A34 (MAXIMA) DESCRIPTION











The figure show the areas which are sealed at the factory. Sealant which has been applied to these areas should be smooth and free from cuts or gaps. Care should be taken not to apply an excessive amount of sealant and not to allow other unaffected parts to come into contact with the sealant.

UNDERCOATING





The underside of the floor and wheelhouse are undercoated to prevent rust, vibration, noise and stone chipping. Therefore, when such a panel is replaced or repaired, apply undercoating to that part. Use an undercoating which is rust preventive, soundproof, vibration-proof, shock-resistant, adhesive, and durable.

Precautions in Undercoating

1. Do not apply undercoating to any place unless specified (such as the areas above the muffler and three-way catalyst, which are subjected to heat).

2. Do not undercoat the exhaust pipe or other parts which become hot.

3. Do not undercoat rotating parts.

4. Apply bitumen wax after applying undercoating.