Measure and mark the cutlines on the side sill outer panel as indicated in the illustration. Cut the side sill outer panel along the cutlines.
When cutting the side sill outer panel, take care not to cut through the mating flanges or the front pillar outer reinforcement and center pillar outer reinforcement.
Drill out all spotwelds attaching the side sill outer panel.
Remove the side sill outer panel.
Measure and mark the cutline on the front pillar outer reinforcement as indicated in the illustration. Cut the front pillar outer reinforcement along the cutline.
When cutting the front pillar outer reinforcement, take care not to cut through the mating flanges.
Drill out all spotwelds attaching the front pillar outer reinforcement, center pillar outer reinforcement and side sill outer reinforcement.
Remove the side sill outer reinforcement, front pillar outer reinforcement and center pillar outer reinforcement.
Clean cut portions with a grinder.
After removing, apply the welding primer.
Measure and mark the cutlines on the new side sill outer reinforcement, front pillar outer reinforcement and center pillar outer reinforcement. Cut the new side sill outer reinforcement, front pillar outer reinforcement and center pillar outer reinforcement along the cutlines.
Drill 8mm holes along the new side sill outer reinforcement, front pillar outer reinforcement and center pillar outer reinforcement flanges for MIG plug welding.
Fit and clamp the new side sill outer reinforcement, front pillar outer reinforcement and center pillar outer reinforcement in place.
Measure each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position.
MIG plug weld all holes and MIG butt weld the seam.
Clean and prepare all welds, and remove all residues.
After removing, apply the welding primer.
Measure and mark the cutlines on the new side sill outer panel. Cut the new side sill outer panel along the cutlines.
Drill 8mm holes along the new side sill outer panel flanges for MIG plug welding.
Fit and clamp the new side sill outer panel in place.
Measure each measurement point (Refer to the BODY DIMENSIONS) and correct the installation position.
MIG plug weld all holes and MIG butt weld the seams.
Clean and prepare all welds, and remove all residues.
Apply body filler to the side sill panel seams.
Apply the epoxy primer to the interior of the side sill panel.
Apply metal conditioner and water rinse.
Apply conversion coating and water rinse.
Apply the correct seam sealer to all joints (Refer to the BODY SEALING LOCATIONS).
Reprime over the seam sealer to complete the repair.
