1.
To remove the front side member, drill out all spotwelds and MIG plug welds, and grind away MIG lap weld attaching the fender apron inner panel.
note
When spotwelded portions are not apparent, remove paint with a rotary wire brush.
Before repairing, remove Engine and Suspension Components.
Refer to the body dimension charts and measure the vehicle to determine straightening and alignment requirements. The body must return to its original dimension after the repair procedure.
To remove the front side member, drill out all spotwelds and MIG plug welds, and grind away MIG lap weld attaching the fender apron inner panel.
When spotwelded portions are not apparent, remove paint with a rotary wire brush.
Remove the fender apron inner front panel.
To remove the front side member, drill out all spotwelds attaching the battery tray leg bracket.
Remove the battery tray leg bracket.
Measure and mark the cutlines on the front side member. Cut the front side member along the cutlines.
When cutting the front side member, take care not to cut through the mating flanges or front side member reinforcement.
Drill out all spotwelds attaching the front side member.
Remove the front side member.
Prepare all surfaces to be welded.
After removing, apply the welding primer.
Measure and mark the cutlines on the new front side member. Cut the new front side member along the cutlines.
Drill 8mm holes along the new front side member for MIG plug welding.
Fit and clamp the new front side member 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.
After removing, apply the welding primer.
Drill 8mm holes along the new battery tray leg bracket flanges for MIG plug welding.
Fit and clamp the new battery tray leg bracket in place.
Measure each measurement point (Refer to the Body Dimensions) and correct the installation position.
MIG plug weld all holes.
Clean and prepare all welds, and remove all residues.
Drill 8mm holes along the new fender apron inner panel flanges for MIG plug welding.
Fit and clamp the new fender apron inner front panel in place.
Measure each measurement point (Refer to the Body Dimensions) and correct the installation position.
MIG plug weld all holes and MIG lap weld the seam.
Clean and prepare all welds, and remove all residues.
Apply an anti-corrosion agent as required (Refer to the Corrosion Protection).
Prepare the exterior surfaces for priming using wax and grease remover.
Apply metal conditioner and water rinse.
Apply conversion coating and water rinse.
Apply the correct seam sealer to all joints carefully (Refer to the Body Sealing Location).
