Measure and mark the cutlines on the front side sill outer panel. Cut the front side sill outer panel along the cutlines.
When cutting the front side sill outer panel, take care not to cut through the mating flanges or the front pillar outer reinforcement and side sill outer reinforcement.
Drill out all spotwelds attaching the front side sill outer panel.
Remove the front side sill outer panel.
Measure and mark the cutlines on the front pillar outer reinforcement and side sill outer reinforcement. Cut the front pillar outer reinforcement and side sill outer reinforcement along the cutlines.
When cutting the front pillar outer reinforcement and side sill outer reinforcement, take care not to cut through the mating flanges or the front pillar inner panel and side sill inner panel.
Drill out all spotwelds attaching the front pillar outer reinforcement and side sill outer reinforcement.
Remove the front pillar outer reinforcement and side sill 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 and front pillar outer reinforcement. Cut the new side sill outer reinforcement and front pillar outer reinforcement along the cutlines.
Drill 8mm holes along the new side sill outer reinforcement and front pillar outer reinforcement flanges for MIG plug welding.
Fit and clamp the new side sill outer reinforcement and front pillar outer reinforcement in place.
Measure each measurement point (Refer to the Body Dimensions) and correct the installation position.
Spot weld all holes and MIG butt weld the seams.
If spot welding is imposible, MIG plug weld all holes.
Apply epoxy adhesive to the weld points of new panel or body panel.
Be sure to use the recommended epoxy adhesive below.
Epoxy adhesive : 3M(PN8115), Henkel (Terokal 5055) or equivalent
Clean and prepare all welds, and remove all residues.
After removing, apply the welding primer.
Measure and mark the cutlines on the new front side sill outer panel. Cut the new front side sill outer panel along the cutlines.
Drill 8mm holes along the new front side sill outer panel flanges for MIG plug welding.
Fit and clamp the new front 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 an anti-corrosion agent to the welded parts and the interior of the side sill panel (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 (Refer to the Body Sealing Locations).
Reprime over the seam sealer to complete the repair.
