1.
To remove the front side member, drill out all spotwelds attaching the fender apron inner lower panel.
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 attaching the fender apron inner lower panel.
Remove the fender apron inner lower panel.
Measure and mark the cutlines on the front side inner member from the front side inner member tooling hole center. Cut the front side inner member along the cutlines.
Drill out all spotwelds attaching the front side inner member section.
Remove the front side inner member section.
Measure and mark the cutline on the front side member inner reinforcement 105mm from the front side inner member tooling hole center. Cut the front side member inner reinforcement along the cutline.
Measure and mark the cutlines on the front side outer member from the front side outer member tooling hole center. Cut the front side outer member along the cutlines.
Drill out all spotwelds attaching the front side outer member section.
Remove the front side outer member section.
Measure and mark the cutline on the front side member outer reinforcement 130mm from the front side outer member tooling hole center. Cut the front side member outer reinforcement along the cutline.
Drill out the spotweld attaching the front side outer 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 the hole and MIG butt weld the seams.
Clean and prepare all welds, and remove all residues.
After removing, apply the welding primer.
Reattach the cut front side outer member section, then MIG plug weld all holes and MIG butt weld the seams.
Reattach the cut front side inner member section, then 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.
Fit and clamp the 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.
Clean and prepare all welds, and remove all residues.
Apply the epoxy primer to the interior of each panel.
Apply an anti-corrosion agent as required
(Refer to the BODY 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).
