2.
To remove the front pillar, drill out and grind away all spotwelds and MIG plug welds attaching the cowl side upper outer panel.
Before cutting the front pillar, be sure to support the roof panel.
To remove the front pillar, drill out and grind away all spotwelds and MIG plug welds attaching the cowl side upper outer panel.
Remove the cowl side upper outer panel.
Measure and mark the cutlines on the front pillar outer panel.
Cut the front pillar outer panel along the cutlines.
When cutting the front pillar 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 pillar outer panel sections.
Remove the front pillar outer panel sections.
Measure and mark the cutline on the side sill outer reinforcement. Cut the side sill outer reinforcement along the cutline.
When cutting the side sill outer reinforcement, take care not to cut through the mating flanges or the side sill inner panel.
Drill out and grind away all spotwelds attaching the front pillar outer panel assembly.
Remove the front pillar outer panel assembly.
Drill out all spotwelds, and grind away MIG lap weld attaching the front pillar inner panel.
Remove the front pillar inner panel.
Straighten all flanges as necessary, prepare all surfaces to be welded.
Clean and prepare all welds, and remove all residues.
After removing, apply the welding primer.
Drill the holes in the flange of the replacement new front pillar inner panel for MIG plug welding.
Fit and clamp the new front pillar inner panel in place for welding.
Measure each measurement point (Refer to the Body Dimensions) and correct the installation position.
MIG plug weld all holes and MIG lap weld the seams.
Clean and prepare all welds, and remove all residues.
After removing, apply the welding primer.
Measure and mark the cutline on the new front pillar outer panel assembly. Cut the new front pillar outer panel assembly along the cutline.
Drill the holes in the flange of the replacement new front pillar outer panel assembly for MIG plug welding.
Fit and clamp the new front pillar outer panel assembly in place.
Apply body filler to the front pillar outer seam. Sand and finish.
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
Reattach the front pillar outer panel sections that was cut off, then MIG butt weld the seams and MIG plug weld all holes.
Clean and prepare all welds, and remove all residues.
After removing, apply the welding primer.
Before welding the cowl side upper outer panel, apply the epoxy primer and anti-corrosion agent to the interior of the fender apron panel.
Drill the holes in the flange of the replacement new cowl side outer upper panel for MIG plug welding.
Install the new cowl side upper outer panel in place.
Measure each measurement point and correct the installation position.
MIG plug weld all holes.
Clean and prepare all welds, and remove all residues.
Apply an anti-corrosion agent as required (Refer to the Corrosion Protection).
Prepare exterior surfaces for priming, using wax and grease remover.
Apply the correct seam sealer to all joints carefully (Refer to the Body Sealing Locations).
