FRONT PILLAR INSTALLATION [PANEL REPLACEMENT]

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1.  To cut and join the new and existing parts, cut the new part at the specified location shown in the figure, and chamfer the joint surfaces of the new and existing parts.

2.  Drill holes for the plug welding before installing the new parts.

3.  Apply body sealer to the joints of old and new parts for waterproofing and rust protection.

4.  Install the front pillar (inner).

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5.  Make a reinforcement panel using the material from the front pillar reinforcement.

6.  Because the front pillar reinforcement cannot be welded to the existing parts from the inside of the panel, drill 2 plug weld holes at the locations indicated by (A) on the existing parts. Install the reinforcement and the existing parts by plug welding from the outside, then butt weld the new and existing parts.

Caution

•  Press fit the reinforcement panel and the body side material, and then plug weld them.

7.  Weld the 2 locations indicated by (B) from the interior.

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8.  Make a reinforcement panel using the material from the front pillar reinforcement.

9.  Because the front pillar reinforcement cannot be welded to the existing parts from the inside of the panel, drill 3 plug weld holes at the locations indicated by (C) on the existing parts. Install the reinforcement and the existing parts by plug welding from the outside, then butt weld the new and existing parts.

Caution

•  Press fit the reinforcement panel and the body side material, and then plug weld them.

10.  Install the front pillar reinforcement.

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11.  After temporarily installing new parts, make sure the related parts fit properly.

12.  Weld the 1 locations indicated by (D) from the interior.

13.  Weld the 81 locations indicated by (E) and install the front pillar (outer).

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