FRONT SIDE FRAME (PARTIAL CUTTING) INSTALLATION [PANEL REPLACEMENT]

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RH

Caution

•  The cut-and-joint area indicates the maximum size range of the installation position.

1.  Make a reinforcement panel using the material from the front side frame (inner).

2.  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.

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

4.  When installing the new parts, trial-fit new and existing parts, and then measure and adjust the body to conform with standard dimensions.

5.  Trial-fit the new and existing parts, weld the existing parts and the reinforcement, and then butt weld the new and existing parts.

Caution

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

•  To prevent weld bead drop from the reinforcement panel, weld the reinforcement plate such that the weld bead are longer than their widths.

6.  Install the front side frame (inner).

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7.  Install the suspension mount reinforcement.

8.  Install the suspension mount bolt.

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9.  Because the front side frame (outer) cannot be welded to the existing parts from the inside of the panel, drill 5 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.

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

11.  Install the front side frame (outer).

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LH

Caution

•  The cut-and-joint area indicates the maximum size range of the installation position.

1.  Make a reinforcement panel using the material from the front side frame (inner).

2.  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.

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

4.  When installing the new parts, trial-fit new and existing parts, and then measure and adjust the body to conform with standard dimensions.

5.  Trial-fit the new and existing parts, weld the existing parts and the reinforcement, and then butt weld the new and existing parts.

Caution

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

•  To prevent weld bead drop from the reinforcement panel, weld the reinforcement plate such that the weld bead are longer than their widths.

6.  Install the front side frame (inner).

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7.  Install the suspension mount reinforcement.

8.  Install the suspension mount bolt.

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9.  Because the front side frame (outer) cannot be welded to the existing parts from the inside of the panel, drill 5 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.

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

11.  Install the front side frame (outer).

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