2.0 petrol and diesel models (page 4 of 4)

9. Set the new front side frame and check that the weld flange surfaces fit closely.

A. New Front Side Frame

• Recheck the position of the new front side frame and rear support stiffener.
• Remove the new front side frame.

10. Main weld the new rear support stiffener and inside sill extension.

WARNING: To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.

11. Set the new front side frame.

• Remove the undercoat from both sides of the welding section, and expose the steel plate using a disc sander.

WARNING: To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting or grinding.

NOTE: Apply the spot sealer to the welding surface when spot welding. Tighten the front side frame against the

• front floor and side sill using vice-grips or pliers. • Place a jack under the front side frame end and support it, and measure the positions for temporary attachment.

NOTE: Use of a positioning jig is recommended.

A. Positioning Jig

• Clamp the front bulkhead and front inner wing/spring housing with squill vices and vice-grips.
• Measure the front compartment diagonally.
• Spot weld several points in the clamped sections, and temporarily attach the front side frame.

WARNING: To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.

• Check the body dimensions.
• Install the rear beam, and check the front side frame position.