Replacement

Replacement

1. Remove the related parts.

• Front seat
• Carpet
• Refer to the front side frame.

2. Pull out and straighten the damaged area.

• The front side outrigger receives impact through the front side frame or side sill. Such impact generally requires replacement of all these parts.
• Before cutting off the front side frame or side sill, pull out the damaged area with the frame straightener and correct the related parts such as the front floor and dashboard. Check the clearance and level differences of the front doors.
• Jack up the body and place safety stands at the four designated places on the side sills. If necessary, place safety stands at the rear of the side sill.

3. Peel off the undercoat. Heat the undercoat at the weld areas of the front side extension and side frame with a gas torch and peel off the undercoat with a metal spatula.

CAUTION: Be careful not to burn the fittings inside the passenger compartment and dashboard insulator when heating.

4. Remove the front side outrigger.

• Centre punch around the spot weld imprints on the front side outrigger from inside the passenger compartment.
• Drill holes in the spot welded areas with a 5 mm (0.2 in) drill.

NOTE: Drill holes through the parts completely since the replacement front side outrigger will be welded by MIG welding.

A. Inside sill extension B. Front side Outrigger

• Leave the inside sill extension and rear support stiffener attached to the dashboard lower side.

NOTE: When drilling holes, be careful not to drill down to the inside sill extension, rear support stiffener and inside sill.

A. Rear Support Stiffener B. Inside Sill Extension C. Inside Sill D. Front Side Outrigger