- Remove the related parts.
- Doors.
- Weather strips, pillar trims and related parts.
- Carpet.
- Seat belt assembly
- Door switch and wiring harness.
- Fuel pipe and brake oil pipe.
- Other related parts.
Note : Pull out and straighten the damaged area to approximately the original shape.
- Remove the related parts.
- Damage may extend to the inner roof frame, the
inner frame door opening and the floor. Determine
the extent of the damage first, so the frame can
be pulled out properly.
Note : Use heat-resistant protective cover for protect painting areas, seats, carpets and other parts.
- Pull out and straighten the damaged areas.
- Do not pull out more than necessary.
- Cut and pry off the frame door opening.
- Check the damage on the frame door opening, then
cut the new frame door opening so it will overlap
by 30mm(1.18in.) in the pillar, front and rear.
- Cut the damaged area with a hand saw along the
bold line as shown.
Note : Be careful not to cut the inner panel. This
could result in extensive repair.
- If the damage involves part of the center pillar, cut
them as shown.
- Center punch around the spot weld imprints on the
welded flange.
- Use the special spot cutter to drill holes at the
spot weld nuggets.
Note : When drilling holes be careful not to drill down
to the inner panel..
- Pry off the frame door opening panel with an air
chisel, leaving the welding flanges intact.
Caution : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grinding.
- Mold damaged related parts.
- Fill any holes drilled by welding.
Caution : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
- Use a hammer and dolly to mold damaged areas
of the remaining inner panel and even out the
welding flanges.
- Level and finish the burrs from the pried off spot
welds with disc sander.
- Sand off the paint and undercoat from both sides
of the flange to be welded.
- Set the new frame door opening.
- Grind both sides of the welding section of the prepared frame door opening part with a disk sander
to remove the paint and expose the steel plate.
- Clamp the new panel in place with the vise grips.
- Tack weld the clamped section for temporary installation.
Caution : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
- Remove the vise grips and temporarily install the
fender and doors, then check the clearances, level
differences and outer appearance.
- Perform the main welding.
- Weld the front, rear frame door opening and center pillar at the butt joints with a gas or MIG
welder.
- Spot weld the frame door opening and center
pillar as shown.
Caution : To prevent eye injury and burns when
welding, wear an approved welding helmet, gloves
and safety shoes.
- Perform a trial welding first, and check the welding condition.
- Increase the number of spot by 20% for areas to
be spot welded.
- Finish the welding areas.
- Level the gas or MIG welded areas with a disc
sander, then even out high areas with a hammer
being careful not to deform them.
Caution : To prevent eye injury, wear goggles or
safety glasses whenever sanding, cutting, or grinding.
- Use a hammer and dolly to even out the spot
welded flanges for a close fit with the surface of
the frame door opening panel.
- Fill in deformations and level differences of the
welded areas with solder or putty, then finish.
- Apply the sealer.
- Apply the sealer to the matching surfaces of the
floor and frame door opening.
- Apply the undercoat.
- Undercoat to the front floor.
- Apply the paint.
- CAUTION
- Ventilate when spraying paint. Most paint contains
substances that are harmful if inhaled or swallowed. Read the paint label before opening paint con
tainer.
- Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriate
clothing when painting.
- Paint is flammable. Store in a safe place, and
keep it away from sparks, flames or cigarettes.
- Coating the anti-rust agents.
- Coating the anti-rust agents to the inside of frame
door opening areas sufficiently.
- Install the related parts.
- Clean the passenger compartment.
- Wiring harness and related parts.
- Seat belt assembly and carpet.
- Trims and weather strips.
- Door and others.
- Install in the reverse order in which they were removed.
- Check and adjust.
- Check clearances and level differences.
- Check the door locking and unlocking condition.
- Check for water leaks in the passenger compartment.