Body Repair Manual

Front wheelhouse/Damper housing
Replacement (cont'd)
5. Mold the related parts.
• Level and finish the burrs left on the welding
surfaces with a sander.
• Fill all drilled holes by MIG or gas welding.
Use a hammer and dolly to even out the welded areas of
the lower dashboard, front side frame and dashboard
upper side member.
2.5TL:
3.2TL:
WHEELHOUSE UPPER
MEMBER DIAGONAL
WHEELHOUSE
UPPER
EXTENSION
FRONT SIDE FRAME
DASHBOARD UPPER
SIDE MEMBER
DASHBOARD LOWER
DAMPER STIFFENER
FRONT SIDE FRAME
6. Set the new front wheelhouse and damper housing.
• Apply body paint to both sides of the new front
wheelhouse and damper housing.
• See Paint Repair section.
• Ventilate when spraying paint. Most paint
contains substances that are harmful if inhaled
or swallowed. Read the paint label before
opening the paint container.
• Avoid contact with skin. Wear an approved
respirator, gloves, eye protection and appropriate
clothing when painting.
• Paint is flammble. Store it in a safe place, and
keep it away from sparks, flames or cigarettes.
• Remove the undercoat from both sides of the weld-
ing section and expose the steel plate using a disc
sander.
To prevent eye injury, wear goggles
or safety glasses whenever sanding, cutting or
grinding.
• Clamp to the front side frame with vise-grips and
squill vises.
NOTE: Apply the spot sealer to the welding surface
when spot welding.
• Clamp the front bulkhead with vise-grips.
• Measure the front compartment diagonally.
NOTE: Use of a positioning jig is recommended (see
page 1-7).
POSITIONING JIG
• Spot weld several points in the clamped sections, and
temporarily attach the front wheelhouse and damper
housing.
To prevent eye injury and burns
when welding, wear an approved welding helmet,
gloves and safety shoes.
7. Check the dimensions, temporarily install the hood, front
fender and headlight, and check for differences in level
and clearance.
DAMPER
HOUSING
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