Body Repair Manual

8. Perform the main welding.
• Weld as much as possible with the jig still mounted.
To prevent eye injury and burns
when welding, wear an approved welding helmet,
gloves and safety shoes.
• Make 20% to 30% more spot welds than there were
holes drilled.
2.5TL:
3.2TL:
9. Weld the wheelhouse upper rear member.
When the upper rear member is to be reused, make MIG
welds at the drilled holes.
2.5TL:
3.2TL:
10. Finish the welded area.
Use a hammer and dolly to even out the side bulkhead
and front side frame flanges for close fit with the surface
of the front wheelhouse and damper housing.
11. Apply the sealer (see section 5).
Apply sealer to the mating surfaces of the lower
dashboard and front side frame, etc.
12. Apply the paint.
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 flammable. Store it in a safe place, and
keep it away from sparks, flames or cigarettes.
13. Apply the undercoat.
Undercoat the front floor, etc, and apply anti-rust agent
to the inside of the welding section of the front side
frame, lower dashboard, and upper member, etc (see
section 7).
14. Install the related parts.
Install in the reverse order in which they were removed.
15. Inspect, check and make adjustment.
• Measure the front wheel alignment.
• Inspect the brake system.
• Adjust the headlight aim.
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