## Replacement

#### Installation

2-9

4. Check the tack weld at positions of the new parts.

- Clamp the new part and check the position of it using the body dimensional drawings (see section 4).
- Tack weld the clamped section.

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

5. Check the alignment of the exterior body parts.

- Temporary install the exterior body parts, windshield and rear window glass, and check for differences in level and clearances.

NOTE: Check the fit of the front fender, door and the rear fender, and make sure the body lines flow smoothly.

6. Main weld the repair parts.

- Use proper welding methods (see pages 2-17, 2-18, 2-19, 2-20).

WARNING 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.
- A new welding position should avoid an old position as much as possible.

NOTE: If there is not room for spot welds, compensate by using MIG welds

- The electric continuity property of zinc-plated steel plate is different from ordinary steel plate. When spot welding, increase the current by 10-20%, or increase the resistance welding line.

- Fillet weld the repair outer side sill it will overlap by 30 mm (1.2 in.) in the front and back.
- Butt weld the front pillar, centre pillar, rear pillar and the wheel arch cut sections of the repaired outer panel.

NOTE: Attach the patches at the cut sections of the outer panel and plug weld them.

1. BUTT WELD
2. PATCH
3. FILLET WELD