NOTE: The front side member section is cut from the front side member service panel.
NOTE: The right section is slightly shorter than the left due to the location of the engine mount.
NOTE: Due to the combined panel thicknesses, it is recommended that spot welds be replaced with MIG welds when performing this repair.
1. When replacing the front side member section, the following elements are removed:
- Front bumper trim
- Front bumper mount
- Hood Latch Panel
- Both front wings
- Front bumper support
NOTE: It is also necessary to remove the engine and suspension as a single unit.
2. For additional information on this repair procedure, refer to the following sources: For additional information, refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation) / Standard Service Station Techniques (100-00 General Information, Description and Operation).
3. Remove the front bumper support. For more information, refer to the chapter: Front Bumper Fastening (501-27 Front Sheet Metal Repairs, Removal and Installation).
4. Remove the radiator cooling unit. For additional information, refer to the chapter: Radiator (303-03A Engine Cooling - 3.2L NA - I6, Removal and Installation).
5. Remove the engine and front suspension as a single unit.
6. Left side: Remove the air intake pipe.
7. Left side: Release the battery junction box and place it aside.
8. Right side: Remove the windshield washer reservoir. For more information, refer to the chapter: Windshield washer reservoir (501-16 Windscreen wipers and washers, Removal and installation).
9. Release the wiring harness and set it aside.
10. Mill out the contact welding areas.
11. Cut off the old panel at the location shown.
12. Separate the connections and remove the old panel.
Installation
1. Cut a new section from the service panel; the cut should be aligned with the cut on the old panel.
2. Prepare the mating surfaces of the old and new panels.
3. Drill holes in the new panel in preparation for MIG welding.
4. Position the new panel in the desired location and secure it in place. Check the alignment. If it is correct, proceed to the next step. If not, make the necessary adjustments and recheck before continuing.
5. After fixing the panels:
- 1. Make tack welds for the butt joint.
- 2. Perform electric rivet welding using MIG technology.
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6. Clean the tack welds.
7. Perform butt welding using MIG technology.
8. Clean all welds.
9. Installation of the relevant panels and mechanical elements is carried out in the reverse order of removal.
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