Cowl: Service and Repair

Removal




Cut and remove the front bulkhead side frame assembly.




- Drill holes completely through the parts since the replacement front bulkhead-side frame assembly will be attached by plug welding.




- Cut and pry off the front side outrigger and grind the fillet welds of the front inner lower pillar and front side outrigger.

NOTE: Be careful not to damage the front inner lower pillar.

Installation




1. Drill the plug weld holes in the new front side outrigger for welding the front inner lower pillar.
2. Set the new front bulkhead-side frame assembly into position, and check the body dimensions.
3. Tack weld the clamped position.
4. Temporarily install the front fender, hood, and door, and check for differences in level and clearance.

5. Perform the main welding.




- Weld the damper housing, dashboard lower, and outrigger to the dashboard upper and front inner lower pillar.




- Weld the the front side outrigger to the inner lower pillar and inside sill.




- Weld the tunnel frame and front floor frame.




- Weld the dashboard lower and front floor.







- Weld the dashboard lower and dashboard upper.