Strut Housing: Service and Repair

Front Wheelhouse/Damper Housing

Removal

Mass production body welding positions and numbers







Construction

NOTE:
- This section explains the procedures after removal of all related parts. For the related parts' removal procedure.
- The component replacement procedure described here refers to recyclable parts removed from damaged units. Therefore, this procedure differs from that where off-the-shelf. repair parts are installed.
- Remove the wheelhouse upper member, and replace the bulkhead side member and the front wheelhouse.
- Check the damper housing position for damage.
- If necessary, replace the damper housing and the wheelhouse extension as an assembly.
- Peel back the inner lower pillar, shown in [DETAIL Z]; drill two welded points at the joints for the wheelhouse extension and the dashboard upper.







Installation







1. Clamp the new damper housing, the front wheelhouse, the bulkhead side member, the front end outrigger, and the front bulkhead, and measure the front compartment diagonally.
2. Check the body dimensions.
- Engine compartment
- Engine side mount position
- Bulkhead side member position
- Engine compartment and front floor, under view
- Repair chart, top view
- Repair chart, side view

3. Tack weld the new parts and the front bulkhead into position.
4. Temporarily install the front subframe, and check the front side frame position.
5. Temporarily install the front fender, the hood, and the door, then check for differences in level and clearance.
Check the external parts fitting positions. If necessary, check the headlight and the front bumper positions. Make sure the body lines flow smoothly.
6. Do the main welding.
Weld the damper housing (A) and the wheelhouse lower gusset (B) to the front side frame (C).







7. Weld the damper base (A), the wheelhouse extension (B), the housing bracket (C), the wheelhouse upper gusset (D), and the wheelhouse middle gusset (E) to the dashboard upper (F).







8. Weld the damper housing extension (A) and the dashboard lower (B).







9. From the passenger's compartment, plug weld the holes in the dashboard lower (A) to the damper housing (B) and the wheelhouse lower gusset (C).







10. Weld the front inner lower pillar (A).







11. Weld the front wheelhouse (A) to the front side frame (B), the bulkhead side member (C), and the bulkhead upper frame (D).







12. Weld the front end outrigger (A).







13. Weld the wheelhouse upper member (A).