Radiator Support: Service and Repair

Front Bulkhead

Removal

Mass production body welding position and number






Construction
- Replace the bulkhead upper center frame and side frame as an assembly.
- If necessary, replace the bulkhead side stay and bulkhead lower cross member.






Installation






1. Before setting the bulkhead upper frame, drill the 2-point spot welds (A) at the joint between the wheelhouse upper member (B) and wheelhouse upper inner (C) on one side.






2. Set the new bulkhead parts, and measure the front compartment diagonally.
3. Check the body dimensions.
- Engine compartment
- Front wheelhouse lower member position
- Engine compartment and front floor under view
- Repair chart, top view
- Repair chart, side view

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






7. Weld the bulkhead upper center frame (A) and side frame (B) to the bulkhead side stay (C).






8. Weld the bulkhead upper side frame (A) to the wheelhouse upper inner (B) and wheelhouse upper member (C).