- Remove the related parts.
- Parts to be removed when removing the front panel and apron panel.
- Parts on passenger side of dash panel which are especially flammable.
- Instrument panel, wiring harness, related parts and others.
Note : Remove according to part damaged.
- Roughly pull out and straighten the damaged area to approximately the original shape.
- Attach the car to the frame straightener by tightening the underbody clamps at the horizontal pinch weld points.
- Before cutting off the damaged sections, pull them out so that they are restored to the original shape.
- Roughly cut off the front longitudinal according to the extent of damage before roughly pulling out the damage makes repair of the related parts difficult.
- Do not pull out more than necessary.
Note : Check the condition of the door and hinges.
- Peel off the undercoat and sealer.
- Heat the undercoat and sealer at the welding areas of the damaged parts with a gas torch and peel off the undercoat and sealer with a steel spatula.
Caution : Be careful not to burn the fittings inside the passenger compartment when heating.
- Cut and pry off the front longitudinal.
Note : It's not necessary to separate the apron panel from the front longitudinal if the apron panel is to be replaced also.
- Center punch around the spot weld imprints on the apron panel and other related parts.
- Use the special spot cutter to drill holes at the spot weld nuggets on the center punched areas.
- Cut off the front longitudinal with an air chisel, leaving the welding flanges intact.
- Level and finish the burrs from the pried off spot welds with a disc sander.
Caution : To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting, or grinding.
- Mold damaged related parts.


- Fill any holes drilled by welding.
Caution : To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.
- Reshape the apron panel and other damaged parts and even out the welding flanges with a hammer and dolly.


- Cut the new front longitudinal to align it with body, then set the apron panel and front panel.
- Cut the new front longitudinal with a hand saw and it will be butt welded.
- Grind both sides of the welding section of the front longitudinal and apron panel with a disc sander to remove the paint and expose the steel plate.
Caution : To prevent eye injury, wear goggles or safety glasses whenever sanding, cutting, or grinding.
- Tighten the new front longitudinal against remaining parts with the vise grips and pliers.
- Place a jack under the front longitudinal end and support it, and measure the positions for correct setting.
- Set and clamp the front panel in place with the vise grips.
Note : Use of jigs is recommended for correct positions and check that the both front longitudinal and apron panel are parallel.
- Tack weld the clamped section for temporary installation.
- Perform the main welding.
- Weld as much as possible with the jig still mounted.
- Make MIG or gas welds at the butt joints at the front longitudinal, carefully.
- Spot weld the apron panel with the front longitudinal flange areas and front panel.
Caution : To prevent eye injury and burns when welding, wear an approved welding helmet, gloves and safety shoes.
- Perform a trial welding first, and check the welding condition.
- Increase the number of spot by 20% for areas to be spot welded.
- Level the weld beads at the longitudinal butt joints area with disc sander.
- Make the stiffener according to the form of longitudinal butt joint areas and weld the stiffener at the longitudinal butt joint areas with MIG welder.


- Finish the welding areas.
- Level the gas or MIG welded areas with disc sander.
- Use a hammer and dolly to even out the apron panel and longitudinal flanges for a close fit.
- Apply the sealer.
- Apply the sealer to the joint areas of the dash panel and floor panel areas.
- Apply the undercoat.
- Undercoat to the joint and overlapped areas of the front floor, longitudinal underside and the inside of apron panel.
- Apply the paint.
Caution :
- Ventilate when spraying paint. Most paint contains substances that are harmful if inhaled or swallowed.
- Read the paint label before opening paint container.
- Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriate clothing when painting.
- Paint is flammable. Store in a safe place, and keep it away from sparks, flames or cigarettes.
- Install the related parts.
- Clean the passenger compartment.
- Wiring harness, instrument panel and related parts.
- Parts of the passenger compartment.
- Chassis components.
- Engine, radiator and related parts.
- Aircon condenser and related parts.
- Head lamps and fenders.
- Hood and bumper.
- Others.
- Install in the reverse order in which they were removed.
Note : After install the all related parts, rub in grease to the moving parts and replenish coolant, brake fluid, aircon gas and others.
- Check and adjust
- Check clearances and level differences.
- Check the hood locking and unlocking condition.
- Adjust the head lamp aim.
- Check all operation.
- Check for gas and fluid leaks.
- Check for water leaks in the passenger compartment.
Note : Use specified check sheet for operation check properly.