Body Repair ManualKalos FRONT

FRONT

FRONT PANEL

GENERAL DESCRIPTION

The front panel is joined to the front wheelhouse andfront longitudinal. It forms the base for the headlampsand other parts and maintains the rigidity of the frontsection of the body. Pay particular attention to twistsand parallelism and check mounting of related partswhen welding.

REPAIR PROCEDURE

Remove the related parts.

Hood, radiator grill and front bumper.
Head lamps and fender.
Engine, radiator and related parts.
Aircon condenser and related parts.
Others.

Roughly pull out and straighten the damaged area.

Check the damage to the front wheelhouse andfront longitudinal before removing the front panel.Use the frame straightener to roughly pull out andrepair the damaged front panel before removingthe front panel.

Note : Check the fit of the door, taking care not topull the damaged area out more than necessary.

Use the horizontal pinch weld clamps and attachthe car to the frame straightener at the clampingpoints securely.

Keep the body, level.

Jack up the body, and place safety stands at thefour designated places of the frame door opening.

Cut and pry off the front panel.

Center punch around the spot weld imprints.
Use the special spot cutter to drill holes at thespot weld nuggets on the front wheel house andlongitudinal.

Note : When drilling holes be careful not to drill downto the front wheelhouse and longitudinal themselves.

Cut off the front panel with an air chisel, leavingthe welding flanges intact.
Level and finish the burrs from the pried off spotwelds with disc sander.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grinding.

Mold damaged related parts.

Use a hammer and dolly to mold damaged areasof the front wheelhouse and longitudinal.
Even out the welding flanges with a hammer anddolly.
Fill any holes drilled by welding.

Set the front panel.

Grind both sides of the welding section of the frontpanel with a sander to remove the paint and expose the steel plate.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grinding.

Clamp both the right and left sides with the visegrips as shown.
Weld the clamped sections for temporary installation.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Note : Make sure that the right and left front panelsare in line with each others.

Measure the front compartment diagonally.

Measure the front compartment diagonally with atracking gauge or convex rule as shown to checkit for twisting or bending.
Temporarily assemble the fender, head lampsand hood, then check the clearances and leveldifferences.

Perform the main welding.

Spot weld the front panel as shown.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Perform a trial welding first, and check the weldng condition.
Increase the number of spot by 20% for areas tobe spot welded.

Finish the welding areas.

Use a hammer and dolly to even out the frontwheelhouse and longitudinal flanges for a closefit with the surface of the front panel.

Apply the undercoat.

Undercoat to the damaged areas of front wheelhouse and longitudinal if necessary.

Apply the paint.
CAUTION

Ventilate when spraying paint. Most paint containssubstances that are harmful if inhaled or swallowed.Rear the paint label before opening paint container.
Avoid contact with skin. Wear an approved respirator, gloves, eye protection and appropriateclothing when painting.
Paint is flammable. Store in a safe place, andkeep it away from sparks, flames or cigarettes.

Coating the anti-rust agents.

Coating the anti-rust agents to the end of frontpanel side and the door hinge areas.

Install the related parts.

Engine, radiator and related parts.
Aircon condenser and related parts.
Head lamps and fenders.
Hood, radiator grill, and bumper.
Others
Install in the reverse order in which they were removed.

Note : After install the all related parts, rub in greaseto the moving parts and replenish cooling liquid,break oil, 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, oil and liquid leaks.

Note : Use specified check sheet for operationcheck properly.

FRONT WHEELHOUSE

GENERAL DESCRIPTION

The front wheelhouse component is constructed as aunit with the locator shockabsorber. Therefore, replacement of the component affects the front wheel alignment.When assembling it, either use a jig or follow dimensions on the body repair chart for positioning. It mustbe welded carefully.

REPAIR PROCEDURE

Remove the related parts.

Parts on passenger side of dash panel lowerwhich are especially flammable.
Instrument panel, wiring harness, related partsand others.

Roughly pull out and straighten the damaged areato approximately the original shape.

Attach the car to the frame straightener by tightening the underbody clamps at the horizontalpinch weld points.
Before cutting off the damaged sections, pull themout so that they are restored to the original shape.
Do not pull out more than necessary.
Pull out and straighten the damaged areas of therear wheelhouse and dash panel lower, front filar and other parts.

Note : Check the condition of the door and hinges.

Remove the brace wheelhouse.

Center punch around the spot weld imprints.
Use the special spot cutter to drill holes at thespot weld nuggets on the brace wheelhouse.
Remove the MIG weld areas with a disc sander.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grinding.

Using a chisel, pry off the welded flange from thefront body puller and wheelhouse.

Peel off the undercoat and sealer.

Heat the undercoat and sealer at the weldingareas of the wheelhouse and longitudinal with agas torch and peel off the undercoat and sealerwith a steel spatula.

Cut and pry off the front wheelhouse.

Center punch around the spot weld imprints onthe longitudinal and rear wheelhouse.
Use the special spot cutter to drill holes at thespot weld nuggets on the center punched areas.
Cut off the front wheelhouse with an air chisel,leaving the welding flanges intact.
Level and finish the burrs from the pried off spotwelds with disc sander.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grindng.

NOTE :

If damage has occurred only front side, cut thedamaged section of the front wheelhouse, trimthe new panel to fit the remaining section, thenbutt weld both parts at the inner ends.

Mold damaged related parts.

Fill any holes drilled by welding.
Use a hammer and dolly to mold damaged areasof the front longitudinal, rear wheelhouse andother panels.
Even out the welding flanges with a hammer anddolly.

Set the new front wheelhouse panel.

Grind both sides of the welding section of thefront, rear wheelhouse and front longitudinal witha disc sander to remove the paint and exposethe steel plate.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grinding.

Clamp to the front longitudinal with vise grips andsquill vises.
Clamp the front panel with vise grips.

Note : Use of jigs is recommended.

Weld the clamped sections for temporary installation.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Measure the front compartment diagonally.

Measure the front compartment diagonally with atracking gauge or convex rule to check it for twisting or bending.
Temporarily assemble the fender and hood, thencheck the clearances and level differences.

Perform the main welding.

Weld as much as possible with the jig stillmounted.
Perform a trial welding first, and check the welding condition.
Perform the welding.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Increase the number of spot by 20% for areas tobe spot welded.

Apply the sealer tape.

Apply the sealer tape to the hinge and bracewheelhouse matching area as shown.

Weld the brace wheelhouse.

Spot weld the brace wheelhouse as shown.
Make MIG or gas welds at the door hinge areas.

Finish the welding areas.

Use a hammer and dolly to even out the rearwheelhouse and front longitudinal flanges for aclose fit with the surface of the front wheelhouse.

Apply the sealer

Apply the sealer to the matching and overlappedsurface.

Apply the undercoat.

Undercoat to the inside of the front, rear wheelhouse and longitudinal.

Apply the paint.
CAUTION

Ventilate when spraying paint. Most paint containssubstances 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 appropriateclothing when panting.
Paint is flammable. Store in a safe place, andkeep it away from sparks, flames or cigarettes.

Coating the anti-rust agents.

Coating the anti-rust agents to the end of frontpanel side and the door hinge areas.

Install the related parts.

Wiring harness, instrument panel and relatedparts.
Parts of the passenger compartment.
Parts to be installed when install the front panel.
Others.
Install in the reverse order in which they were removed..

Note : After install the all related parts, rub in greaseto the moving parts and replenish cooling liquid,break oil, aircon gas and others.

Check and adjust

Measure the front wheel alignment.
Check clearances and level differences.
Check the hood locking and unlocking condition.
Adjust the head lamp aim.
Check all operation.
Check for gas, oil and liquid leaks.

Note : Use specified check sheet for operationcheck properly.

FRONT LONGITUDINAL

GENERAL DESCRIPTION

The front longitudinal is joined to the wheelhouse andfront panel, it forms the base for the front suspension,engine, transmission and others. Therefore, replacement of the component affects the front wheel alignmentand maintains the rigidity of the front section. Whenassembling it, either use a jig or follow dimensions onthe body repair chart for positioning. It must be weldedcarefully.

REPAIR PROCEDURE

Remove the related parts.

Parts to be removed when removing the frontpanel and front wheelhouse.
Parts on passenger side of dash panel lower whichare especially flammable.
Instrument panel, wiring harness, related parts andothers.

Note : Remove according to part damaged.

Roughly pull out and straighten the damaged areato approximately the original shape.

Attach the car to the frame straightener by tightening the underbody clamps at the horizontalpinch weld points.
Before cutting off the damaged sections, pull themout so that they are restored to the original shape.
Roughly cut off the front longitudinal accordingto the extent of damage before roughly pulling outthe damage makes repair of the related partsdifficult.
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 weldingareas of the damaged parts with a gas torch andpeel off the undercoat and sealer with a steelspatula.

Caution : Be careful not to burn the fittings insidethe passenger compartment when heating.

Cut and pry off the front longitudinal.

Note : It's not necessary to separate the wheelhousefrom the front longitudinal if the wheelhouse is to bereplaced also.

Center punch around the spot weld imprints on thewheelhouse and other related parts.
Use the special spot cutter to drill holes at thespot 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 spotwelds with a disc sander.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grinding.

Mold damaged related parts.

Fill any holes drilled by welding.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Reshape the wheelhouse and other damagedparts and even out the welding flanges with ahammer and dolly.

Cut the new front longitudinal to align it with body,then set the wheelhouse and front panel.

Cut the new front longitudinal with a hand sawand it will be butt welded.
Grind both sides of the welding section of the frontlongitudinal and wheelhouse with a disc sanderto remove the paint and expose the steel plate.

Caution : To prevent eye injury, wear goggles orsafety 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 andsupport it, and measure the positions for correctsetting.
Set and clamp the front panel in place with thevise grips.

Note : Use of jigs is recommended for correct positions and check that the both front longitudinal andwheelhouse are parallel.

Tack weld the clamped section for temporary installation.

Perform the main welding.

Weld as much as possible with the jig stillmounted.
Make MIG or gas welds at the butt joints at thefront longitudinal, carefully.

Spot weld the wheelhouse with the front longitudinal flange areas and front panel.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Perform a trial welding first, and check the welding condition.
Increase the number of spot by 20% for areas tobe spot welded.

Level the weld beads at the longitudinal butt jointsarea with disc sander.
Make the stiffener(Thickness: 2.8 mm Min., Width:80 mm) according to the form of longitudinal buttjoint 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 discsander.
Use a hammer and dolly to even out the wheelhouse and longitudinal flanges for a close fit.

Apply the sealer.

Apply the sealer to the joint areas of the dashpanel lower and floor panel areas.

Apply the undercoat.

Undercoat to the joint and overlapped areas ofthe front floor, longitudinal under side and theinside of front, rear wheelhouse.

Apply the paint.
CAUTION

Ventilate when spraying paint. Most paint containssubstances 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 appropriateclothing when painting.
Paint is flammable. Store in a safe place, andkeep it away from sparks, flames or cigarettes.

Coating the anti-rust agents.

Coating the anti-rust agents to the end of frontpanel side and the front door hinge areas.

Install the related parts.

Clean the passenger compartment.
Wiring harness, instrument panel and relatedparts.
Parts of the passenger compartment.
Chassis components.
Engine, radiator and related parts.
Aircon condenser and related parts.
Head lamps and fenders.
Heed, radiator grill, and bumper.
Others.
Install in the reverse order in which they were removed.

Note : After install the all related parts, rub in greaseo the moving parts and replenish cooling liquid,break oil, 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, oil and liquid leaks.
Check for water leaks in the passenger compartment.

Note : Use specified check sheet for operationcheck properly.

SUPPORT CONTROL ARM

GENERAL DESCRIPTION

The support control arm is joined to the front longitudinal and crossmember dash lower center. I forms the base for the front suspension and is maintaining the rigidity of the front parts. Pay particular attention to the position and dimensions of the weld joints and weld carefully.

REPAIR PROCEDURE

Check the damaged areas.

Check the damaged parts and the extent of damage properly.
The support control arm receives impact throughthe front longitudinal.Such impact generally requires replacement of allthese parts.

Remove the related parts.

Front seats.
Trims and carpet.
Wiring harness and others.
Parts to be removed when removing the frontlongitudinal.

Note : Remove according to part damaged.

Pull out and straighten the damaged area to approximately the original shape.

Note : Use heat-resistant protective cover for protect painting areas, seats, carpets and other parts.

Before cutting off the damaged parts, pull out thedamaged area with the frame straightener andcorrect the related parts such as the crossmember front floor panel and front floor panel.
Do not pull out more than necessary.
Check the clearance and level difference of thefront doors.
Jack up the body and place safety stands at thefour designated places of the frame door opening. If necessary, place safety stands at the rearof frame.

Peel off the undercoat, sealer and deadner.

Heat the undercoat and sealer at the welding areas of the longitudinal, cross member front floorpanel and front floor panel with a gas torch andpeel off the under with a steel spatula.
Peel off the deabner at the surface or front floor.

Caution : Be careful not to burn the fittings insideof the passenger compartment when heating.

Cut and pry off the support control arm.

Center punch around the spot weld imprints on thesupport control arm.
Use the special spot cutter to drill holes at thespot weld nuggets on the center punch areas.

Note : When drilling holes be careful not to drill downto the crossmember front floor panel and other remaining parts.

Cut and pry off the support control arm with anair chisel, leaving the welding flanges intact.
Level and finish the burrs from the drilled holesand pried off spot welds with disc sander.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grinding.

Note : Check again the extent of damage and crack.

Mold damaged related parts.

Reshape the dash panel lower, crossmemberfront floor panel and other related parts with ahammer and dolly.
Even out the welding areas with a hammer anddolly.
Fill any holes drilled by welding.

Set the new support control arm.

Preset the new support control arm at the position and marked welding position and will bewelded by MIG plug welding.
Increase the number of plug welding by 20%.
Drill holes through the marked position with a 5mm drill for MIG plug welding.

Grind both sides of the welding section of the support control arm and the matching surface of partswith a disk sander to remove the paint and expose the steel plate.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grinding.

Set the support control arm in place using a jackand clamp with the vise grips.

Note : Use of jigs is recommended for correct positions.

Check the clearance and even out the flanges forwith a hammer and dolly.

Perform the main welding.

Plug weld the holes of support control arm with aMIG welder.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Finish the welding areas.

Level the plug welded areas with a disc sander.

Apply the sealer.

Apply the sealer to the inside of passenger compartment joint areas.

Apply the undercoat.

Undercoat to the surface of front floor,crossmember front floor, support control arm andothers.

Apply the paint.
CAUTION

Ventilate when spraying paint. Most paint containssubstances that are harmful if inhaled or swallowed.Read the paint label before opening paint container.
Avoid contact with skin. Wear an approved resirator, gloves, eye protection and appropriateclothing when painting.
Paint is flammable. Store in a safe place, andkeep it away from sparks, flames or cigarettes.

Apply the deadner.

Clean the passenger compartment.
Apply the deadner to the surface of floor panel.

Install the related parts.

Clean the passenger compartment.
Wiring harness and related parts.
Parts of the passenger compartment.
Chassis components.
Parts of the front compartment.
Hood, radiator grill, and bumper.
Other.
Install in the reverse order in which they were removed.

Note : After install the all related parts, rub in greaseto the moving parts and replenish cooling liquid,break oil, aircon gas and others.

Check and adjust

Measure the front wheel alignment.
Check clearances and level differences.
Check the hood locking and unlocking condition.
Adjust the head lamp aim.
Check all operation.
Check for gas, oil and liquid leaks.
Check for water leaks in the passenger compartment.

Note : Use specified check sheet for operationcheck properly.

FRONT PILLAR

GENERAL DESCRIPTION

The front pillar area is part of the frame door openingpanel. It's connected to the roof, windshield, door hingesand floor frame and is important as a support for thefront side of the cabin. Connection of the front pillardetermines the position of the windshield and front door.Align the fender, door and windshield while the frontpillar is temporary mounted, and check the clearancesand level differences.

REPAIR PROCEDURE

Remove the related parts.

Hood, radiator grill and front bumper.
Door and fender.
Wiper, cowl and windshield.
Weatherstrip and pillar trims.
Instrument panel and wiring harness.
Carpet and others.

Roughly pull out and straighten the damaged area.

Check the damage to the wheelhouse and roofbefore removing the brace wheelhouse and frontpillar and determine the extent of the damage.
Use the frame straightener to roughly pull out andrepair the damaged front pillar before removingthe brace wheelhouse and front panel.

Note : Pull out until the pillar is lined up with thesurface of the windshield and do not pull out morethan necessary.

Remove the brace wheelhouse.

Center punch around the spot weld imprints.
Use the special spot cutter to drill holes at thespot weld nuggets on the brace wheelhouse.
Remove the MIG weld areas with a disc sander.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grind-ing.

Using a chisel, pry off the welded flange from thefront body pillar and wheelhouse.

Peel off the undercoat and sealer.

Heat the undercoat and sealer at the weldingareas of the wheelhouse and longitudinal with agas torch and peel off the undercoat and sealerwith a steel spatula.

Cut and pry off the front pillar.

Cut off the front pillar along the bold lines asshown in the figure below with a handsaw andsnips carefully.

Note : Be careful not to cut the inner section.

Center punch around the spot weld imprints withthe rear wheelhouse, front body pillar inner, rein-forcement front body pillar inner and floor panelside.
Use the special spot cutter to drill holes at thespot weld nuggets on the front pillar.

Note : When drilling holes be careful not to drill downto the front body pillar inner, reinforcement front bodypillar inner and floor panel side themselves.

Pry off the remaining flanges from the body withan air chisel and leaving the welding flanges.
Level and finish the burrs from the pried off spotwelds with a hammer, dolly and disc sander.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding, cutting, or grind-ing.

Mold damaged related parts.

Fill any holes drilled by welding.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Use a hammer and dolly to mold damaged areasof the remaining inner panel and even out thewelding flanges.

Set the new front pillar.

Align the new part with the top section, then cutit with a hand saw.
Cut the floor panel side joint area so it will overlap by 30mm(1.18in.) in the floor panel side witha hand saw.
Grind both sides of the welding section with a disksander to remove the paint and expose the steelplate.
Clamp the new panel in place with the vise grips.
Tack weld the clamped section for temporary installation.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Remove the vise grips and temporarily install thefender and doors, then check the clearances,level differences and outer appearance.

Perform the main welding.

Weld the frame door opening area and pillar atthe butt joints with a gas or MIG welder.
Spot weld the flanges of the front pillar as shown.

Caution : To prevent eye injury and burns whenwelding, wear an approved welding helmet, glovesand safety shoes.

Perform a trial welding first, and check the welding condition.
Increase the number of spot by 20% for areas tobe spot welded.

Finish the welding areas.

Level the gas or MIG welded areas with a discsander, then even out high areas with a hammerbeing careful not to deform them.

Caution : To prevent eye injury, wear goggles orsafety glasses whenever sanding cutting or grinding.

Use a hammer and dolly to even out the spot weldedflanges for a close fit with the surface of the innerpanel.
Fill in deformations and level differences of thewelded areas with solder or putty, then finish.

Apply the sealer tape.

Apply the sealer tape to the hinge and bracewheelhouse matching area as shown.

Weld the brace wheelhouse.

Spot weld the brace wheelhouse as shown.
Make MIG or gas welds at the door hinge areas.

Finish the welding areas.

Use a hammer and dolly to even out the bracewheelhouse for a close fit with the surface of thewheelhouse.

Apply the sealer.

Apply the sealer to the matching and overlappedsurface.

Apply the undercoat.

Undercoat to the inside of the front, rear wheelhouse and longitudinal.

Apply the paint.
CAUTION

Ventilate when spraying paint. Most paint containssubstances 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 appropriateclothing when painting.
Paint is flammable. Store in a safe place, andkeep it away from sparks, flames or cigarettes.

Coating the anti-rust agents.

Coating the anti-rust agents to the end of frontpanel side and the door hinge areas.

Install the related parts.

Clean the passenger compartment.
Windshield, cowl and wiper.
Wiring harness, instrument panel and relatedparts.
Carpet, trims and weatherstrip.
Door
Fender and hood.
Radiator grill, bumper and others.
Install in the reverse order in which they were removed.

Check and adjust.

Check the door for proper installation and operation.
Check clearances and level differences.
Check the hood locking and unlocking condition.
Check all operation.
Check for water leaks in the passenger compartment.

Note : Use specified check sheet for operationcheck properly.