REPLACING FRONT END ASSEMBLY Read "Introduction"! Remove engine hood, both side panels, radiator, engine with transmission and front axle assembly, battery, engine oil cooler, exhaust system, propeller shaft, brake lines and fuel lines in engine compartment, relay/fuse carrier and wire harness, speedometer shaft, pedal assembly base, ignition coil, windshield washer tank, power steering tank, windshield, instrument panel trim, front bumper, all radiator grill sections, both double headlights, both horns, windshield wipers, rain moldings, engine hood locks, carpet in passenger compartment and noise insulation on engine firewall. Check and adjust front and rear axle alignment. Bleed brakes and clutch. Adjust engine idle speed and fuel/air mixture. Aim headlights. Stamp chassis number and transfer data plate. | |
Cut off front end along line. |  |
Cut off front end along line. |  |
Drill out welding spots from wheel house remainder. |  |
Remove scrap metal. |  |
Remove scrap metal. |  |
Make cuts in engine carrier. Distance A = 190 mm (7.480´´) Distance B = 225 mm (8.858´´) |  |
Take off insulation sheet and drill out welding spots from engine carrier. Distance C = 320 mm (12.598´´) Distance D = 280 mm (11.024´´) |  |
Grind off welding seams and remove section of engine carrier. |  |
Align mating surfaces and grind bright on both sides. |  |
Align mating surfaces and grind bright on both sides. |  |
Cut off approx. 120 mm (4.724´´) from removed section of engine carrier and prepare as a reinforcement. |  |
Cut apart U-section member and cut off piece equalling twice thickness of sheet metal. Position U-section member in new engine carrier and tack weld. |  |
Cut off engine carrier from new front end custom fit. Distance A = 190 mm (7.480´´) Distance B = 225 mm (8.858´´) |  |
Use 8 mm (0.315´´) dia. drill bit to drill 3 holes from each side and 1 hole from bottom in area of reinforcement. |  |
Grind mating surfaces on new front end bright from both sides. |  |
Prepare engine carrier section not removed. Use 8 mm (0.315´´) dia. drill bit to drill 3 holes from each side and 1 hole from bottom in area of reinforcement. |  |
Push in reinforcing U-section members in remaining section of engine carrier by approx. 60 mm (2 3/8´´) and inert gas plug weld. |  |
Mount body on straightening bench. |  |
Tack weld front end to body. Bolt attachments for spring struts and front axle to straightening bench and front end. |  |
Tack weld wheel housings to firewall. |  |
Tack weld engine carrier. |  |
Inert gas plug weld engine carrier and wheel housings to floor plate and firewall. |  |
Inert gas weld and inert gas plug weld engine carrier. |  |
Inert gas weld wheel housings to firewall. |  |
Braze guide tube for engine hood cable. Inert gas weld heater wall to wheel housings. |  |
Inert gas weld heater wall and wheel housings. |  |
Drill holes in wheel house outer panels for inert gas welding. |  |
Inert gas plug weld wheel house outer panels. Grind down all welding seams and coat with zinc dust paint. |  |
Coat wheel house/firewall joint with special sealant for joints. |  |
Coat wheel house/firewall joint with special sealant for joints. |  |
Coat spring strut shell with special sealant for joints. |  |
Coat wheel house/firewall joint with special sealant for joints. |  |
Coat wheel house joint with special sealant for joints. |  |
Coat engine carrier/floor plate joint with special sealant for joints. Spray an anti-drumming agent on all joints and wheel housings. |  |
Vehicles after change point in 1982 REPLACING COMPLETE FRONT END Refer to information on page 41 - 001. Remove engine hood, both side panels, radiator, engine complete with transmission and front axle, battery, engine oil cooler, exhaust assembly, propeller shaft, brake lines and fuel lines in engine compartment, central electric board and wire harness, speedometer drive cable, pedal assembly base, ignition coil, washing fluid tank, power steering tank, complete windshield, instrument panel trim, complete front bumper, all radiator grill sections, both double headlights, both horns, windshield wipers, rain molding strips, engine hood locks, carpet in passenger compartment and insulation sheet on engine compartment wall. Checking and adjusting front and rear wheel alignment. Bleeding brakes and clutch. Adjusting engine idle speed and fuel/air mixture. Aiming headlights. Die stamping chassis number and transfering data plate. | |
Cut off front end along line. | |
Cut off front end along line. | |
Drill off welding spots on remaining wheel house panel. | |
Remove scrap metal. | |
Remove scrap metal. | |
Cut into engine carrier. Distance A = 190 mm (7.480´´) Distance B = 225 mm (8.858´´) | |
Loosen insulation plate and drill off welding spots on engine carrier. Distance C = 320 mm (12.598´´) Distance D = 280 mm (11.024´´) | |
Grind off welding seams and remove piece of engine carrier. | |
Straighten and grind both sides of mating surfaces. | |
Straighten and grind both sides of mating surfaces. | |
Cut off approx. 120 mm (4.724´´) from cut out piece of engine carrier and prepare as reinforcement panel. | |
Cut U-section apart and cut off twice the sheet metal thickness. Place and tack weld U-section in new engine carrier. | |
Cut off engine carrier from new front end to size. Distance A = 190 mm (7.480´´) Distance B = 225 mm (8.858´´) | |
Drill three holes from each side in area of reinforcement and one hole from below. Hole dia. = 8 mm (0.315´´). | |
Grind both sides of mating surfaces on new front end. | |
Prepare old piece of engine carrier. Drill three holes from each side in area of reinforcement panel and one hole form below. Hole dia. = 8 mm (0.315´´). | |
Slide reinforcement U-section into old piece of engine carrier approx. 60 mm (2.362´´) and inert gas plug weld. | |
Set up body on straightening bench. | |
Tack weld front end on body. Bolt attachments for spring struts and front axle on straightening bench and front end. | |
Tack weld wheel houses on firewall. | |
Tack weld engine carrier. | |
Inert gas plug weld engine carrier and wheel houses on floor plate and firewall. | |
Inert gas weld and inert gas plug weld engine carrier. | |
Inert gas weld wheel houses on firewall. | |
Braze guide tube for engine hood cable. Inert gas weld heater wall on wheel houses. | |
Inert gas weld heater wall and wheel houses. | |
Drill holes in wheel house outside panels for inert gas plug welding. | |
Inert gas plug weld wheel house outside panels. Grind down and coat all welding seams with zinc dust paint. | |
Coat wheel house/firewall joint with joint sealing compound. | |
Coat wheel house/firewall joint with joint sealing compound. | |
Coat spring strut shell jooint with joint sealing compound. | |
Coat wheel house/firewall joint with joint sealing compound. | |
Coat wheel house joint with joint sealing compound. | |
Coat engine carrier/floor plate joint wiht joint sealing compound. | |
Spray anti-drumming compound on all joints and wheel houses. |  |
