To keep you abreast of the latest repair bps and procedures, here are technical service bulletins from carmakers, paint companies and equipment manufacturers.
Some 1987-95 Nissan Pathfinders equipped with V6 engines and fourwheel drive may develop a rust perforation in the floor near the gas pedal. To remedy this problem, Nissan has developed a service procedure that involves replacing the floor sheet metal and installing a different front exhaust pipe.
The first step in the repair is to measure and record the vehicle's front ride height, referring to the appropriate service manual.You will need this as a reference when you reinstall the torsion bar. Next, put the vehicle on a hoist and remove the left side torsion bar, catalytic converter and front propeller shaft. If the vehicle has an automatic transmission, remove the right torsion bar as well. These need to be removed so the new exhaust tube can be installed. Removing them also provides more clearance for the floor repair procedure. (Note: Throughout the procedure, be sure to wear appropriate safety gear, including safety glasses, ear plugs, a respirator and gloves.)
Now support the transmission assembly with the appropriate jack, and take the transmission crossmember off. Remove the O2 sensor, followed by the right and front exhaust tubes-right exhaust manifold flange to catalytic converter flange as an assembly. Reinstall the transmission crossmember now so it is supported during the next several steps. (Caution: Do not allow the weight of the transmission to be supported by the driveshaft resting on the torsion bar crossmember. This can bend the driveshaft.)
Now remove the driver's side front seat assembly and center console, followed by:
* the negative battery cable from the negative battery terminal;
* the kick plate;
* remote glass door/rear hatch lever;
* door weatherstrip;
* dash side trim;
* front floor carpet assembly;
* rear floor heater duct, if applicable;
* body mount flange cover and bolt.
After all of these components are removed, move the wiring harness out of the repair area. Inspect the corroded area and then clean the area to be cut-this includes removing the floor insulation. Ensure that the original spot welds are visible, and draw a chalk outline around the area to be removed (See Fig. 1.), leaving as much of the original sheet metal as possible.
To prepare for the next step, cover all interior panels, the door panel and the wiring harness to protect them from sparks. Now drill out any spot welds located in the material being replaced and cut out the corroded area (See Fig. 2).
From the new body pieces, cut out a panel to patch the opening (See Fig. 3). The cut panel should be 3/4 in. (20 nun) wider than the opening. Flange the edges, and stamp or drill plug-weld holes in the new panel at 15-mm intervals for MIG welding. Using a nylon abrasive pad, wire brush or similar tool, remove all paint, the E-coat and the undercoating along the edges of the opening and the replacement panel. Clean both sides of both panels a minimum of 2 in. from the edge. Next, straighten all mating edges and apply a conductive, anti-corrosive weld-through primer to the floor and new body panel.
Now, check the fit of the new part carefully inside the vehicle (See Fig. 4). Make sure the edges of the new panel match to the metal of the original body with a tight, solid fit and that the frame bolt hole aligns with the hole in the body mount flange. Using a MIG welder, plugweld the replacement panel to the floor (See Fig. 5).
If the lower dash panel is being replaced, include the following steps:
* Remove the left front tire.
* Remove the inner fender liner.
* MIG-weld the panel from the inside of the wheel housing. This will give better structural strength
* Replace removed components after priming and undercoating.
Now, drill two 1/4-in. (7-mm) holes in the floor. Use Fig. 6 as a guide for installing the heat insulator stud bolts. From the interior, install the two stud bolts through the two drilled holes.Weld the bolts to the floor pan-two spots per bolt-using a seam weld. Then remove excess weld metal or slag with a grinder. Install the body mount flange bolt.
Mask off the vehicle-including the stud bolts-to prepare for painting. Apply primer surfacer (DuPont P/N 215S or equivalent) to the repaired area-interior and exterior. Also apply this to the stud bolt holes. Now install the body mount flange bolt plastic cover.
Once the primer dries, apply sealer (Nissan recommends Lord Corp.'s Fusor Urethane sealant P/N 800 or equivalent) to all edges of the repair. (See Fig. 7) After this dries, apply undercoating to the repaired area. Nissan suggests using 3M Rubberized Undercoating P/N 05113508883. Allow the undercoat to dry, and then apply bitumen wax to the repaired underbody area, using only Tectyl 517 Bitumen Wax, Nissan P/N 999MP-9G001.
Now install the new underbody heat shield (See Fig. 8). Apply a sound-deadening material, such as Q-pad or 3M silencer strips P/N 051135-08585, to the repair area (See Fig. 9). Reinstall the vehicle harness, carpeting, driver's seat, center console and all other trim.
Next, support the transmission and remove the crossmember again. Using the "Pathfinder Parts Information" chart, locate the proper part number, install the new front exhaust tube and heat shield assembly and the existing catalytic converter. Following this, install the front propeller shaft, the transmission crossmember, the O2 sensor, torsion bar assembly and torsion bar member. Now adjust the ride height using the procedure and specifications from the service manual. (Caution: Failure to set the proper ride height can result in accelerated tire wear) Reconnect the negative battery cable, and finish the repair by checking the exhaust system for leaks.
If this repair is completed under warranty, Nissan allows 9.8 hours of labor time.
VW Molding Adherence Advice
If the body side molding on 1994-99 Volkswagen Golfs,jettas and Cabrios does not adhere after it's replaced, the problem could be caused by incorrect installation procedures.
Models manufactured before October 1994 featured injection molded-black with fastening clips-body side moldings, Beginning in November, the side moldings were an extruded design.
When installing these extruded moldings, follow these steps:
* Ensure that the working temperature is about 68 deg F (20 deg C).
* Clean exterior panels with isopropyl alcohol, treat with silicone remover and then rub dry.
* If necessary, warm the molding and body surface with a hot air blower before installing. The materials should be warm to the touch.
* Pull the protective foil from the back of the molding and attach molding lightly.
* Press the molding on evenly using a roller. Apply about 10 lbs. of rolling pressure. One complete pass is required for each adhesive strip on the molding.
* Wait at least 24 hours before taking the vehicle through a car wash.
Bonneville Door Tdm Removal Hints
Pontiac is providing technicians with door trim removal procedures and door water deflector installation steps for the 2000 Bonneville.
To remove the trim on the front and rear doors, follow these steps:
* Remove the door handle bezel by prying outboard on the front and then pulling forward to remove the bezel.
* Remove the front side door upper trim (mirror patch) using the J 3877 8 door trim pad and garnish clip. The bezel is attached with one retainer.
* Using the J 38778, disengage all of the push-in retainers and then remove them. Pull upward to remove the trim panel.
* Use needle-nose pliers to remove two spring clips from the metal bracket on the door trim pad.
* Reinsert the spring clips in the plastic retainers on the inner door panel with the flat side of the spring clip facing upward.
* Hold the top of the trim pad away from the top of the door. Align the three lower push pins in the door retainers.
* With all of the pins aligned, set the three lower pins. This automatically aligns the metal clips to the plastic retainers.
* Set all of the remaining clips.
* Push the top of the trim pad outward to set it. This engages the top of the trim pad over the inner belt retaining flange.
* Install the door handle bezel and the front side door upper trim (mirror patch).
When service is required to the vehicle's water deflector, which directs water away from the inner panel, make sure it is re-installed properly.The correct installation steps for front and rear doors are:
* Install the inner water deflector after the glass but before the inner belt seal.
* Insert the deflector through the belt line. It must be inboard of the door glass.
* Position the deflector against the mirror patch.
* Fold the perforated portion of the deflector over the inner belt retaining flange. Press on it to secure it.
Whenever service procedures require the water deflector to be "disturbed," the piece must be properly resealed to the door panel to prevent water leaks. To reseal the piece, clean the door surface around the perimeter of the water deflector with one of these cleaners or an equivalent product: 3M General Purpose Adhesive Cleaner; Dominion Sure Seal Sure Solve Stock BSS; Kent Acrysol.
Next, use a 2 in. wallpaper roller to roll out the butyl adhesive. (Note: The door surface must be at room temperature,) Now, start at the bottom center and work outboard up the right and left sides.
Prevent Buick Mirror Breakage
During repairs to 1997-99 Buick Park Avenues and Ultras, technicians may damage the power pack crossmember on the side mirrors.
To prevent this when removing left side assemblies, apply thumb pressure to the inboard side of the mirror glass and case assembly and pull from the bottom corner of the outboard side of the mirror glass and case assembly until it "snaps away" from the power pack.
When removing right side components, apply thumb pressure to the inboard side and pull from the top corner of the outboard side until the mirror and case assembly let go.
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