Inner Wheel Housings & Door Frames - Replacement

CATEGORY
Body



SECTION
8



PAGE
55



ISSUE
12/92-0292



CODE
810



Subject:
Replacement of Inner Wheel Housings and Door Frames


Application:
1986-1991 9000 Models



When replacing inner wheel housings or door frames, new spare parts must be modified prior to installation due to structural changes introduced on later body styles.



Cars Affected:

Inner Wheel housings, both sides 1986-1991
Door Frames 1986-1990

Parts:
Bolt 79 75 436
Washer 41 00 897
Bolt (3) 79 22 362
Nut washer 79 75 006

Action:

1. Inner Wheel Housing (structural member)

a. Both sides:





See Figure 1. Fit a washer and bolt (see Figure 1-A) between the wheel housing (see Figure 1B) and the fender (see Figure 1-C) the same as on 1992 9000 models.

b. Right-hand side:

If the inner wheel housing on 1991 and earlier model year cars is welded behind the bracket for the power steering fluid reservoir, or if a complete spare part is to be fitted, a hole must be made in the spare part prior to mounting it to the vehicle.

NOTE:
The hole must be made before any anticorrosion treatment or paint is applied.





1. Drill out the spot welds that secure the power steering fluid reservoir bracket to the new inner wheel housing. Remove the bracket. See Figure 2-1.

2. Fit the nut washer on the new inner wheel housing. See Figure 2-2.

3. Apply identifying paint to the lower locating lug on the power steering fluid reservoir. See Figure 2-3.

4. Fit the reservoir, marking the position of the locating lug's hole. This should be 183 mm from the front of the torque rod bracket See Figure 2-4.

5. Make a hole measuring 10 mm wide x 24 mm long. See Figure 2-5.



6. Mount the power steering fluid reservoir, checking to make certain it fits correctly. Final mounting should take place after the car has been painted.


c. Left-hand side:

The bracket for the front relay box must be moved to the new inner wheel housing when replacing this part on the left-hand side of 1991 and earlier cars.


NOTE:
Perform this modification prior to application of anti-corrosion treatment or paint

1. Remove the bracket for the relay box from the old inner wheel housing.





2. Cut (see 2-A) and bend (2-B) the bracket as shown in Figure 3.

3. Bracket holes should be marked on the new inner wheel housing as indicated in Figure 3-3.

4. Position the bracket according to the markings made in step 3. Using a 4 mm bit, drill 3 holes in the inner wheel housing, using the bracket as a template.

5. Install the bracket after the car has been treated for ant-corrosion and painted.

2. Door Frames and Outer Sills:

The following steps must be taken when installing a replacement door frame on 1990 and earlier 9000's:





a. Drill the seat belt anchor point out of the reinforcement on the car. See Figure 4-1.

b. Cut off the three flanges on the new door frame so that it can be mated to the reinforcement on the car body. See Figure 4-2.

c. Using a high quaiity product, prime all ground metal surfaces.

NOTE:
The seat belt anchor points are included in the new door frames.