SAAB WIS ONLINE

PRE-RELEASE

Front Compartment Front Inner Side Rail Extension Replacement

Front Compartment Front Inner Side Rail Extension Replacement

Removal Procedure

Refer to Approved Equipment for Collision Repair Warning .

Refer to Collision Sectioning Warning .

Refer to Glass and Sheet Metal Handling Warning .


1. Disable the SIR system. Refer to SIR Disabling and Enabling .

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

3. Visually inspect the damage. Repair as much of the damage as possible.

4. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (Base) Anti-Corrosion Treatment and Repair (Corrosion Protection) .

5. Remove the front wheelhouse front liner. Refer to Front Wheelhouse Front Liner Replacement .

6. Remove the front wheelhouse rear liner. Refer to Front Wheelhouse Rear Liner Replacement .

7. Locate and drill out all of the battery tray support bracket factory welds.


8. Remove the front compartment upper side rail sectioning. Refer to Front Compartment Upper Side Rail Sectioning .

9. Remove the front wheelhouse front panel. Refer to Front Wheelhouse Front Panel Replacement .

10.
Note

Do not damage any inner panels or reinforcements.


Note

Note the number and location of the welds for installations of the service part.


Cut out the front compartment front inner side rail extension.


11. Locate and drill out all of the necessary factory welds (1).

12.
Note

Do not damage any inner panels or reinforcements.


Note

Note the number and location of the welds for installations of the service part.


Cut out the front compartment front outer side rail (1) 10 mm (0.4 in) staggered to the front compartment front inner side rail extension.


13. Remove the damaged front compartment front inner side rail extension and front compartment front outer side rail.


Installation Procedure


1. Prepare battery tray support bracket in the area (1).

4x slots 6x20 mm (0.2x0.7 in)

2. Prepare the new front compartment front inner side rail extension in the areas:


2.1. 2x slots 8x24 mm (0.3x0.9 in)

2.2. 2x slots 8x24 mm (0.3x0.9 in)

3. Prepare the new front compartment front outer side rail in the area (1).


4. Cut the new front compartment front outer side rail section in the corresponding locations to fit the original panel. The sectioning joint should be trimmed to allow min. 1 times the metal thickness at the sectioning joint (1).

5.
Note

Refer SPP, PSO welding parameters for resistance spot welding. See TIS Newsletter for equipment recommendations.


Apply bodywork repair through structural adhesive to body (1). Refer to Structural Adhesive Body Repairs .


6. Position the front compartment front inner side rail extension onto the vehicle.


7. Verify the fit of the front compartment front inner side rail extension.

8. Clamp the front compartment front inner side rail extension into position.

9.
Note

Refer to Welded, Brazed, and Riveted Joint Specifications .


Spot weld (1) the front compartment front inner side rail extension accordingly.


10. MIG-braze (2) the front compartment front inner side rail extension.

11.
Note

Refer SPP, PSO welding parameters for resistance spot welding. See TIS Newsletter for equipment recommendations.


Note

Refer to Welded, Brazed, and Riveted Joint Specifications .


Position the front compartment front outer side rail.


12. Verify the fit of the front compartment front outer side rail.

13. Clamp the front compartment front outer side rail into position.

14. MIG-braze (1) the front compartment front outer side rail.

15. Grind all MIG-brazed seams.

16.
Note

Refer to Welded, Brazed, and Riveted Joint Specifications .


Spot weld (1) the front compartment front outer side rail accordingly.


17. Install the front wheelhouse front panel. Refer to Front Wheelhouse Front Panel Replacement .

18.
Note

Refer to Welded, Brazed, and Riveted Joint Specifications .


Position the battery tray support bracket.


19. Verify the fit of the battery tray support bracket.

20. Clamp the battery tray support bracket into position.

21. MIG-braze (1) the battery tray support bracket.

22. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (Base) Anti-Corrosion Treatment and Repair (Corrosion Protection) .

23. Install all related panels and components.

24. Install the front wheelhouse rear liner. Refer to Front Wheelhouse Rear Liner Replacement .

25. Install the front wheelhouse front liner. Refer to Front Wheelhouse Front Liner Replacement .

26. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

27. Enable the SIR system. Refer to SIR Disabling and Enabling .


PRE-RELEASE