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PRE-RELEASE

Luggage Carrier Side Rail Rear Support Reinforcement Replacement

Luggage Carrier Side Rail Rear Support Reinforcement Replacement

Removal Procedure

Refer to Approved Equipment for Collision Repair Warning .

Refer to Collision Sectioning 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. Remove the headlining trim panel. Refer to Headlining Trim Panel Replacement (With Sunroof) Headlining Trim Panel Replacement (Without Sunroof) .

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

5. 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) .

6.
Note

Do not damage any inner panels or reinforcements.


Create cut lines on the upper rear side panel.


7.
Note

Do not damage any inner panels or reinforcements.


Create cut lines on the upper rear side panel.


8.
Note

Do not damage any inner panels or reinforcements.


Create cut lines on the upper rear side panel.


9. Cut the upper rear side panel where sectioning is to be performed.

10. Locate and mark all the necessary factory welds of the upper rear side panel.

11. Drill all factory welds. Note the number and location of welds for installation of the service assembly.

12. Remove the damaged upper rear side panel.

13. Remove the damaged luggage carrier side rail rear support reinforcement (1).



Installation Procedure


1. Install the luggage carrier side rail rear support reinforcement with structural adhesive to body. Refer to Structural Adhesive Body Repairs .


2. Cut the replacement upper rear side panel in 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.


3. Prepare new upper rear side panel.

Joggle the flange of the new upper rear side panel (1) downwards.


4. Clean and prepare the attaching surfaces for welding.


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

6. Position the upper rear side panel on the vehicle.


7. Verify the fit of the roof outer panel.

8. Clamp the upper rear side panel into position.

9.
Note

Refer to Welded, Brazed, and Riveted Joint Specifications .


MIG-braze (1) the upper rear side panel.


10. Spot weld (2) the upper rear side panel accordingly.

11. Grind MIG brazed seams.

12.
Note

Before installing the luggage carrier side rail rear support reinforcement nut fix the luggage carrier side rail rear support reinforcement.


Spray the structure foam through the luggage carrier side rail front support reinforcement holes (1). Refer to Chemical Products .


13. Install the luggage carrier side rail rear support reinforcement nut before the structure foam gets hard.

14. 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) .

15. Install the headlining trim panel. Refer to Headlining Trim Panel Replacement (With Sunroof) Headlining Trim Panel Replacement (Without Sunroof) .

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

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


PRE-RELEASE