PRE-RELEASE
Front Compartment Side Rail Sectioning
Front Compartment Side Rail Sectioning |
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
.
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2. |
Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
|
3. |
Remove the front compartment upper side rail. Refer to
Front Compartment Upper Side Rail Replacement
.
|
4. |
Remove the headlamp mount panel. Refer to
Headlamp Mount Panel Replacement
.
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5. |
Remove the front wheelhouse panel brace - inner.
|
6. |
Remove the front wheelhouse. Refer to
Front Wheelhouse Panel Replacement
.
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7. |
Visually inspect the damage. Repair as much of the damage as possible.
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8. |
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)
.
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10. |
Drill out all of the necessary factory welds.
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11. |
Make a cut-out in the area (1) at the front compartment front outer side rail. ![]() |
12. |
Drill out the factory weld spot (2).
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13. |
Remove the structural adhesive and the anti-corrosion materials from the repair area (1) with the aid of a hot air gun. ![]() |
14. |
Locate and mark all the necessary factory welds of the front compartment side rail (2).
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15. |
Drill out the necessary factory welds (2).
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16. |
Locate and mark all the necessary factory welds of the front compartment front rail. ![]() |
17. |
Drill out the necessary factory welds (1).
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18. |
Remove the damaged front compartment side rail.
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Installation Procedure |
1. |
Prepare front compartment rear side rail in the area (1).
Specification2 x slots (6 x 20 mm / 0.2 x 0.8 in)![]() |
2. |
Clean and prepare the attaching surfaces for welding.
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3. |
Apply bodywork repair through structural adhesive to body (2). Refer to
Structural Adhesive Body Repairs
.
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4. |
Prepare front compartment rear side rail in the area (1).
Specification1 x slot (8 x 24 mm / 0.3 x 0.9 in)![]() |
5. |
Prepare new front compartment side rail in the area (1).
Specification8 x slots (8 x 24 mm / 0.3 x 0.9 in)![]() |
6. |
Prepare new front compartment side rail in the area (1).
Specification4 x slots (8 x 24 mm / 0.3 x 0.9 in) |
7. |
Prepare new front compartment side rail in the area (1).
Specification8 x slots (8 x 24 mm / 0.3 x 0.9 in)![]() |
8. |
Prepare new front compartment side rail in the area (2).
Specification3 x slots (8 x 24 mm / 0.3 x 0.9 in) |
9. |
Clean and prepare the attaching surfaces for welding.
![]() |
10. |
Apply bodywork repair through structural adhesive to body. Refer to
Structural Adhesive Body Repairs
.
|
11. |
Position the front compartment side rail on the vehicle.
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12. |
Verify the fit of the front compartment side rail.
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13. |
Clamp the front compartment side rail into position.
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14. |
MIG-braze the front compartment side rail in the area (1). ![]() |
15. |
Spot weld (2) the front compartment side rail accordingly.
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16. |
MIG-braze full seam (1) interrupted 30 mm (1.2 in) . ![]() |
17. |
MIG-braze the front compartment front rail in the areas (1, 2). ![]() |
18. |
Spot weld (1) the front compartment side rail accordingly.
![]() |
19. |
MIG-braze the front compartment side rail in the areas (1). ![]() |
20. |
Spot weld (2) the body rear end panel accordingly.
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21. |
MIG-braze full seam (1) interrupted 30 mm (1.2 in) . ![]() |
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 the front compartment upper side rail. Refer to
Front Compartment Upper Side Rail Replacement
.
|
24. |
Install the headlamp mount panel. Refer to
Headlamp Mount Panel Replacement
.
|
25. |
Install the front wheelhouse panel brace - inner.
|
26. |
Install the front wheelhouse. Refer to
Front Wheelhouse Panel Replacement
.
|
27. |
Install the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
|
28. |
Enable the SIR system. Refer to
SIR Disabling and Enabling
.
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