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
.
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2. |
Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
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3. |
Visually inspect the damage. Repair as much of the damage as possible.
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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
.
|
11. |
Locate and drill out all of the necessary factory welds (1).
|
12. |
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.
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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. |
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.
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7. |
Verify the fit of the front compartment front inner side rail extension.
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8. |
Clamp the front compartment front inner side rail extension into position.
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9. |
Spot weld (1) the front compartment front inner side rail extension accordingly. |
10. |
MIG-braze (2) the front compartment front inner side rail extension.
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11. |
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.
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14. |
MIG-braze (1) the front compartment front outer side rail.
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15. |
Grind all MIG-brazed seams.
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16. |
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. |
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
.
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