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Roof Side Rail Reinforcement Replacement

Roof Side Rail Reinforcement Replacement

Removal Procedure

Refer to Approved Equipment for Collision Repair 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. Remove the body lock pillar outer panel reinforcement. Refer to Body Lock Pillar Outer Panel Reinforcement Replacement .

4. Remove the body side outer upper panel. Refer to Body Side Outer Upper Panel Replacement .

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

6. 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) .

7.
Note

Do not damage any inner panels or reinforcements.


Create a cut line (1) on the body side outer upper panel.


8. Cut the body side outer upper panel where sectioning is to be performed.

9. Locate and mark all the necessary factory welds of the body side outer upper panel.

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

11. Remove the body side outer upper panel.

12.
Note

Do not damage any inner panels or reinforcements.

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


Locate and drill out all of the necessary factory welds.


13. Remove the damaged roof side rail reinforcement (1).


Installation Procedure


1. Prepare new roof side rail reinforcement in the area (1).

2 x slots (8 x 24 mm / 0.3 x 0.9 in)


2. Clean and prepare the attaching surfaces for welding (1).


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

4. Position the roof side rail reinforcement on the vehicle.


5. Verify the fit of the roof outer panel.

6. Clamp the roof side rail reinforcement into position.

7.
Note

Refer to Welded, Brazed, and Riveted Joint Specifications .


Spot weld the roof side rail reinforcement (1) accordingly.


8. MIG-braze the roof side rail reinforcement (2).

9. Grind MIG brazed seams.

10. 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) .

11. Install the body lock pillar outer panel reinforcement. Refer to Body Lock Pillar Outer Panel Reinforcement Replacement .

12. Install the body side outer upper panel. Refer to Body Side Outer Upper Panel Replacement .

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

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