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Front Compartment Upper Side Rail Sectioning

Front Compartment Upper Side Rail Sectioning

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. Repair as much of the damaged area as possible. Refer to Dimensions - Body .

4. Remove all related panels and components.

Remove the front fender. Refer to Front Fender Replacement .

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


Create cut lines 60 mm (1) or 80 mm (2) on the front compartment upper side rail.


7. Cut the front compartment upper side rail where sectioning is to be performed.

8. Locate and mark all the necessary factory welds of the front compartment upper side rail.

9. Drill all factory welds.

10. Remove the damaged front compartment upper side rail.


Installation Procedure


1. Cut the front compartment upper side rail (1) in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of one-and-one-half-times the metal thickness at the sectioning joint.


2. Clean and prepare the attaching surfaces for welding.

3. Clean and prepare the attaching surfaces for welding.


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

5. Position the front compartment upper side rail on the vehicle.


6. Verify the fit of the front compartment upper side rail.

7. Clamp the front compartment upper side rail into position.

8.
Note

Refer to Welded, Brazed, and Riveted Joint Specifications .


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


9. MIG-braze the front compartment upper side rail (2).

10. Grind MIG-brazed seams.

11. 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) .

12. Install the front fender. Refer to Front Fender 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 .