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Luggage Carrier Side Rail Front Support Reinforcement Replacement

Luggage Carrier Side Rail Front Support Reinforcement Replacement


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 (Without Sunroof) Headlining Trim Panel Replacement (With 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 front side panel.


7.
Note

Do not damage any inner panels or reinforcements.


Create cut lines on the upper front side panel.


8.
Note

Do not damage any inner panels or reinforcements.


Create cut lines on the upper front side panel.


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

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

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



Installation Procedure


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


2. Cut the replacement upper front 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 front side panel.

Joggle the flange of the new upper front 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 front side panel on the vehicle.


7. Verify the fit of the roof outer panel.

8. Clamp the upper front side panel into position.

9.
Note

Refer to Welded, Brazed, and Riveted Joint Specifications .


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


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

11. Grind MIG brazed seams.

12.
Note

Before installing the luggage carrier side rail front support reinforcement nut fix the luggage carrier side rail front 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 front 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 (Without Sunroof) Headlining Trim Panel Replacement (With 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 .