Front Compartment Upper Side Rail Replacement

Materials Structure Adhesive Metal Panel Bonding Structure Rivet [SR1 4x] Fastener Specifications Structure Rivet [SR2 1x] Fastener Specifications Removal Procedure

Front Compartment Upper Side Rail Replacement — figure 1

Warning

Refer to Approved Equipment for Collision Repair Warning.

Warning

Refer to Collision Sectioning Warning.

Warning

Refer to Glass and Sheet Metal Handling Warning.

Note

Left shown, right similar.

Note

The outer rail is High Strength Low Alloy Steel. High Strength Low Alloy Steel

Note

The outer rail assembly contains an inner reinforcement that is Ultra High Strength Steel. Ultra High Strength Steel

Note

Refer to Collision Repair Specifications

1. Disable the SIR system. SIR Disabling and Enabling.
2. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
3. Remove all related panels and components.
4. Remove the sealers and anti-corrosion materials from the repair area as necessary. Anti-Corrosion Treatment and Repair

Front Compartment Upper Side Rail Replacement — figure 2

Note

Do not damage or cut attaching panels and reinforcements.

5. Remove spot welds (1). [52x]

Front Compartment Upper Side Rail Replacement — figure 3

Note

1st and 2nd layer of panel will need to be cut through for removal.

Note

Do not damage or cut attaching panels and reinforcements.

6. Remove spot welds (1). [6x]

Front Compartment Upper Side Rail Replacement — figure 4

7. Apply heat to shaded area (1) to release adhesive

Front Compartment Upper Side Rail Replacement — figure 5

8. Remove outer rail (1) from the vehicle.
9. Remove remaining adhesive from vehicle. Installation Procedure

Note

Prepare outer rail before installation.

1. Prepare outer rail per installation requirements.

Note

Temporarily install the outer rail for proper fit.

2. Position outer rail (1) to vehicle using 3-dimensional measuring equipment and clamp into place.

Front Compartment Upper Side Rail Replacement — figure 6

Note

Use 6.7 mm (17/64”) holes for rivet installation.

3. Drill 6.7 mm (17/64”) hole (1) through outer rail for rivet installation. [5x]

4. Remove outer rail (1) from the vehicle.

5. Prepare all joining surfaces for welding as necessary.

6. Apply weld-thru coating or equivalent to all welding surfaces. Anti-Corrosion Treatment and Repair

Front Compartment Upper Side Rail Replacement — figure 7

Note

Only remove E-coat where adhesive will be applied.

7. Clean and prepare outer rail and vehicle for adhesive according to adhesive manufacturer’s recommendations. Metal Panel Bonding

8. Apply structural adhesive (1) on the mating surfaces of outer rail and vehicle according to adhesive manufacturer’s recommendations. Metal Panel Bonding

9. Install outer rail (1) to vehicle using 3-dimensional measuring equipment and clamp into place.

Front Compartment Upper Side Rail Replacement — figure 8

10. Install rivets (1) in outer rail. [SR1 4x] Fastener Specifications

Front Compartment Upper Side Rail Replacement — figure 9

11. Install rivets (1) in outer rail. [SR2 1x] Fastener Specifications

Front Compartment Upper Side Rail Replacement — figure 10

12. Install spot welds (1). [53x]
13. Apply the sealers and anti-corrosion materials to the repair area as necessary. Anti-Corrosion Treatment and Repair

Note

Before refinishing, refer to Anti-Corrosion Treatment and Repair

14. Paint the repaired area. Basecoat/Clearcoat Paint Systems.
15. Install all related panels and components.
16. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection
17. Enable the SIR System. SIR Disabling and Enabling.