Underbody Outer Front Side Rail Replacement (Inner)

Materials Structure Adhesive Metal Panel Bonding Structure Rivet [SR1 7x] Fastener Specifications Structure Rivet [SR2 2x] Fastener Specifications Removal Procedure

Underbody Outer Front Side Rail Replacement (Inner) — 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

Squeeze Type Resistance Spot Welds (STRSW) are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG 8 mm (5/16 in) plug welds may be used to replace those specific welds, unless otherwise noted:

Note

Left shown, right similar.

Note

The underbody front rail is dual phase steel. Dual Phase 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

Underbody Outer Front Side Rail Replacement (Inner) — figure 2

Note

Do not damage or cut attaching panels and reinforcements.

5. Remove all spot welds (1). [26x]

Underbody Outer Front Side Rail Replacement (Inner) — figure 3

6. Apply heat to shaded area (1) to release adhesive from underbody front rail.

Underbody Outer Front Side Rail Replacement (Inner) — figure 4

7. Remove underbody front rail (1) from the vehicle.
8. Remove remaining adhesive from vehicle. Installation Procedure

Note

Temporarily install the underbody front rail for proper fit.

1. Position underbody front rail (1) to vehicle using 3-dimensional measuring equipment.

Underbody Outer Front Side Rail Replacement (Inner) — figure 5

Note

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

2. Drill 6.7 mm (17/64 in) hole (1) on underbody front rail and vehicle for rivet installation. [9x]

3. Remove the underbody front rail (1) from the vehicle.

Note

Prepare service part before installation.

Note

Squeeze Type Resistance Spot Welds (STRSW) are recommended. If access to use Squeeze Type Resistance Spot Welds is not possible, MIG/MAG 8 mm (5/16 in) plug welds may be used to replace those specific welds, unless otherwise noted:

4. Prepare underbody front rail per installation requirements.
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

Underbody Outer Front Side Rail Replacement (Inner) — figure 6

Note

Only remove E-coat where adhesive will be applied.

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

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

9. Install underbody front rail (1) to vehicle and clamp into place.

Underbody Outer Front Side Rail Replacement (Inner) — figure 7

10. Install rivets (1) in underbody front rail. [SR1 7x] Fastener Specifications.
11. Install rivets (2) in underbody front rail. [SR2 2x] Fastener Specifications.

Underbody Outer Front Side Rail Replacement (Inner) — figure 8

12. Install all spot welds (1). [17x]
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.