Installation Procedure

1. 1
   Cut the front compartment front rail 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. 2
   Create a 50 mm (2 in) backing plate from the unused portion of the service part.

Note: Place backing plate only in areas where adequate space is available.

1. 1
   Drill 8 mm (5/16 in) along the sectioning cut on the remaining original part. Locate these holes 13 mm (1/2 in) from the edge of part and spaced 40 mm (1 1/2 in) apart.
2. 2
   Prepare all mating surfaces as necessary.
3. 3
   Fit the backing plates halfway into the sectioning joints, clamp in place and plug weld to the vehicle.
4. 4
   Align the front compartment front rail.

   

Note: Left side only.

1. 1
   Drill 8 mm (5/1 in) for plug welding along the edges of the front compartment front rail as noted from the original panel.
2. 2
   Clean and prepare the attaching surfaces for welding.

   

3. 3
   Position the front compartment front rail on the vehicle.
4. 4
   Verify the fit of the front compartment front rail.
5. 5
   Clamp the front compartment front rail into position.

   

6. 6
   Plug weld accordingly.
7. 7
   To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them. Then go back and complete the stitch weld.
8. 8
   Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
9. 9
   Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
10. 10
    Install all related panels and components.
11. 11
    Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection
12. 12
    Enable the SIR system. Refer to SIR Disabling and Enabling.