Removal and Installation - Front Side Member

Special Service Tools / General Equipment

Removal

NOTICE: Battery electric vehicles (BEV), hybrid electric vehicles (HEV) and plug-in hybrid electric vehicles (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery, it must be removed to prevent damage.

1. 1
   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   Refer to: High-Voltage Systems Health and Safety Precautions — Overview (100-00 General Information, Description and Operation).
2. 2
   If necessary:
   Restore the vehicle dimensions to the pre-damage condition.
   Refer to: Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
3. 3
   Left side only: Remove the battery tray.
4. 4
   Remove the fender apron panel reinforcement.
   Refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).
5. 5
   Support the subframe and remove the bolt.

   

6. 6
   Remove the welds.
   Use common equipment: spot weld drill bit

   

7. 7
   Remove the welds.
   Use common equipment: spot weld drill bit

   

8. 8
   Remove the front side member.

   

Installation

NOTICE: Battery electric vehicles (BEV), hybrid electric vehicles (HEV) and plug-in hybrid electric vehicles (PHEV) contain a high-voltage battery. Before cutting or welding near the high-voltage battery, it must be removed to prevent damage.

NOTICE: The high-voltage battery in a battery electric vehicle (BEV), hybrid electric vehicle (HEV) or plug-in hybrid electric vehicle (PHEV) can be affected and damaged by excessively high temperatures. Temperatures in the paint booths of some body shops may exceed 60 °C. Therefore, during paint work the paint booth temperature must be set to 60 °C or lower, with a bake time of 45 minutes or less. A temperature above 60 °C or a bake longer than 45 minutes requires removing the high-voltage battery from the vehicle before placing it in the paint booth.

NOTICE: If the paint curing temperature exceeds 60 °C, the charge port indicator ring on plug-in vehicles must be removed.

1. 1
   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   Refer to: High-Voltage Systems Health and Safety Precautions — Overview (100-00 General Information, Description and Operation).
2. 2
   Drill the plug weld holes.
   Use common equipment: 8 mm drill bit.

   

3. 3
   Install, position and secure the front side member.
   Use common equipment: locking pliers

   

4. 4
   Install the welds.
   Use primary equipment: resistance spot welding equipment.

   

5. 5
   Install the welds.
   Use common equipment: MIG/MAG welding equipment

   

6. 6
   Install the fender apron panel reinforcement.
   Refer to: Fender Apron Panel Reinforcement (501-27 Front End Sheet Metal Repairs, Removal and Installation).
7. 7
   Left side only: Install the battery tray.
8. 8
   Install the bolt.
   Torque: 129 lb-ft (175 N·m)