Orlando

Front End Upper Tie Bar Support Sectioning - MIG Brazing

Note : According to different corrosion warranties, only the regional mandatory joining methods are allowed.

Warning : Refer to Approved Equipment for Collision Repair Warning in the Preface section.

Warning : Refer to Collision Sectioning Warning in the Preface section.

Warning : Refer to Glass and Sheet Metal Handling Warning in the Preface section.

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 : without Start/Stop System
3. Remove all related panels and components.
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



6. Create cut lines on the front end upper tie bar.



7. Cut the panel where sectioning is to be performed.

Note : Do not damage any inner panels or reinforcements.




8. Locate and mark all the necessary factory welds of the front end upper tie bar.
9. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



10. Remove the damaged front end upper tie bar.

1. Cut the front end sheet metal cross panel reinforcement (1) 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. Cut the front end upper tie bar support (1) 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.
3. Prepare all mating surfaces as necessary.
4. Align the front end upper tie bar.
5. Clean and prepare the attaching surfaces for brazing.



6. Position the front end upper tie bar on the vehicle.
7. Verify the fit of the front end upper tie bar.
8. Clamp the front end upper tie bar into position.



9. Braze accordingly.
10. To create a solid braze with minimum heat distortion, make 25 mm (1 in) stitch brazes along the seam with 25 mm (1 in) gaps between them. Then go back and complete the stitch braze.



11. Position the front end sheet metal cross panel reinforcement (1) on the vehicle.
12. Clamp the front end sheet metal cross panel reinforcement into position.



13. Spot weld accordingly (1).



14. Position the bonnet front bumper bracket (1) on the vehicle.
15. Clamp the bonnet front bumper bracket into position.



16. Spot weld accordingly (1).
17. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair : Base
18. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems
19. Install all related panels and components.
20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System
21. Enable the SIR system. Refer to SIR Disabling and Enabling