Spark

Front Compartment Upper Side Rail Replacement

Warning: Refer to Approved Equipment for Collision Repair 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 .
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 .



6. Locate and mark all the necessary factory welds and weld seams of the front compartment upper side rail.
7. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



8. Grind factory weld seams.



9. Remove the front compartment upper side rail.

1. Drill 8 mm (5/16 in) for plug welding along the edges of the front compartment upper side rail as noted from the original panel.
2. Clean and prepare the attaching surfaces for welding.
3. Position the front compartment upper side rail on the vehicle.
4. Verify the fit of the front compartment upper side rail.
5. Clamp the front compartment upper side rail into position.




Note: Plug weld factory slots in the front hinge pillar body area (1) as noted from the original panel.

6. Plug weld accordingly.
7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
8. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
9. Install all related panels and components.
10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
11. Enable the SIR system. Refer to SIR Disabling and Enabling .