Orlando

Front End Upper Tie Bar Replacement — Welding

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 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. Locate and mark all the necessary factory welds of the bonnet front bumper bracket (1).



7. Locate and mark all the necessary factory welds of the front end sheet metal cross panel reinforcement (1).
8. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



9. Remove the front end sheet metal cross panel reinforcement (1).
10. Drill all factory welds.



11. Grind factory welds of the front end upper tie bar support (1).



12. Remove the front end upper tie bar support (1).

1. Position the front end upper tie bar support (1) on the vehicle.
2. Verify the fit of the front end upper tie bar support.
3. Clamp the front end upper tie bar support into position.



4. Weld accordingly (1).



5. Weld accordingly (1).
6. Grind down weld seams as needed for related panels and components.



7. Drill 8 mm (5/16 in) holes for plug welding along the edges of the front end sheet metal cross panel reinforcement as noted from the original panel (1).
8. Clean and prepare the attaching surfaces for welding.



9. Position the front end sheet metal cross panel reinforcement (1) on the vehicle.
10. Verify the fit of the front end upper tie bar.
11. Clamp the front end sheet metal cross panel reinforcement into position.



12. Plug weld accordingly (1).
13. Use factory slots for slot brazing.



14. Drill 8 mm (5/16 in) holes for plug welding as noted from the original panel (1).



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



17. Plug weld accordingly (1).
18. Install front bumper impact bar before applying the sealers and anti-corrosion materials. Refer to Front Bumper Impact Bar Replacement .
19. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair : Base .
20. Paint the repaired area.
21. Install all related panels and components.
22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
23. Enable the SIR system. Refer to SIR Disabling and Enabling .