Orlando

Front Compartment Upper Side Rail 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 battery negative 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 and weld seams of the front compartment upper side rail (1).
7. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



8. Grind the factory weld seams (2) of the front compartment upper side rail (1).



9. Remove the front compartment upper side rail (1).

1. Drill 8 mm (5/16 in) for plug welding along the edges of the front compartment upper side rail (1) where the spotwelder cannot be applied.
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 the front compartment upper side rail (1) factory slots in the body hinge pillar body area as noted from the original panel.

6. Weld accordingly.



7. Spotweld the front compartment upper side rail (1) weld accordingly.
8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair : Base .
9. Paint the repaired area.
10. Install all related panels and components.
11. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
12. Enable the SIR system. Refer to SIR Disabling and Enabling .