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Body Hinge Pillar Lower Reinforcement Replacement

Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks:

   • Identify how to disable high voltage.
   • Identify how to test for the presence of high voltage.
   • Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.
Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:
   • Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.
   • Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.
      - Visually and functionally inspect the gloves before use.
      - Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energised or not.
Failure to follow the procedures exactly as written may result in serious injury or death.

Removal Procedure

    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. Inspect the high voltage system. Refer to High Voltage System Inspection .
  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. Section body side outer-hinge pillar area. Refer to Front Hinge Pillar Body Sectioning .

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  7. Locate and mark all the necessary factory welds of the body hinge pillar lower reinforcement (1).
  8. Drill all factory welds. Note the number and location of welds for installation of the service assembly.

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    Note : There is a hidden weld on the inside of the pillar reinforcement.

  9. Remove hidden spot weld (1) with a chisel.

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  10. Remove the damaged body hinge pillar lower reinforcement (1).

Installation Procedure
  1. Prepare all mating surfaces as necessary.

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  2. Drill 8 mm (5/16 in) for plug welding along the edges of the body hinge pillar lower reinforcement (1) as noted from the original panel.

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  3. Remove weld tab portion (1) from inner bracket with appropriate tool.
  4. Clean and prepare the attaching surfaces for welding.

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  5. Position the body hinge pillar lower reinforcement (1) on the vehicle.
  6. Verify the fit of the body hinge pillar lower reinforcement.
  7. Clamp the body hinge pillar lower reinforcement into position.

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  8. Plug weld the body hinge pillar lower reinforcement (1) accordingly.
  9. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  10. Install the bodyside outer hinge pillar section. Refer to Front Hinge Pillar Body Sectioning .
  11. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
  12. Install all related panels and components.
  13. If disabled, enable the high voltage system. Refer to High Voltage Enabling .
  14. Enable the SIR system. Refer to SIR Disabling and Enabling .
   


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