Removal Procedure
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
- Remove the front fascia. Refer to Front Bumper Fascia Replacement.
- Remove the front end module. Refer to Front End Panel Module Carrier Assembly Replacement.
- Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement.
- Remove the washer solvent container. Refer to Windshield Wiper and Washer Switch Replacement.
- Remove the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement.
- Remove the radiator. Refer to Radiator Replacement.
- Remove the front bumper impact bar bracket. Refer to Front Bumper Impact Bar Replacement.
- Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
- Locate, mark and drill out all factory welds attaching the front rail end crush cap to the front rail assembly (1).
Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.
Caution: Refer to Vehicle Lifting Caution in the Preface section.
Caution: Refer to Safety Glasses Caution in the Preface section.
Caution: Refer to Foam Sound Deadeners Caution in the Preface section.
Caution: Refer to Battery Disconnect Caution in the Preface section.
Important: Disable the SIR system. Refer to SIR Disabling and Enabling.
Important: Note the orientation of the front rail end crush cap for installation.
Installation Procedure
- Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original assembly.
- Clean and prepare the mating surfaces of both the front rail and the front rail end crush cap.
- Align the new front rail end crush cap to the weld points marked during the removal from the front rail assembly and weld the front end crush cap to the front rail assembly (1).
- Install the front bumper impact bar bracket. Refer to Front Bumper Impact Bar Replacement.
- Install the radiator. Refer to Radiator Replacement.
- Install the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement.
- Install the washer solvent container. Refer to Windshield Wiper and Washer Switch Replacement.
- Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement.
- Install the front end module. Refer to Front End Panel Module Carrier Assembly Replacement.
- Install the front fascia. Refer to Front Bumper Fascia Replacement.
- Install the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
- Enable the SIR system. Refer to SIR Disabling and Enabling.
Important: If the front rail is damaged, the front rail must be replaced.
Important: Spot welding is the preferred method for attaching panels and should be used whenever possible. A plug weld should only be performed where spot welding is not possible.
Important: If the location of the original spot weld holes cannot be determined, or if structural weld-thru adhesive is present, space the puddle weld holes every 32 mm (1¼ in).
Important: Secondary sealer must be applied to the perimeter of all flanges. Secondary sealer must be applied to all welds/joints that were originally covered by secondary sealer.
