Page 4129 of 4402
Mea\furing \boint\f and dimen\fion\f
1\f-10\f=\f1062\fmm4\f-7\f=\f1365\fmm
2\f-11\f=\f1393\fmm5\f-8\f=\f859\fmm
3\f-6\f=\f1230\fmm9\f-12\f=\f837\fmm
5. Re\br\fbody\fdimensions,\fS-MAX\f All\fdimensions\fwith\ftoler\bnce\f±\f3\fmm.\fAll\f
di
mensions\fwere\fdetermined\fst\brting\ffrom\f
the\fcenter\fof\fthe\fwelded\ffl\bnge\fusing\f\b\f
symmetric\blly\f\bdjusted\fme\bsuring\fg\buge.\f
Mea\furing \boint\f and dimen\fion\f
1\f-4\f=\f1193\fmm3\f-6\f=\f1451\fmm
2\f-5\f=\f1021\fmm
\f
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Page 4130 of 4402
6. Re\br\fbody\fdimensions,\fG\bl\bxy\fAll\fdimensions\fwith\ftoler\bnce\f±\f3\fmm.\fAll\f
di
mensions\fwere\fdetermined\fst\brting\ffrom\f
the\fcenter\fof\fthe\fwelded\ffl\bnge\fusing\f\b\f
symmetric\blly\f\bdjusted\fme\bsuring\fg\buge.\f
Mea\furing \boint\f and dimen\fion\f
1\f-4\f=\f1240\fmm3\f-6\f=\f1456\fmm
2\f-5\f=\f1105\fmm
\f
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Page 4131 of 4402
7. P\bssenger\fcomp\brtment\fbody\fdimensions,\fS-MAX\fAll\fdimensions\fwith\ftoler\bnce\f±\f3\fmm.\fAll\f
di
mensions\fwere\fdetermined\fst\brting\ffrom\f
the\fcenter\fof\fthe\fwelded\ffl\bnge\fusing\f\b\f
symmetric\blly\f\bdjusted\fme\bsuring\fg\buge.\f
Mea\furing \boint\f and dimen\fion\f
1\f-4\f=\f1508\fmm5\f-6\f=\f1498\fmm
2\f-3\f=\f1476\fmm
\f
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Page 4132 of 4402
8. P\bssenger\fcomp\brtment\fbody\fdimensions,\fG\bl\bxy\fAll\fdimensions\fwith\ftoler\bnce\f±\f3\fmm.\fAll\f
di
mensions\fwere\fdetermined\fst\brting\ffrom\f
the\fcenter\fof\fthe\fwelded\ffl\bnge\fusing\f\b\f
symmetric\blly\f\bdjusted\fme\bsuring\fg\buge.\f
Mea\furing \boint\f and dimen\fion\f
1\f-4\f=\f1508\fmm5\f-6\f=\f1498\fmm
2\f-3\f=\f1476\fmm
\f
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Page 4133 of 4402
\f
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Page 4134 of 4402
Front En\b Sheet \fetal Repairs -
SpecificationsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Lubricants, Flui\bs, Sealers an\b A\bhesives
Part Nu\bberS\fecification
PU\fgl\bss\f\bdhesive\f(150\fml)1\f102\f109WSK-M11\fP57-A1
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Page 4135 of 4402

Front En\b Sheet \fetal Repairs - Fen\ber
Apron Panel ReinforcementS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal an\b Installation
Removal
NOTE:\f\f If\fpossible,\fit\fis\fbetter\fto\fperform\f\b\fp\brti\bl\frepl\bcement\fof\fthe\fouter\f\bnd\finner\f\bpron\f
p\bn
el\freinforcements\fr\bther\fth\bn\f\b\ffull\frepl\bcement,\f\bs\fthis\foffers\fsignific\bnt\ftime\f
s\bvings\fin\fterms\fof\fthe\finst\bll\btion\fwork\frequired\fin\fthe\finner\fA-pill\br\f\bre\b.\f\f
The\fp\brti\bl\frepl\bcement\foptions\fshown\f(see\fillustr\btions\fE77709\f\bnd\fE77710)\fdo\fnot\f
re
quire\fthe\fMIG\fweld\fse\bms\fon\fthe\fA-pill\br\fto\fbe\fsep\br\bted.\f\f
The\frep\bir\fshown\fonly\fdescribes\f\b\fcomplete\frepl\bcement\fin\ffull.\f 1.
R
eplacement parts
\f
Outer\f\bpron\fp\bnel\freinforcement\f
Inner\f\bpron\fp\bnel\freinforcement\f
1 .
Gener\bl\finform\btion\f Necess\bry\fremov\bl\fwork:\fDoor,\fhood,\f
fe
nder,\fbumper,\fhood\fclosing\fp\bnel,\f
crossmember\fwith\fcr\bsh\felements,\f
he\bdl\bmp\f\bnd\fwheelhouse\fliner.\f
2. Outer\f\bpron\fp\bnel\freinforcement\f 1. Grind\fout\fthe\fMIG\fbr\bzed\fjoints.\f
2. Grind\fout\fthe\fMIG\fweld\fse\bms.\f
3. Outer\f\bpron\fp\bnel\freinforcement\f Mill\fout\fthe\fspot\fwelds.\f
4 .
Inner\f\bpron\fp\bnel\freinforcement\f Grind\fout\fthe\fMIG\fbr\bzed\fjoints.\f
5.
Inner\f\bpron\fp\bnel\freinforcement\f Mill\fout\fthe\fspot\fwelds.\f
\f
\f
\f\f
\f\f
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Page 4136 of 4402

Installation
NOTE:\fBefore\fresist\bnce\fspot\fwelding\fof\fbody\fp\bnels\fwith\f\b\ftot\bl\fp\bnel\fthickness\fof\f3\fmm\f
\bn
d\fgre\bter,\fthe\fwelding\fequipment\finstructions\fcont\bined\fin\fsub-section\f501-25\fmust\fbe\f
followed.\f
NOTE:\f\f
The\ff\bctory-inst\blled\fMIG\fbr\bzed\fjoints\fmust\fbe\frepl\bced\fby\fMIG\fwelds\fin\f\b\fdifferent\f
po
sition\fif\f\b\frep\bir\fis\fperformed.\f\f
These\fMIG\fwelds\fmust\fnot\fbe\fc\brried\fout\fon\for\fin\fthe\fimmedi\bte\fvicinity\fof\fexisting\fMIG\f
br
\bzed\fse\bms\f\bs\feven\fthe\fsm\bllest\f\bmount\fof\fbr\bzing\fsolder\fc\bn\fresult\fin\f\b\freduction\fin\f
the\fstrength\fof\fthe\fweld\fse\bm.\f 6. P\brti\bl\frepl\bcement,\fouter\f\bpron\fp\bnel\f
reinforcement\fCut\floc\btion\ffor\fp\brti\bl\frepl\bcement.\f
7 .
P\brti\bl\frepl\bcement,\finner\f\bpron\fp\bnel\f
reinforcement\f Cut\floc\btion\ffor\fp\brti\bl\frepl\bcement.\f
1. N
OTE:\fFor\fthe\fre\bsons\fdescribed\f\bbove,\f
w h
en\fprep\bring\fthe\finner\f\bpron\fp\bnel\f
reinforcement\fthe\fexisting\fopenings\fneed\fto\f
be\fenl\brged\fby\f10\fmm\f(see\fillustr\btion\f
E77702).\f
Inner\f\bpron\fp\bnel\freinforcement\f Mill\fout\fthe\fopenings\fwith\f\b\fspheric\bl\f
cu
tter.\f
\f\f
\f\f
\f\f
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