Jeep Compass, Repair Manual

Page 1: ...JEEP COMPASS BODY REPAIR MANUAL...

Page 2: ...en working with spring or tension loaded fasteners and devices such as E Clips Circlips Snap rings etc since careless removal may cause personal injury Always wear safety goggles when working on vehic...

Page 3: ...SHERWIN WILLIAMS TEAM PSE FACILITY PLANNING SERVICES TECH AUTHORITY Copies of the following Body Repair Manuals are available by calling 1 800 890 4038 Chrysler 300 81 316 0531CD Jeep Grand Cherokee...

Page 4: ...n Characteristics History of Collision Repair Corrosion Protection Vehicle Identification Number Information Paint Codes Information Welded Panel Replacement Sealer Locations Structural Adhesive Locat...

Page 5: ...to the hardening process die Sheet blanks are heat treated in the furnace on an inert gas or air atmosphere and then formed in the press die and hard ened at the same time The boron is produced in tw...

Page 6: ...er to provide maximum corrosion prevention and protection 1 The use of galvannealed coatings throughout the body structure 2 Ecoat is used on the complete body in all instances 3 Body sealing 4 Stone...

Page 7: ...Back to Index...

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Page 9: ...Back to Index...

Page 10: ...Back to Index...

Page 11: ...Flow had it race cars have it and now the driving public worldwide has it The change came quickly Manufacturers devoted time money and talent to develop the unibody car The public was ready to buy an...

Page 12: ...Metal finishing metal working and fatigue can cause the breakdown of many of the corrosion barriers installed at the factory The use of heat for stress relief and welding also destroys factory instal...

Page 13: ...de spot weld lap joints threaded or riveted connections gasket fittings porous welds valve seats Pitting is the corrosion of a metal surface at points or small areas which look like a small hole in th...

Page 14: ...reduction in stress and the use of coatings Fretting is the deterioration of a metal at contact surfaces due to the presence of a corrosive and relative motion between the surfaces The two metal surf...

Page 15: ...ion The material must be compatible with paint systems as many areas of the car must be treated before paint is applied Materials containing silicones will cause paint conditions such as fish eyes if...

Page 16: ...fog application to the weld areas and the crevices formed during assembly after the rails are assembled Brush application keeps the foreign material from getting between welded joints during assembly...

Page 17: ...wipe off easily without solvent when wet with solvent when dry The material should also dry clean off clothing 5 Guarantee Warranty The corrosion protection has to be done to maintain factory corrosio...

Page 18: ...Back to Index...

Page 19: ...vehicle Refer to VIN Code Breakdown Chart for decoding information To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of...

Page 20: ...Kg G 5001 6000 Lbs 2268 2721 Kg 5 Vehicle Line T Left Hand Drive FWD F Left Hand Drive 4 x 4 7 Right Hand Drive 4 x 4 6 Series 2 L Low Line 4 H High Line 5 P Premium F Continuously Variable Transmiss...

Page 21: ...lso lists Month and year of vehicle manufacture Gross Vehicle Weight Rating GVWR The gross front and rear axle weight ratings GAWR s are based on a minimum rim size and maximum cold tire inflation pre...

Page 22: ...Back to Index...

Page 23: ...lic Clear Coat ECG Jeep Green Metallic Clear Coat CB6 Marine Blue Pearl Coat DBM Steel Blue Metallic Pearl Coat WS2 Bright Silver Metallic Clear Coat DX8 Black Clear Coat SW1 Stone White Clear Coat IN...

Page 24: ...Back to Index JEEP COMPASS PAINT CODE LOCATION The vehicle certification label identifies the paint code This label is located on the driver s door shut face VEHICLE CERTIFICATION LABEL...

Page 25: ...Back to Index...

Page 26: ...ions and procedures Note Diagrams do not show all of the parts Explanation of Manual Contents Engine Box Assembly Front Floor Plenum Dash Assembly Sidemember Assembly Engine Box Complete Rear Floor Fr...

Page 27: ...ate the supporting structure for all com ponents and assemblies of the vehicle Here are some examples for replacement of these parts Certain body components must use sealers to ensure proper assembly...

Page 28: ...x Core Arc Weld MFG Manufacturing Weld S WELD Spot Welds SD Per Side Examples AA TO AB 5 SD S WELDS ORD PART AA WELDED TO PART AB 5 PER SIDE 5 RIGHT 5 LEFT SPOT WELDS STANDARD AA TO AB 12 PROJ WELDS C...

Page 29: ...WELD LOCATION OVERVIEW ZONES Back to Index...

Page 30: ...NIBS NO FIN PARK BRAKE LEVER TO TUNNEL REINF AE NUT WELD HEX NIBS NO FIN PILOT PT BRKT TO WIPER MODULE AF NUT WELD HEX NIBS NO FIN PILOT PT A C ACCUM TO FRT RAIL OTR RT AG HOOK MUFFLER HANGER BRACKET...

Page 31: ...TERNAL HEADER PT NIBS NO FIN PARK BRAKE LEVER TO TUNNEL REINF AE NUT WELD HEX NIBS NO FIN PILOT PT BRKT TO WIPER MODULE AF NUT WELD HEX NIBS NO FIN PILOT PT A C ACCUM TO FRT RAIL OTR RT AG HOOK MUFFLE...

Page 32: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 33: ...01 AB TO AA 10 S WELDS ORD Back to Index...

Page 34: ...02 AF TO AA 2 PROF WELDS ORD 03 AC TO AA 13 S WELDS ORD 04 AD TO AB 2 PROJ WELDS ORD 05 AE TO AA 2 PROJ WELDS ORD Back to Index...

Page 35: ...06 AK TO AH 1 PROJ WELD ORD 07 AH TO AJ 19 S WELDS ORD 08 AG TO AJ 2 STRUC ADH 09 AG TO AJ 1 PROJ WELD ORD Back to Index...

Page 36: ...OOR SIDEMEMBER RT AM BULKHEAD RR FLOOR SIDEMEMBER LT AN EXTENSION RR FLOOR SIDEMEMBER LT AP REINF RR FLOOR SIDEMEMBER EXTENSION RT AP REINF RR FLOOR SIDEMEMBER EXTENSION LT AR BULKHEAD RR FLOOR SIDEME...

Page 37: ...ULKHEAD RR FLOOR SIDEMEMBER RT AM BULKHEAD RR FLOOR SIDEMEMBER LT AN EXTENSION RR FLOOR SIDEMEMBER LT AP REINF RR FLOOR SIDEMEMBER EXTENSION RT AP REINF RR FLOOR SIDEMEMBER EXTENSION LT AR BULKHEAD RR...

Page 38: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 39: ...5 SD S WELD CRT 02 AH TO AF 2 SD S WELDS CRT 03 AH TO AG TO AF 2 SD S WELDS CRT 04 AG TO AF 2 SD S WELDS ORD Back to Index 05 AJ TO AD 5 S WELDS ORD 06 AR TO AJ TO AD 2 SD S WELDS CRT 07 AP TO AD 7 SD...

Page 40: ...08 AP TO AD 11 SD S WELDS ORD 09 AR TO BB TO AD 2 SD S WELDS CRT 10 AY TO AD 1 SD S WELD ORD 11 AE TO AC 12 SD S WELDS ORD Back to Index...

Page 41: ...12 AT TO AC 1 SD S WELDS CRT 13 AL TO AC 12 SD S WELD CRT 14 AV TO AC 1 SD S WELD CRT 15 AT TO AL TO AC 1 SD S WELD CRT 16 AU TO AL TO AC 1 SD S WELD CRT 17 AC TO AG 7 SD S WELDS CRT Back to Index...

Page 42: ...18 AV TO AC 2 SD S WELDS ORD 19 AW TO AC 13 SD S WELDS CRT Back to Index...

Page 43: ...AK TO AC TO AV 4 SD S WELDS ORD 21 AK TO AC 2 SD S WELDS ORD 22 AZ TO AC TO AG 2 SD S WELDS CRT 23 AX TO AG TO AC 2 SD S WELDS CRT 24 AX TO AC 5 SD S WELDS CRT 25 AC TO AG 3 SD S WELDS ORD Back to Ind...

Page 44: ...26 AY TO AC 5 SD S WELDS CRT 27 AY TO AL 2 SD S WELDS CRT 28 AY TO AE TO AC 2 SD S WELDS CRT 29 AN TO AC 9 SD S WELDS ORD Back to Index...

Page 45: ...TO AC TO AA 2 SD S WELDS ORD 31 AY TO AC TO AA 14 SD S WELDS CRT 32 AM TO AE 1 SD S WELD ORD 33 AY TO AE TO AA 6 SD S WELDS CRT 34 AE TO AC TO AA 1 SD S WELD ORD 35 AD TO AC 6 SD S WELDS ORD Back to...

Page 46: ...36 AD TO AA 11 SD S WELDS ORD 37 AD TO AC TO AA 3 SD S WELD CRT 38 AC TO AA 2 SD S WELDS ORD 39 AC TO AA 1 SD S WELD CRT 40 AY TO AC TO AA 6 SD S WELDS CRT Back to Index...

Page 47: ...ELDS ORD 42 AD TO AB TO AA 2 SD S WELDS ORD 43 AG TO AA 4 SD S WELDS CRT 44 AG TO AF TO AC 2 SD S WELDS CRT 45 AG TO AC TO AA 2 SD S WELDS CRT 46 AH TO AG TO AA 2 SD S WELDS CRT 47 AB TO AA 5 SD S WEL...

Page 48: ...48 AE TO AC 1 SD FCAW ORD 49 AY TO AE 1 SD ADH BEAD ORD 50 AC TO AE 1 SD ADH BEAD ORD 51 AX TO AC 1 SD FCAW CRT 52 AX TO AC 1 SD FCAW CRT 53 BA TO AX 2 SD FCAW CRT Back to Index...

Page 49: ...54 AG TO AC TO AA 1 SD ADH BEAD ORD 55 AB TO AA 1 SD ADH BEAD ORD 56 AC TO AG TO AH TO AA 1 SD ADH BEAD ORD 57 AY TO AE TO AA 1 SD ADH BEAD ORD Back to Index...

Page 50: ...58 BA TO AC 1 SD FCAW CRT 59 BA TO AC 1 SD FCAW CRT 60 AG TO AF TO AC 1 SD ADH BEAD ORD Back to Index...

Page 51: ...LT AE STUD WELD INTERNAL HEADER PT NIBS NO FIN RR BUMPER TO BUMPER SUPPORT AF REINF RR FLOOR SIDEMEMBER RT AF REINF RR FLOOR SIDEMEMBER LT AG STUD WELD INTERNAL NO FIN PILOT PT ROUND SPECIAL RR SEAT...

Page 52: ...NONE AD SUPPORT RR BUMPER RT AD SUPPORT RR BUMPER LT AE STUD WELD INTERNAL HEADER PT NIBS NO FIN RR BUMPER TO BUMPER SUPPORT AF REINF RR FLOOR SIDEMEMBER RT AF REINF RR FLOOR SIDEMEMBER LT AG STUD WEL...

Page 53: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 54: ...AE TO AD 2 SD PROJ WELDS ORD 03 AD TO AC 7 SD S WELDS ORD 04 AE TO AC 1R 2L PROJ WELDS ORD Back to Index 05 AG TO AF 1 SD PROJ WELD ORD 06 AH TO AF 2 SD PROJ WELDS ORD 07 AK TO AL 1 SD PROJ WELD ORD 0...

Page 55: ...O AM 1 SD PROJ WELD ORD 10 AN TO AP 1 SD PROJ WELD ORD 11 AR TO AS 4 SD FCAW SAF 12 AH TO AW 1 PROJ WELD ORD Back to Index 13 AR TO AP 2 PROJ WELDS ORD 14 AH TO AT 2 PROJ WELDS ORD 15 AV TO AT 4 S WEL...

Page 56: ...Back to Index 16 AY TO AX 12 S WELDS ORD 17 AZ TO AX 14 S WELDS SAF 18 BC TO BB 4 S WELDS SAF 19 BB TO BA 4 S WELDS SAF...

Page 57: ...20 BE TO BD 4 SD S WELDS ORD 21 BF TO BD 2 PROJ WELDS ORD 22 BE TO BE 4 SD S WELDS ORD 23 BF TO BG 6 PROJ WELDS ORD Back to Index...

Page 58: ...ELD HEX NIBS NO FIN PILOT PT SPEED SENSOR TO RAIL OTR LT AK NUT WELD HEX NIBS NO FIN PILOT PT DIESEL INT TO RAIL OTR LT AK NUT WELD HEX NIBS NO FIN PILOT PT POWER STEERING LINE TO RAIL INR LT AL REINF...

Page 59: ...FIN PILOT PT A C ACCUM TO FRT RAIL OTR RT AK NUT WELD HEX NIBS NO FIN PILOT PT SPEED SENSOR TO RAIL OTR LT AK NUT WELD HEX NIBS NO FIN PILOT PT DIESEL INT TO RAIL OTR LT AK NUT WELD HEX NIBS NO FIN PI...

Page 60: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 61: ...AB TO AA 4R S WELDS ORD 02 AC TO AB TO 2R FCAW ORD 03 AC TO AB TO AA 3R S WELDS ORD 04 AB TO AA 16R S WELDS ORD Back to Index 05 AB TO AA 2R FCAW ORD 06 AE TO AB TO AA 5R S WELDS ORD 07 AF TO AB 1R F...

Page 62: ...TO AB TO AA 3L S WELDS ORD 09 AC TO AB 2L FCAW ORD 10 AD TO AB TO AA 2L S WELDS ORD 11 AE TO AB TO AA 5L S WELDS ORD Back to Index 12 AB TO AA 2L FCAW CRT 13 AB TO AA 16L S WELDS ORD 14 AF TO AB 1L FC...

Page 63: ...AB 1R S WELD ORD 17 AH TO AB TO AA 2R S WELDS ORD 18 AH TO AB 2R S WELDS ORD 19 AH TO AG TO AB 4R S WELDS ORD Back to Index 20 AG TO AB 1R FCAW ORD 21 AJ TO AG TO AA 1R S WELD ORD 22 AH TO AG TO AA 4...

Page 64: ...O AA 4L S WELDS ORD 26 AH TO AB 3L S WELDS ORD 27 AH TO AB TO AA 2L S WELDS ORD 28 AJ TO AB 1L S WELD ORD Back to Index 29 AJ TO AB TO AA 1L S WELD ORD 30 AJ TO AG TO AA 1L S WELD ORD 31 AG TO AB 1L F...

Page 65: ...1R PROJ WELD ORD 34 AL TO AD TO AA 2R S WELDS ORD 35 AE TO AD TO AA 4R S WELDS ORD 36 AD TO AA 2R S WELDS ORD 37 AC TO AJ TO AA 4R S WELDS ORD 38 AJ TO AA 3R S WELDS ORD 39 AE TO AA 3R S WELDS ORD 40...

Page 66: ...AA 3L PROJ WELDS ORD 42 AP TO AA 1L PROJ WELD ORD 43 AN TO AA 4L FCAW ORD 44 AM TO AA 2L PROJ WELDS ORD 45 AJ TO AA 3L S WELDS ORD 46 AC TO AJ TO AA 4L S WELDS ORD 47 AE TO AA 3L S WELDS ORD 48 AE TO...

Page 67: ...49 AF TO AC TO AA 5 SD S WELDS CRT 50 AC TO AA 7 SD S WELDS ORD 51 AS TO AA 4 SD S WELDS ORD 52 AR TO AC 2 SD FCAW CRT Back to Index...

Page 68: ...53 AK TO AJ 2R PROJ WELDS ORD 54 AM TO AD 2R 2L PROJ WELDS ORD 55 AF TO AF 6 SD S WELDS ORD 56 AR TO AF 1 SD PROJ WELDS ORD Back to Index...

Page 69: ...57 AT TO AB 2 SD S WELDS CRT 58 AK TO AB 5R 4L PROJ WELDS ORD Back to Index...

Page 70: ...59 AR TO AH 1R 1L PROJ WELDS CRT 60 AU TO AH 8R 8L S WELDS ORD 61 AK TO AS 4 SD PROJ WELDS ORD Back to Index...

Page 71: ...62 AW TO AV 2 SD FCAW CRT 63 AX TO AV TO AG 2 SD S WELDS ORD 64 AH TO AG 1 SD S WELD ORD 65 AH TO AV TO AG 1 SD S WELD ORD 66 AV TO AG 27 SD S WELDS ORD Back to Index...

Page 72: ...AX TO AW TO AG 2 SD S WELDS ORD 68 AY TO AH TO AG 2 SD S WELDS CRT 69 AH TO AG 1 SD S WELDS CRT 70 AW TO AH TO AG 1 SD S WELDS ORD 71 AX TO AG 3 SD S WELDS ORD 72 AW TO AG 4 SD S WELDS ORD Back to Ind...

Page 73: ...73 AY TO AH TO AG 2 SD S WELDS ORD 74 AW TO AG 3 SD S WELDS ORD 75 AH TO AG 4 SD S WELDS ORD 76 AW TO AH TO AG 2 SD S WELDS ORD 77 AR TO AY 1 SD FCAW CRT 78 AY TO AG 3 SD FCAW CRT Back to Index...

Page 74: ...Back to Index WELD LOCATION OVERVIEW ZONES...

Page 75: ...Back to Index...

Page 76: ...AD I P AE BRACKET WIPER AF BRACKET VIN PLATE ATTACH AG PANEL COWL TOP INNER AH PANEL COWL TOP LOWER AJ BRACKET WIPER AK BRACKET COWL PLENUM AL REINF BRAKE PEDAL AM STUD WELD EXTERNAL HEADER PT PNT CUT...

Page 77: ...EAD I P AE BRACKET WIPER AF BRACKET VIN PLATE ATTACH AG PANEL COWL TOP INNER AH PANEL COWL TOP LOWER AJ BRACKET WIPER AK BRACKET COWL PLENUM AL REINF BRAKE PEDAL AM STUD WELD EXTERNAL HEADER PT PNT CU...

Page 78: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 79: ...01 AC TO AB 4 S WELDS ORD 02 AC TO AB TO AA 5 S WELDS ORD 03 AD TO AA 6 S WELDS ORD 04 AF TO AA 2 S WELDS ORD 05 AE TO AA 3 S WELDS ORD Back to Index...

Page 80: ...06 AG TO AA 38 S WELDS ORD Back to Index...

Page 81: ...07 AH TO AG TO AA 25 S WELDS ORD 08 AH TO AA 2 S WELDS ORD Back to Index...

Page 82: ...09 AK TO AC TO AA 2 S WELDS ORD 10 AJ TO AH 5 S WELDS ORD 11 AK TO AH 2 S WELDS ORD 12 AL TO AG 2 S WELDS ORD Back to Index...

Page 83: ...Back to Index 13 AH TO AA 4 PROJ WELDS ORD 14 AM TO AH 4 PROJ WELDS ORD 15 AP TO AL 1 PROJ WELD ORD...

Page 84: ...Back to Index 16 AG TO AC 1 BEAD STRUC ADH ORD 17 AD TO AC 1 BEAD STRUC ADH ORD...

Page 85: ...SECTION Back to Index AA PANEL DASH AB CROSSMEMBER DASH AC REINF DASH PANEL AD STUD WELD INTERNAL HEADER PT NIBS NO FIN CLUTCH TO DASH AE SPACER WELD AF STUD WELD INTERNAL HEADER PT NIBS NO FIN ACCEL...

Page 86: ...VERVIEW 7 Back to Index AA PANEL DASH AB CROSSMEMBER DASH AC REINF DASH PANEL AD STUD WELD INTERNAL HEADER PT NIBS NO FIN CLUTCH TO DASH AE SPACER WELD AF STUD WELD INTERNAL HEADER PT NIBS NO FIN ACCE...

Page 87: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 88: ...01 AB TO AA 9 S WELDS ORD 02 AD TO AA 4 PROJ WELDS 03 AE TO AC 4 PROJ WELDS 04 AC TO AB TO AA 1 S WELD ORD 05 AF TO AA 3 PROJ WELDS 06 AC TO AA 11 S WELDS ORD Back to Index...

Page 89: ...07 AG TO AA 9 S WELDS ORD Back to Index...

Page 90: ...L FRT RT BK EXTENSION RAIL FRT LT BL BULKHEAD CROSSMEMBER BN BRACKET BATTERY HOLD DOWN BP NUT WELD HEX NIBS NO FIN PILOT PT BATTERY HOLD DOWN BR 06104987AA CANISTER TO DASH BS 05115828AABRACKASSY ACCE...

Page 91: ...RAIL FRT RT BK EXTENSION RAIL FRT LT BL BULKHEAD CROSSMEMBER BN BRACKET BATTERY HOLD DOWN BP NUT WELD HEX NIBS NO FIN PILOT PT BATTERY HOLD DOWN BR 06104987AA CANISTER TO DASH BS 05115828AABRACKASSY A...

Page 92: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 93: ...01 AD TO AC 4R 4L S WELDS ORD 02 AC TO AA 8R 8L S WELDS ORD 03 AC TO AB 16 S WELDS ORD 04 AD TO AC TO AA 2 S WELDS ORD 05 AE TO AC 8 S WELDS ORD Back to Index...

Page 94: ...6 AL TO AG 1 PROJ WELD ORD 07 AF TO AG 1 SD S WELD ORD 08 AH TO AF 2 SD S WELDS ORD 09 AJ TO AE 4 FCAW ORD Back to Index 10 AK TO AC 3 PROJ WELDS ORD 11 AC TO AB 17 S WELDS ORD0 12 AC TO AB 3 FCAW ORD...

Page 95: ...Back to Index 13 AR TO AP 20R 19L S WELDS CRT 14 AR TO AP TO AN 1 SD S WELD CRT 15 AR TO AM 7R 2L S WELDS ORD 16 AP TO AN 2 SD S WELDS ORD 17 AM TO AT 1L S WELD ORD 18 AS TO AR 6R S WELD ORD...

Page 96: ...Back to Index 20 AV TO AU TO AM 4R S WELDS ORD 21 AU TO AM 3R S WELDS ORD 22 AV TO AM 6R S WELDS ORD 23 AS TO AR 6L S WELDS ORD 24 AW TO AM 5L S WELD ORD 25 AW TO AR 4L S WELDS ORD...

Page 97: ...o Index 26 AX TO AC TO AB 4 S WELDS ORD 27 AY TO AC TO AB 4 S WELDS ORD 28 BA TO AZ 1 PROJ WELD ORD 29 AY TO AX 2 S WELDS ORD 30 AX TO AC 3 S WELDS ORD 31 AY TO AC 3 S WELDS ORD 32 BB TO AC 3 PROJ WEL...

Page 98: ...Back to Index 33 BD TO BC 4 PROJ WELDS ORD 34 BF TO BE 6 S WELDS ORD 35 BH TO BF 1 PROJ WELDS ORD 36 BG TO BF TO BE 2 S WELDS CRT 37 BG TO BF 1 S WELD ORD...

Page 99: ...Back to Index 38 BK TO BJ 6R 8L S WELDS ORD 39 BL TO BJ 1 SD S WELD ORD...

Page 100: ...Back to Index 40 BP TO BN 2 PROJ WELDS ORD 41 BS TO BR 2 PROJ WELDS ORD 42 BU TO BT 2 PROJ WELDS ORD 43 BW TO BV 1 PROJ WELD ORD...

Page 101: ...ILLAR LWR DOOR HINGE RT AB REINF BODY FRT HINGE PILLAR LWR DOOR HINGE LT AC REINF INR BODY SILL RT AC REINF INR BODY SILL LT AD REINF BODY CTR PILLAR INR LWR RT AD REINF BODY CTR PILLAR INR LWR LT AE...

Page 102: ...ILLAR LWR DOOR HINGE RT AB REINF BODY FRT HINGE PILLAR LWR DOOR HINGE LT AC REINF INR BODY SILL RT AC REINF INR BODY SILL LT AD REINF BODY CTR PILLAR INR LWR RT AD REINF BODY CTR PILLAR INR LWR LT AE...

Page 103: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 104: ...01 AC TO AB 1 SD S WELD ORD 02 AB TO AA 5 SD S WELDS ORD 03 AC TO AA 12 SD S WELDS ORD Back to Index...

Page 105: ...04 AD TO AC 12 SD S WELDS ORD Back to Index...

Page 106: ...05 AE TO AC 12 SD S WELDS ORD 06 AF TO AC 3 SD S WELDS ORD Back to Index...

Page 107: ...07 AG TO AA 6 SD S WELDS ORD Back to Index...

Page 108: ...Back to Index WELD LOCATION OVERVIEW ZONES...

Page 109: ...FRONT FENDER LT AB PANEL FRT FENDER HEADLAMP CLOSURE RT AB PANEL FRT FENDER HEADLAMP CLOSURE LT AC PANEL HOOD OTR AD REINF HOOD INR PANEL SLAM AD REINF HOOD INR PANEL SLAM AE REINF HOOD INR PANEL HIN...

Page 110: ...RT AA PANEL FRONT FENDER LT AB PANEL FRT FENDER HEADLAMP CLOSURE RT AB PANEL FRT FENDER HEADLAMP CLOSURE LT AC PANEL HOOD OTR AD REINF HOOD INR PANEL SLAM AD REINF HOOD INR PANEL SLAM AE REINF HOOD I...

Page 111: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 112: ...01 AB TO AA 6 SD S WELDS ORD Back to Index...

Page 113: ...02 AD TO AF 13 S WELDS ORD 03 AE TO AF 3 SD S WELD ORD 04 AD TO AD 4 S WELDS ORD 05 AD TO AG 2 S WELDS ORD Back to Index...

Page 114: ...06 AG TO AF 14 S WELDS CRT Back to Index...

Page 115: ...07 AF TO AC 2 STRUC ADH 08 AF TO AC 2 STRUC ADH 09 AD TO AC 1 STRUC ADH Back to Index...

Page 116: ...10 AF TO AC 1 STRUC ADH 11 AF TO AC 2 STRUC ADH Back to Index...

Page 117: ...C BRACKET REINF OTR BELT FRT DR RR RT AC BRACKET REINF OTR BELT FRT DR RR LT AD REINF FRT DOOR LATCH RT AD REINF FRT DOOR LATCH LT AE BEAM ASSY IMPACT FRT DOOR RT AE BEAM ASSY IMPACT FRT DOOR LT AF ST...

Page 118: ...GLASS RUN LT AC BRACKET REINF OTR BELT FRT DR RR RT AC BRACKET REINF OTR BELT FRT DR RR LT AD REINF FRT DOOR LATCH RT AD REINF FRT DOOR LATCH LT AE BEAM ASSY IMPACT FRT DOOR RT AE BEAM ASSY IMPACT FRT...

Page 119: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 120: ...01 AB TO AA 24 SD S WELDS ORD Back to Index...

Page 121: ...02 AD TO AA 10 SD S WELDS ORD 03 AC TO AA 3 SD S WELDS ORD 04 AE TO AA 10 SD S WELDS SAF Back to Index...

Page 122: ...05 AF TO AA 4 SD S WELDS CRT 06 AG TO AA 2 SD S WELDS ORD 07 AH TO AA 3 SD S WELDS ORD Back to Index...

Page 123: ...08 AK TO AJ 1 STRUC ADH ORD 09 AM TO AJ 7 STRUC ADH ORD Back to Index...

Page 124: ...Back to Index 10 AM TO AJ 1 STRUC ADH ORD 11 AJ TO AB 1 STRUC ADH ORD 12 AJ TO AB 1 STRUC ADH ORD 13 AJ TO AB 1 STRUC ADH ORD...

Page 125: ...Back to Index 14 AJ TO AB 1 STRUC ADH ORD...

Page 126: ...LATE DOOR HINGE AE BRACKET GLASS CHANNEL MOUNTING RR RT AE BRACKET GLASS CHANNEL MOUNTING RR LT AF STUD PLATE DOOR HINGE MTG STUD AF STUD PLATE DOOR HINGE MTG STUD AG REINF RR DOOR LATCH RT AG REINF R...

Page 127: ...LATE DOOR HINGE AE BRACKET GLASS CHANNEL MOUNTING RR RT AE BRACKET GLASS CHANNEL MOUNTING RR LT AF STUD PLATE DOOR HINGE MTG STUD AF STUD PLATE DOOR HINGE MTG STUD AG REINF RR DOOR LATCH RT AG REINF R...

Page 128: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 129: ...01 AB TO AA 8 SD S WELD SAF 02 AC TO AA 4 SD S WELD ORD 03 AD TO AA 2 SD S WELD CRT 04 AE TO AA 2 SD S WELDS ORD 05 AF TO AA 2 SD S WELDS CRT Back to Index...

Page 130: ...06 AG TO AA 6 SD S WELDS CRT 07 AH TO AA 2 SD S WELDS ORD 08 AJ TO AA 24 SD S WELDS ORD Back to Index...

Page 131: ...09 AK TO AL 7 SD STRUC ADH 10 AB TO AL 3 SD GUM DROP Back to Index...

Page 132: ...11 AA TO AL 1 SD STRUC ADH 12 AJ TO AL 3 SD STRUC ADH Back to Index...

Page 133: ...LIFTGATE SECTION Back to Index AA PANEL LIFTGATE INR AB PANEL LIFTGATE INR PANEL LATCH MOUNTING AC TAPPING PLATE LIFTGATE INR PANEL HINGE MOUNTING AD REINF TAPPING PLATE LIFTGATE TO GAS PROP AE PANEL...

Page 134: ...ON LEGEND OVERVIEW 14 Back to Index AA PANEL LIFTGATE INR AB PANEL LIFTGATE INR PANEL LATCH MOUNTING AC TAPPING PLATE LIFTGATE INR PANEL HINGE MOUNTING AD REINF TAPPING PLATE LIFTGATE TO GAS PROP AE P...

Page 135: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 136: ...01 AB TO AA 17 S WELDS CRT Back to Index...

Page 137: ...02 AE TO AA 3 S WELDS ORD 03 AD TO AA 2 S WELDS ORD 04 AE TO AA 6 S WELDS ORD Back to Index...

Page 138: ...Back to Index 05 AE TO AA S WELDS ORD 06 AD TO AA 2 S WELDS ORD 07 AC TO AA 3 S WELDS ORD...

Page 139: ...Back to Index 08 AE TO AA 1 STRUC ADH ORD 09 AE TO AA 1 STRUC ADH ORD 10 AE TO AA 1 STRUC ADH ORD...

Page 140: ...Back to Index...

Page 141: ...Back to Index WELD LOCATION OVERVIEW ZONES...

Page 142: ...AD CROSSMEMBER AN CROSSMEMBER DASH AP BRACKET FRT ENGINE MOUNT AR PANEL SIDE FRT RAIL OTR RT AR PANEL SIDE FRT RAIL OTR LT AS PANEL FRT SIDE RAIL INR RT AS PANEL FRT SIDE RAIL INR LT AT SHIELD FRT FEN...

Page 143: ...LWR AM BULKHEAD CROSSMEMBER AN CROSSMEMBER DASH AP BRACKET FRT ENGINE MOUNT AR PANEL SIDE FRT RAIL OTR RT AR PANEL SIDE FRT RAIL OTR LT AS PANEL FRT SIDE RAIL INR RT AS PANEL FRT SIDE RAIL INR LT AT...

Page 144: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 145: ...01 AE TO AC TO AA 1 SD S WELDS ORD 02 AC TO AA 6 SD S WELDS ORD 03 AC TO AB 2 SD S WELDS ORD 04 AD TO AC 8 SD S WELDS ORD 05 AF TO AE TO AD 3 S WELDS CRT Back to Index...

Page 146: ...06 AG TO AC 4 S WELDS ORD 07 AH TO AC 6 SD S WELDS ORD 08 AH TO AE TO AC 1 SD S WELDS ORD 09 AK TO AJ 3 SD S WELDS ORD Back to Index...

Page 147: ...10 AN TO AM TO AL 4 SD S WELDS ORD 11 AS TO AR TO AA 1 S WELD ORD 12 AP TO AE 1 S WELD ORD 13 AP TO AE TO AA 1 S WELD ORD 14 AP TO AG TO AA 1 S WELD ORD Back to Index...

Page 148: ...5 AU TO AT TO AP 1 S WELDS ORD 16 AT TO AP TO AE 1 S WELD ORD 17 AP TO AE 2 S WELDS ORD 18 AR TO AE 2 SD S WELDS ORD 19 AW TO AV TO AR 2 SD S WELDS ORD 20 AW TO AR TO AE 6 SD S WELDS ORD Back to Index...

Page 149: ...21 AZ TO AY 8 SD S WELDS ORD 22 AY TO AX 5 SD S WELDS ORD Back to Index...

Page 150: ...23 BD TO AS 2 SD S WELDS ORD 24 BA TO AS 6 SD S WELDS ORD 25 BC TO AS 2 SD S WELDS ORD 26 BB TO BA 1 SD S WELD ORD 27 BC TO BA 1 SD S WELD ORD Back to Index...

Page 151: ...28 BD TO AK 4 SD S WELDS ORD 29 BE TO BD 2 SD S WELDS ORD 30 BD TO AS TO AK 2 SD S WELDS ORD 31 AR TO AK 5 SD S WELDS ORD 32 BD TO AK 4 SD S WELDS ORD Back to Index...

Page 152: ...33 AS TO AR TO AE 1 S WELD ORD 34 AT TO AR TO AS 3 S WELDS ORD 35 BF TO AR 1 S WELD ORD 36 BF TO AU TO AT 1 S WELDS ORD 37 AR TO AA 1 MIGBRZ CRT Back to Index...

Page 153: ...38 AU TO AC 4 S WELDS ORD 39 AV TO AC 2 SD S WELDS ORD 40 AE TO AC 1 SD S WELDS ORD 42 AV TO AE TO AC 1 SD S WELDS ORD Back to Index...

Page 154: ...42 BH TO AR 1 PROJ WELD ORD 43 BG TO AE 1 PROJ WELD ORD 44 BH TO AE 1 PROJ WELD ORD 45 AR TO AE 1 MIGBRZ CRT 46 AR TO AA 1 MIGBRZ CRT Back to Index...

Page 155: ...47 BH TO AR 1 PROJ WELD ORD 48 BH TO AS 1 PROJ WELD ORD 49 BJ TO BB 1 PROJ WELD ORD 50 BG TO BB 1 PROJ WELD ORD 51 BH TO AZ 1 PROJ WELD ORD Back to Index...

Page 156: ...SPECIAL HVAC TO DASH AP STUD WELD EXTERNAL PNT CUTTER PILOT PT SPECIAL DEAD PEDAL TO DASH AR STUD WELD EXTERNAL HEADER PT PNT CUTTER SPECIAL HVAC INLET TO COWL TOP INR AR STUD WELD EXTERNAL HEADER PT...

Page 157: ...TER PILOT PT SPECIAL HVAC TO DASH AP STUD WELD EXTERNAL PNT CUTTER PILOT PT SPECIAL DEAD PEDAL TO DASH AR STUD WELD EXTERNAL HEADER PT PNT CUTTER SPECIAL HVAC INLET TO COWL TOP INR AR STUD WELD EXTERN...

Page 158: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 159: ...AA 10R S WELDS ORD 02 AC TO AA 2R S WELDS ORD 03 AU TO AA 2 SD S WELDS ORD 04 AB TO AA 8R S WELDS ORD 05 AC TO AB TO AA 2R S WELDS ORD 06 AD TO AB TO AA 1R S WELDS ORD 32 AV TO AE 1 PROJ WELD ORD Back...

Page 160: ...07 AD TO AB TO AA 1L S WELD ORD 08 AC TO AB TO AA 2L S WELDS ORD 09 AB TO AA 8L S WELDS ORD 10 AC TO AA 2L S WELDS ORD 11 AD TO AA 10L S WELDS ORD 33 AW TO AA 2L PROJ WELD ORD Back to Index...

Page 161: ...12 AD TO AB 30 S WELDS ORD 13 AF TO AD TO AB 4 S WELDS ORD 34 AP TO AD 2 PROJ WELDS ORD Back to Index...

Page 162: ...14 AR TO AA 2 SD PROJ WELDS ORD 15 AR TO AH 3 SD PROJ WELDS ORD 16 AJ TO AA 2 SD S WELDS ORD 17 AG TO AA 6 SD S WELDS ORD 35 AH TO AB TO AA 4 SD S WELDS ORD Back to Index...

Page 163: ...18 AK TO AB 7 S WELDS ORD 19 AM TO AB 11 S WELDS ORD 20 AL TO AB 6 S WELDS ORD 36 AX TO AA 2L PROJ WELDS ORD Back to Index...

Page 164: ...21 AP TO AB 14 PROJ WELDS ORD 22 AN TO AB 8 S WELDS ORD 23 AX TO AL 2 PROJ WELDS ORD 24 AX TO AT 2 PROJ WELDS ORD 37 AX TO AB 2 PROJ WELDS ORD Back to Index...

Page 165: ...25 AS TO AH TO AA 10 SD S WELDS ORD 26 AH TO AA 8 SD S WELDS ORD 27 AS TO AH 23 SD S WELDS ORD Back to Index...

Page 166: ...28 AT TO AB TO AC 2 R1L S WELDS ORD 29 AT TO AL TO AB 5 S WELDS ORD 30 AT TO AB TO AN 6 S WELDS ORD 31 AT TO AB 16 S WELDS ORD Back to Index...

Page 167: ...PANEL SIDE FRT RAIL QTR RT AR PANEL SIDE FRT RAIL QTR LT AS CROSSMEMBER DASH AS CROSSMEMBER DASH AT CROSSMEMBER DASH AU PANEL DASH LWR AV EXTENSION DASH LWR AV EXTENSION DASH LWR AW EXTENSION RAIL FR...

Page 168: ...ING FRT LT AR PANEL SIDE FRT RAIL QTR RT AR PANEL SIDE FRT RAIL QTR LT AS CROSSMEMBER DASH AS CROSSMEMBER DASH AT CROSSMEMBER DASH AU PANEL DASH LWR AV EXTENSION DASH LWR AV EXTENSION DASH LWR AW EXTE...

Page 169: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 170: ...01 AC TO AB 5 SD S WELDS ORD 02 AC TO AA 3 SD S WELDS ORD 03 AC TO AB TO AA 2 SD S WELDS ORD 04 AE TO AB 4 SD S WELDS ORD 05 AE TO AD TO AB 2 SD S WELDS ORD 06 AF TO AD 1 SD S WELDS ORD Back to Index...

Page 171: ...07 AH TO AA 4 SD S WELDS ORD 08 AG TO AC TO AB 2 SD S WELDS ORD 09 AL TO AK TO AJ 3 SD S WELDS ORD Back to Index...

Page 172: ...1 AJ TO AM TO AN 1 SD S WELD ORD 12 AM TO AJ 1 SD S WELDS ORD 13 AM TO AN 5 SD S WELDS ORD Back to Index 14 AS TO AR TO AJ 2 SD S WELDS ORD 15 AR TO AJ 1 SD S WELD ORD 16 AE TO AJ 3 SD S WELDS ORD 17...

Page 173: ...8 AU TO AT 3 S WELDS ORD 19 AU TO AT TO AJ 11 S WELDS ORD 20 AT TO AJ 4 S WELDS ORD 21 AV TO AJ 1R 1L S WELDS ORD 22 AV TO AT TO AJ 2R 2 L S WELDS ORD 23 AU TO AT TO AW 1R 1L S WELDS ORD Back to Index...

Page 174: ...24 AK TO AJ 1 SD FCAW CRT 25 AL TO AJ 5 SD FCAW CRT Back to Index...

Page 175: ...ER SPECIAL DIESEL COOLER TO FRT FLOOR PAN ASSY AH STUD WELD EXTERNAL HEADER PT PNT CUTTER SPECIAL FRT FLR PAN FRT H SHLD TO FLR PAN AH STUD WELD EXTERNAL HEADER PT PNT CUTTER SPECIAL FRT FLR PAN RR H...

Page 176: ...R SPECIAL DIESEL COOLER TO FRT FLOOR PAN ASSY AH STUD WELD EXTERNAL HEADER PT PNT CUTTER SPECIAL FRT FLR PAN FRT H SHLD TO FLR PAN AH STUD WELD EXTERNAL HEADER PT PNT CUTTER SPECIAL FRT FLR PAN RR H S...

Page 177: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 178: ...01 AB TO AA 35 S WELDS ORD Back to Index...

Page 179: ...02 AD TO AB TO AA 4 S WELDS SAF 03 AG TO AA 27 S WELDS ORD 04 AD TO AG TO AA 4 S WELDS SAF 05 AD TO AA 4 SD S WELDS ORD 06 AD TO AG TO AA 2 S WELDS SAF Back to Index...

Page 180: ...Back to Index 07 AF TO AA TO AE 2 S WELDS ORD 08 AE TO AA TO AG 4 S WELDS ORD 09 AE TO AA 14 S WELDS ORD 10 AB TO AA TO AF 4 S WELDS SAF 11 AA TO AF 2 SD S WELDS ORD 12 AB TO AA 2 S WELDS SAF...

Page 181: ...Back to Index 13 AF TO AA TO AB 2 S WELDS ORD 14 AE TO AB 2 S WELDS ORD 15 AF TO AE TO AA 14 S WELDS ORD 16 AE TO AA 14 S WELDS ORD 17 AE TO AA TO AG 4 S WELDS ORD...

Page 182: ...Back to Index 18 AA TO AG 30 S WELDS ORD 19 AC TO AA 3 SD S WELDS ORD 20 AD TO AA TO AG 4 S WELDS SAF 21 AD TO AA TO AG 4 S WELDS ORD...

Page 183: ...Back to Index 22 AJ TO AE 5 PROJ WELDS ORD 23 AH TO AG 6 PROJ WELS ORD 24 AH TO AA 21 PROJ WELDS ORD...

Page 184: ...LWR RT AR SIDEMEMBER RR FLOOR LWR LT AS REINF RR SEAT BELT AT EXTENSION RR FLOOR CROSSMEMBER FRT RT AT EXTENSION RR FLOOR CROSSMEMBER FRT LT AU BRACKET RR SEAT AV CROSSMEMBER RR FLOOR FRT AW STUD WEL...

Page 185: ...EMBER RR FLOOR LWR RT AR SIDEMEMBER RR FLOOR LWR LT AS REINF RR SEAT BELT AT EXTENSION RR FLOOR CROSSMEMBER FRT RT AT EXTENSION RR FLOOR CROSSMEMBER FRT LT AU BRACKET RR SEAT AV CROSSMEMBER RR FLOOR F...

Page 186: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 187: ...01 AB TO AA 17 S WELDS ORD 02 AB TO AC TO AA 1 SD S WELD ORD 03 AD TO AC 5 SD S WELDS ORD Back to Index...

Page 188: ...04 AA TO AG 23 S WELDS ORD 05 AA TO AH TO AG 6 S WELDS SAF 06 AA TO AC 3 SD S WELDS ORD 07 AA TOA F 5 SD S WELDS ORD Back to Index...

Page 189: ...08 AP TO AM TO AL 2 S WELD ORD 09 AP TO AN TO AL 2 S WELDS ORD 10 AL TO AM 6 S WELDS ORD 11 AF TO AL 16 S WELDS ORD 12 AL TO AM TO AF 2 S WELDS ORD Back to Index...

Page 190: ...13 AP TO AN TO AL 2 S WELDS ORD 14 AP TO AM TO AL 2 S WELDS ORD 15 AL TO AM TO AF 2 S WELDS ORD 16 AF TO AL 16 S WELDS ORD 17 AL TO AM 6 SD S WELDS ORD Back to Index...

Page 191: ...18 AK TO AJ 4 SD S WELDS ORD 19 AF TO AK TO AL 1 SD S WELDS ORD 20 AJ TO AK TO AL 1 SD S WELDS ORD 21 AW TO AJ 2 PROJ WELDS ORD 22 AH TO AJ 4 SD S WELDS ORD 23 AP TO AN 4 SD FCAW CRT Back to Index...

Page 192: ...24 AA TO AF TO AR 8 SD S WELDS ORD 25 AA TO AF 9 SD S WELDS ORD Back to Index...

Page 193: ...26 AA TO AT 2 SD S WELDS ORD 27 AA TO AS 22 S WELDS ORD 28 AA TO AS 9 S WELDS SAF 29 AA TO AU 7 S WELDS ORD Back to Index...

Page 194: ...30 AA TO AV 7 S WELDS ORD 31 AA TO AT TO AV 4 SD S WELDS ORD 32 AW TO AT 1 PROJ WELD ORD 33 AA TO AS TO AV 11 S WELDS SAF 34 AA TO AU TO AV 6 S WEDLS SAF Back to Index...

Page 195: ...35 BC TO BA TO AA 19 S WELDS ORD 36 BC TO BA 19 S WELDS ORD 37 BC TO AJ 2 SD S WELDS ORD 38 BC TO AJ TO AF 1 SD ORD Back to Index...

Page 196: ...39 BC TO AA 9 S WELDS ORD 40 BE TO BC TO BA 2 SD S WELDS ORD 41 BE TO BC 2 SD S WELDS ORD 42 BC TO BB 1 SD S WELDS ORD 43 BC TO BB TO BA 1 SD S WELD ORD Back to Index...

Page 197: ...44 AV TO AT 11 SD S WELDS ORD 45 BA TO AW 1 PROJ WELD ORD 46 BD TO BA TO AR 2 SD S WELDS ORD 47 BB TO AB TO AR 1 SD S WELD ORD 48 BA TO AR TO AF 1 SD S WELD ORD Back to Index...

Page 198: ...49 BG TO AA 1 PROJ WELD ORD 50 BG TO AR 4 PROJ WELD ORD 51 AW TO AA 8 PROG WELD ORD 52 AW TO AF 3 PROJ WELDS ORD 53 AW TO AC 1 PROJ WELD ORD Back to Index...

Page 199: ...50 BG TO AR 4 PROJ WELD ORD 51 AW TO AA 8 PROJ WELD ORD 52 AW TO AF 3 PROJ WELDS ORD 53 AW TO AC 1 PROJ WELD ORD Back to Index...

Page 200: ...ORQUE BOX RT AL BRACE TORQUE BOX LT AM CROSSMEMBER FRT FLOOR PAN FRT RT AM CROSSMEMBER FRT FLOOR PAN FRT LT AN BRACKET FRT SEAT RR AP SILL FRT FLOOR AP SILL FRT FLOOR AR SILL RR FLOOR SIDEMEMBER RT AR...

Page 201: ...LWR AL BRACE TORQUE BOX RT AL BRACE TORQUE BOX LT AM CROSSMEMBER FRT FLOOR PAN FRT RT AM CROSSMEMBER FRT FLOOR PAN FRT LT AN BRACKET FRT SEAT RR AP SILL FRT FLOOR AP SILL FRT FLOOR AR SILL RR FLOOR SI...

Page 202: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 203: ...01 AC TO AE TO AA 1 S WELD ORD 02 AC TO AF TO AD 1 S WELD ORD 03 AD TO AB TO AA 1 S WELD ORD 04 AF TO AD TO AB 3 S WELDS ORD Back to Index...

Page 204: ...05 AC TO AE TO AA 2 S WELDS ORD 06 AC TO AF TO AD 2 S WELDS ORD 07 AD TO AA TO AB 2 S WELDS ORD 08 AD TO AF TO AB 2 S WELDS ORD 09 AC TO AF TO AB 1 S WELD ORD Back to Index...

Page 205: ...10 AG TO AH TO AB 11 S WELDS ORD 11 AG TO AH 8 S WELDS ORD Back to Index...

Page 206: ...12 AK TO AA TO AB 1 S WELD ORD 13 AA TO AB 3 S WELDS ORD 14 AG TO AA TO AB 1 S WELD ORD 15 AJ TO AB 12 SD S WELDS ORD 16 AA TO AL TO AB 3 SD S WELDS ORD Back to Index...

Page 207: ...T 4 SD S WELDS ORD 18 AP TO AR 2 SD S WELDS ORD 19 AP TO AB 4L S WELDS SAF 20 AP TO AB TO AN 2 SD S WELDS SAF 21 AP TO AN 4 SD S WELDS SAF 22 AM TO AP 2 SD S WELD ORD 23 AS TO AP TO AM 4 SD S WELDS OR...

Page 208: ...24 AN TO AB TO AU 7 SD S WELDS ORD 25 AU TO AB TO AV 2 SD S WELDS ORD 26 AV TO AW 3 SD S WELDS ORD 27 AW TO AB 2 SD S WELDS ORD Back to Index...

Page 209: ...S ORD 29 AP TO AR TO AY 2 SD S WELD ORD 30 AR TO AP TO AB 1 SD S WELDS ORD 31 AR TO AP TO AB 1 SD S WELDS ORD 32 AP TO AB 13R 9L S WELDS ORD 33 AX TO AR TO AA 1 SD S WELD ORD 34 AP TO AX TO AB 5 SD S...

Page 210: ...35 AZ TO AP 11 SD S WELDS ORD CRT 36 AR TO AZ TO AP 7 SD S WELDS ORD CRT 37 AZ TO AP TO AU 2 SD S WELDS ORD CRT Back to Index...

Page 211: ...38 AT TO AB 2 SD S WELDS ORD 39 AV TO AT TO AB 4 SD S WELDS ORD 40 AV TO AB 14 AD S WELDS ORD 41 AW TO AV TO AB 2 SD S WELDS ORD Back to Index...

Page 212: ...42 AY TO AB 17 S WELDS ORD 40 AY TO AW TO AB 2 S WELDS ORD Back to Index...

Page 213: ...44 AY TO AB 13 S WELDS ORD 45 AW TO AY TO AB 2 S WELDS ORD Back to Index...

Page 214: ...46 AE TO AA 2 FCAW ORD 47 AB TO AA 2 FCAW ORD 48 AF TO AB 2 FCAW ORD Back to Index...

Page 215: ...Back to Index WELD LOCATION OVERVIEW ZONES...

Page 216: ...T AG PANEL B PILLAR INR RT AG PANEL B PILLAR INR LT AH RAIL ROOF SIDE INR RT AH RAIL ROOF SIDE INR LT AJ PANEL B PILLAR INR RT AJ PANEL B PILLAR INR LT AK REINF QTR INR BELTLINE RT AK REINF QTR INR BE...

Page 217: ...EL B PILLAR INR RT AG PANEL B PILLAR INR LT AH RAIL ROOF SIDE INR RT AH RAIL ROOF SIDE INR LT AJ PANEL B PILLAR INR RT AJ PANEL B PILLAR INR LT AK REINF QTR INR BELTLINE RT AK REINF QTR INR BELTLINE L...

Page 218: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 219: ...01 AB TO AA 10 SD S WELDS ORD 02 AD TO AC 8 SD S WELDS ORD Back to Index...

Page 220: ...2 SD S WELDS ORD 05 AJ TO AG 6 SD S WELDS ORD 06 AG TO AH 3 SD S WELDS ORD 07 AG TO AH TO AF 2 SD S WELDS ORD Back to Index 08 AF TO AG 5 SD S WELDS ORD 09 AJ TO AH TO AD 4 SD S WELDS ORD 10 AA TO AH...

Page 221: ...2R S WELDS ORD 13 AL TO AG TO AF 2R S WELDS SAF 14 AF TO AG 3 SD S WELDS SAF 15 AG TO AF 1 SD S WELDS ORD 16 AF TO AK 2 SD S WELDS ORD 17 AG TO AK TO AF 4 SD S WELDS ORD 18 AK TO AG 3 SD S WELDS ORD B...

Page 222: ...L S WELDS ORD 20 AK TO AM TO AG 4R S WELDS ORD 21 AG TO AN 9R 2L S WELDS ORD 22 AN TO AG TO AK 3R S WELDS ORD 23 AP TO AN TO AG 2 SD S WELDS ORD 24 AG TO AP 1 SD S WELDS ORD 25 AN TO AP 8 SD S WELDS O...

Page 223: ...26 AG TO AF 3L S WELDS ORD 27 AG TO AK 4L S WELDS ORD 28 AK TO AM TO AG 3 L S WELDS ORD 29 AN TO AG TO AK 1 L S WELDS ORD 30 AR TO AG TO AN 1 SD S WELDS ORD 31 AN TO AG 13L S WELD ORD Back to Index...

Page 224: ...32 AN TO AR 2 SD S WELDS ORD 33 AR TO AS 1 SD S WELDS ORD 34 AJ TO AH 1 SD STRUC ADH Back to Index...

Page 225: ...AB REINF RETAINER ASSY BODY SIDE APERTURE C PILLAR DOOR LATCH STRKR AC TAPPING PLATE DOOR STRIKER RR DR STRIKER AD TROUGH LIFTGATE SIDE DRAIN RT AD TROUGH LIFTGATE SIDE DRAIN LT AE PANEL TAIL LAMP RT...

Page 226: ...RETAINER ASSY BODY SIDE APERTURE C PILLAR DOOR LATCH STRKR AC TAPPING PLATE DOOR STRIKER RR DR STRIKER AD TROUGH LIFTGATE SIDE DRAIN RT AD TROUGH LIFTGATE SIDE DRAIN LT AE PANEL TAIL LAMP RT AE PANEL...

Page 227: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 228: ...01 AB TO AA 6 SD S WELDS ORD 02 AC TO AB 2 SD S WELDS ORD Back to Index...

Page 229: ...03 AF TO AE TO AA 1 SD S WELD ORD 04 AF TO AA 3 SD S WELDS ORD 05 AE TO AA 8 SD S WELDS ORD 06 AF TO AE 6 SD S WELDS ORD 07 AF TO AD 3 SD S WELDS ORD Back to Index...

Page 230: ...08 AD TO AA 11 SD S WELDS ORD 09 AE TO AD 8 SD S WELDS ORD Back to Index...

Page 231: ...RTURE RR FASCIA ATTACHING LT AJ PANEL QTR INR LWR RR RT AJ PANEL QTR INR LWR RR LT AK PANEL B PILLAR INR RT AK PANEL B PILLAR INR LT AL REINF BODY CTR PILLAR INR RT AL REINF BODY CTR PILLAR INR LT AM...

Page 232: ...RR FASCIA ATTACHING LT AJ PANEL QTR INR LWR RR RT AJ PANEL QTR INR LWR RR LT AK PANEL B PILLAR INR RT AK PANEL B PILLAR INR LT AL REINF BODY CTR PILLAR INR RT AL REINF BODY CTR PILLAR INR LT AM REINF...

Page 233: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 234: ...01 AB TO AA 13 SD S WELDS ORD 02 AC TO AB 3 SD S WELDS ORD 03 AC TO AB TO AA 2 SD S WELDS ORD 38 AH TO AD 4 SD S WELDS ORD Back to Index...

Page 235: ...04 AE TO AD TO AA 8 SD S WELDS ORD 05 AD TO AC TO AA 8 SD S WELDS ORD 06 AE TO AD TO AA 2 SD S WELDS ORD Back to Index...

Page 236: ...07 AF TO AD 8 SD S WELDS ORD 08 AG TO AF TO AD 7 SD S WELDS ORD 09 AH TO AF 3 SD S WELDS ORD Back to Index...

Page 237: ...10 AE TO AD TO AA 3 SD S WELDS ORD 11 AE TO AD TO AA 4 SD S WELDS SAF 12 AD TO AA 4 SD S WELD ORD 13 AJ TO AG TO AD 6 SD S WELDS ORD 14 AG TO AD 1 SD S WELD ORD Back to Index...

Page 238: ...15 AL TO AK TO AD 14 SD S WELDS SAF 16 AM TO AK TO AD 5 SD S WELDS ORD 17 AK TO AD 4 SD S WELDS ORD Back to Index...

Page 239: ...18 AL TO AK TO AD 22 SD S WELDS ORD 19 AL TO AD 2 SD S WELDS ORD 20 AN TO AK TO AD 4 SD S WELDS ORD Back to Index...

Page 240: ...21 AR TO AP TO AD 23R 22L S WELDS ORD 22 AP TO AD 3R 4L S WELDS ORD Back to Index...

Page 241: ...AN TO AD 4 SD S WELD ORD 24 AV TO AP TO AD 2 SD S WELDS ORD 25 AT TO AD 1 SD S WELD ORD 26 AU TO AP TO AD 2 SD S WELDS ORD 27 AP TO AD 7 SD S WLEDS ORD 28 AP TO AN TO AD 1 SD S WELDS ORD Back to Inde...

Page 242: ...29 AD TO AA 9 SD S WELDS ORD 30 AL TO AD 3 SD S WELDS ORD 31 AP TO AL TO AD 2 SD S WELDS ORD 32 AP TO AD 7 SD S WELDS ORD 33 AL TO AD TO AA 2 SD S WELDS ORD Back to Index...

Page 243: ...34 AD TO AA 1 SD STRUCT ADH ORD 35 AD TO AA 1 SD STRUCT ADH ORD 36 AS TO AP TO AD 4 SD A WELDS ORD 37 AS TO AD TO AA 9 SD S WELDS ORD Back to Index...

Page 244: ...T SUNROOF SECTION Back to Index AA PANEL ROOF OTR AB 05074902AA HEADER ROOF FRT LWR AC HEADER ROOF FRT UPR AD HEADER ROOF FRT LWR AE REINF RR HEADER UPR AT LIFTGATE HINGE RT ROOF SUPPORT AF BOW ROOF B...

Page 245: ...GEND OVERVIEW 23 Back to Index AA PANEL ROOF OTR AB 05074902AA HEADER ROOF FRT LWR AC HEADER ROOF FRT UPR AD HEADER ROOF FRT LWR AE REINF RR HEADER UPR AT LIFTGATE HINGE RT ROOF SUPPORT AF BOW ROOF B...

Page 246: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 247: ...01 AB TO AA 16 S WELDS ORD Back to Index...

Page 248: ...02 AD TO AC 19 S WELDS ORD 03 AE TO AC 10 S WELDS ORD 04 AC TO AA 7 S WELDS ORD Back to Index...

Page 249: ...05 AB TO AA 1 STRUC ADH 06 AF TO AA 2 STRUC ADH 07 AG TO AA 2 STRUC ADH 08 AC TO AA 1 STRUC ADH Back to Index...

Page 250: ...SECTION Back to Index AA PANEL ROOF PANEL W SUNROOF OPENING AB 05074902AA HEADER ROOF FRT LWR AC HEADER ROOF RR UPR AD HEADER ROOF RR LWR AE REINF RR HEADER UPR LIFTGATE HINGE RT ROOF SUPPORT AF BOW...

Page 251: ...ERVIEW 26 Back to Index AA PANEL ROOF PANEL W SUNROOF OPENING AB 05074902AA HEADER ROOF FRT LWR AC HEADER ROOF RR UPR AD HEADER ROOF RR LWR AE REINF RR HEADER UPR LIFTGATE HINGE RT ROOF SUPPORT AF BOW...

Page 252: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 253: ...01 AB TO AA 16 S WELDS ORD Back to Index...

Page 254: ...02 AD TO AC 19 S WELDS ORD 03 AS TO AC 10 S WELDS ORD 04 AC TO AA 7 S WELDS ORD Back to Index...

Page 255: ...05 AB TO AA 1 STRUC ADH 06 AG TO AA 2 STRUC ADH 07 AC TO AA 1 STRUC ADH Back to Index...

Page 256: ...RR LT AV REINF QTR INR BELTLINE RT AV REINF QTR INR BELTLINE LT AW REINF RR WHEEHOUSE RT PANEL ASSY RR WHEELHOUSE INR AW REINF RR WHEEHOUSE LT PANEL ASSY RR WHEELHOUSE INR AX PANEL RR WHEELHOUSE INR R...

Page 257: ...WHEELHOUSE INR AU PANEL QTR INR RR RT AU PANEL QTR INR RR LT AV REINF QTR INR BELTLINE RT AV REINF QTR INR BELTLINE LT AW REINF RR WHEEHOUSE RT PANEL ASSY RR WHEELHOUSE INR AW REINF RR WHEEHOUSE LT P...

Page 258: ...WELD LAYOUT LOCATION GUIDE Back to Index...

Page 259: ...01 AB TO AC TO AA 2 SD S WELDS ORD 02 AD TO AB TO AC 1 SD S WELD ORD 03 AB TO AC 3 SD S WELDS ORD 04 AD TO AC 29 SD S WELDS ORD 05 BS TO AC 2 SD S WELDS ORD Back to Index...

Page 260: ...06 AE TO AG TO AB 2 SD S WELDS ORD 07 AF TO AA 2 SD S WELDS ORD 08 AB TO AA 8 SD S WELDS ORD 09 AE TO AB TO AH 4 SD S WELDS ORD 10 AA TO AB TO AH 24 SD S WELDS ORD Back to Index...

Page 261: ...ELDS ORD 12 AJ TO AB 3 SD S WELDS ORD 13 AK TO AJ TO AB 1 SD S WELDS ORD 14 AL TO AM TO AB 8 SD S WELDS ORD 15 AM TO AA TO AB 1 SD S WELD ORD 16 AA TO AM TO AL 2 SD S WELDS ORD 17 AM TO AL TO AH 11 SD...

Page 262: ...O AR TO AP 2 SD S WELDS ORD 19 AS TO AR TO AM 1 SD S WELD ORD 20 AS TO AL TO AM 7 SD S WELDS ORD 21 AL TO AN TO AM 17 SD S WELDS ORD 22 AS TO AP TO AM 5 SD S WELDS ORD 23 AL TO AN 3 SD FCAW ORD Back t...

Page 263: ...24 AS TO AR TO AH 3 SD S WELDS ORD 25 AT TO AP TO AH 1 SD S WELD ORD 26 AW TO AV TO AU 3R S WELDS ORD 27 AW TO AU 3R S WELDS ORD 28 BT TO AW TO AU 1R S WELD ORD Back to Index...

Page 264: ...O AU 2R S WELDS ORD 30 AX TO AU 6R S WELDS ORD 31 AV TO AX TO AU 4R S WELDS ORD 32 AR TO AX TO AU 2R S WELDS ORD 33 AR TO AX 3R S WELDS ORD 34 AT TO AR TO AX 1R S WELD ORD 35 AT TO AR 4R S WELDS ORD B...

Page 265: ...L S WELDS ORD 37 AT TO AR TO AX 1L S WELD ORD 38 AR TO AX 3L S WELDS ORD 39 AR TO AX TO AU 2L S WELDS ORD 40 AV TO AX TO AU 6L S WELDS ORD 41 AX TO AU 12L S WELDS ORD 42 BE TO AX TO AU 2L S WELDS ORD...

Page 266: ...43 AY TO AU 6 SD S WELDS ORD 44 BA TO AY TO AU 1 SD S WELD ORD 45 BA TO AY 1 SD S WELD ORD 46 BA TO AZ TO AY 5 SD S WELDS ORD Back to Index...

Page 267: ...D S WELDS ORD 49 BD TO BE 1 SD S WELD ORD 50 BC TO BD TO BE 1 SD S WELD ORD 51 BC TO BE 5 SD S WELDS ORD Back to Index 52 BC TO BE TO BA 1 SD S WELD ORD 53 BC TO BA 2 SD S WELDS ORD 54 BC TO BA TO AZ...

Page 268: ...Back to Index 56 BK TO BG 3 SD S WELDS ORD 57 BH TO BJ 3 SD S WELDS ORD 58 BU TO BF TO BG 4 SD S WELDS ORD 59 BF TO BG 2 SD S WELDS ORD...

Page 269: ...Back to Index 60 BM TO AU TO BL 2 SD S WELDS ORD 61 BG TO AU TO BL 2 SD S WELDS ORD 62 BG TO AA TO BL 1 SD S WELD ORD 63 BF TO BG TO BL 1 SD S WELD ORD...

Page 270: ...SD S WELD ORD 65 BA TO BN TO BL 1 SD S WELD ORD 66 BA TO BN 3 SD S WELDS ORD 67 BM TO BP 2 SD S WELDS ORD 68 BM TO BP TO BN 2 SD S WELDS ORD 69 BM TO BN 7 SD S WELDS ORD 70 BN TO AU 2 SD S WELDS ORD 7...

Page 271: ...Back to Index 72 BV TO BJ 1 SD GUM DROP ORD 73 AA TO BR TO AU TO BL 1 SD STRUC ADH ORD 74 BA TO BN 1 SD STRUC ADH ORD...

Page 272: ...Back to Index 75 AL TO AM TO AB TO AA 1 SD STRUC ADH ORD 76 AY TO AU 1 SD STRUC ADH ORD 77 BA TO AZ 1 SD STRUC ADH ORD 78 AE TO AB 1 SD STRUC ADH ORD...

Page 273: ...Back to Index...

Page 274: ...pared for use by all body technicians involved in the repair of Dodge Caliber Body Paint Sealer Locations Structural Adhesive Locations NVH Structural Foam Locations Sound Deadener Locations DaimlerC...

Page 275: ...GH HOLES ON THE INTE RIOR AND EXTERIOR OF TH VEHICLE THAT WOULD PERMIT LEAKAGE OF WATER AIR OR EXHAUST FUMES TYPICAL AREAS OF THE EXTERIOR THAT MUST BE SEALED ARE LISTED IN THIS SECTION AREAS OF THE I...

Page 276: ...NEL 8 LEFT INNER QUARTER PANEL 9 UNDERBODY 10 REAR FLOOR PAN 11 ROOF BODY SIDE APERTURE 12 ROOF ROOF REAR UPPER HEADER 13 BODY SIDE APERTURE LIFTGATE DRAIN TROUGH 14 TAIL LAMP PANEL 15 LOWER LIFTGATE...

Page 277: ...BODY SEALER LOCATIONS Back to Index Figure 1 ROOF CORNER APERTURE PANEL...

Page 278: ...BODY SEALER LOCATIONS Back to Index Figure 2 UPPER COWL TOP COWL SIDE...

Page 279: ...BODY SEALER LOCATIONS Back to Index Figure 3 FRONT WHEELHOUSE SHOCK TOWER...

Page 280: ...BODY SEALER LOCATIONS Back to Index Figure 4 DASH PLENUM COWL SIDE PANEL...

Page 281: ...BODY SEALER LOCATIONS Figure 5 DASH STEERING SHAFT BRACKET Back to Index...

Page 282: ...BODY SEALER LOCATIONS Back to Index Figure 6 DASH FRONT FLOOR PAN...

Page 283: ...BODY SEALER LOCATIONS Back to Index Figure 7 REAR WHEELHOUSES...

Page 284: ...BODY SEALER LOCATIONS Back to Index Figure 8 RIGHT INNER QUARTER PANEL...

Page 285: ...BODY SEALER LOCATIONS Back to Index Figure 9 LEFT INNER QUARTER PANEL...

Page 286: ...BODY SEALER LOCATIONS Back to Index Figure 10 UNDERBODY...

Page 287: ...BODY SEALER LOCATIONS Figure 11 REAR FLOOR PAN Back to Index...

Page 288: ...BODY SEALER LOCATIONS Figure 12 ROOF BODY SIDE APERTURE Back to Index...

Page 289: ...BODY SEALER LOCATIONS Back to Index Figure 13 ROOF ROOF REAR UPPER HEADER...

Page 290: ...BODY SEALER LOCATIONS Back to Index Figure 14 BODY SIDE APERTURE LIFGATE DRAIN TROUGH...

Page 291: ...BODY SEALER LOCATIONS Back to Index Figure 15 TAIL LAMP PANEL...

Page 292: ...BODY SEALER LOCATIONS Back to Index Figure 16 LOWER LIFTGATE CLOSEOUT PANEL...

Page 293: ...BODY SEALER LOCATIONS Back to Index Figure 17 BODY SIDE APERTURE INNER BODY SIDE REINFORCEMENT...

Page 294: ...BODY SEALER LOCATIONS Back to Index Figure 18 REAR WHEELHOUSE...

Page 295: ...BODY SEALER LOCATIONS Back to Index Figure 19 REAR WHEELHOUSE REAR QUARTER PANEL EXTENSION...

Page 296: ...JEEP COMPASS STRUCTURAL ADHESIVE LOCATIONS Back to Index...

Page 297: ...dex DESCRIPTION FIGURE PLENUM ASSEMBLY 1 FRONT FLOOR 2 SIDEMEMBER ASSEMBLY 1 OF 3 3 SIDEMEMBER ASSEMBLY 2 OF 3 4 SIDEMEMBER ASSEMBLY 3 OF 3 5 BODY SIDE APERTURE INNER ASSEMBLY 6 BODY SIDE APERTURE COM...

Page 298: ...STRUCTURAL ADHESIVE LOCATIONS Figure 1 PLENUM ASSEMBLY Back to Index...

Page 299: ...STRUCTURAL ADHESIVE LOCATIONS Figure 2 FRONT FLOOR Back to Index...

Page 300: ...STRUCTURAL ADHESIVE LOCATIONS Figure 3 SIDEMEMBER ASSEMBLY 1 OF 3 Back to Index...

Page 301: ...STRUCTURAL ADHESIVE LOCATIONS Figure 4 SIDEMEMBER ASSEMBLY 2 OF 3 Back to Index...

Page 302: ...STRUCTURAL ADHESIVE LOCATIONS Back to Index Figure 5 SIDE MEMBER ASSEMBLY 3 OF 3...

Page 303: ...STRUCTURAL ADHESIVE LOCATIONS Figure 6 BODY SIDE APERTURE INNER ASSEMBLY Back to Index...

Page 304: ...STRUCTURAL ADHESIVE LOCATIONS Figure 7 BODY SIDE APERTURE COMPLETE Back to Index...

Page 305: ...STRUCTURAL ADHESIVE LOCATIONS Figure 8 ROOF WITHOUT SUNROOF Back to Index...

Page 306: ...STRUCTURAL ADHESIVE LOCATIONS Figure 9 ROOF WITH SUNROOF Back to Index...

Page 307: ...STRUCTURAL ADHESIVE LOCATIONS Figure 10 BODY IN WHITE COMPLETE 1 OF 2 Back to Index...

Page 308: ...STRUCTURAL ADHESIVE LOCATIONS Figure 11 BODY IN WHITE COMPLETE 2 OF 2 Back to Index...

Page 309: ...Back to Index Jeep Compass NVH STRUCTURAL FOAM INFORMATION SOUND DEADENER...

Page 310: ...ATIONS Back to Index DESCRIPTION FIGURE UPPER A PILLAR 1 LOWER B PILLAR 2 INNER B PILLAR 3 LOWER C PILLAR 4 FRONT FLOOR PAN 5 REAR FLOOR PAN 6 SPARE WHEEL WELL 7 Preferred Mopar Products Expandable Fo...

Page 311: ...Figure 1 UPPER A PILLAR Back to Index...

Page 312: ...Figure 2 LOWER A PILLAR Back to Index...

Page 313: ...Figure 3 INNER B PILLAR Back to Index...

Page 314: ...Figure 4 LOWER C PILLAR Back to Index...

Page 315: ...Figure 5 FRONT FLOOR PAN Back to Index...

Page 316: ...Figure 6 REAR FLOOR PAN Back to Index...

Page 317: ...Figure 7 SPARE WHEEL WELL Back to Index...

Page 318: ...JEEP COMPASS FRAME BODY DIMENSIONS Back to Index...

Page 319: ...dimensions are from center of Principal Locating Point PLP or from center to center of PLP and transfer location Vertical dimensions can be taken from the work surface to the locations indicated INDE...

Page 320: ...FRAME BODY DIMENSIONS Figure 1 FRAME DIMENSIONS PLAN VIEW Back to Index...

Page 321: ...FRAME BODY DIMENSIONS Figure 2 FRAME DIMENSIONS SIDE VIEW Back to Index...

Page 322: ...ck to Index OPENING DIMENSIONS DESCRIPTION FIGURE ENGINE BOX OPENING 1 WINDSHIELD OPENING 2 FRONT DOOR OPENING 3 REAR DOOR OPENING 4 QUARTER WINDOW OPENING 5 LIFTGATE OPENING 6 LIFTGATE WINDOW OPENING...

Page 323: ...FRAME BODY DIMENSIONS Figure 1 ENGINE BOX OPENING Back to Index...

Page 324: ...FRAME BODY DIMENSIONS Figure 2 WINDSHIELD OPENING Back to Index...

Page 325: ...FRAME BODY DIMENSIONS Figure 3 FRONT DOOR OPENING Back to Index...

Page 326: ...FRAME BODY DIMENSIONS Figure 4 REAR DOOR OPENING Back to Index...

Page 327: ...FRAME BODY DIMENSIONS Figure 5 QUARTER WINDOW OPENING Back to Index...

Page 328: ...FRAME BODY DIMENSIONS Figure 6 LIFTGATE OPENING Back to Index...

Page 329: ...FRAME BODY DIMENSIONS Figure 7 LIFTGATE WINDOW OPENING Back to Index...

Page 330: ...GAP AND FLUSH DIMENSIONS Back to Index...

Page 331: ...GAP AND FLUSH Back to Index...

Page 332: ...ntion to body dimensions while fitting and welding panels 2 Remove bumper components cooling module headlamp and all other components for clear access to repair area 3 Remove front rail cap panel on d...

Page 333: ...ack to Index 6 Mark existing rail as follows a Right side i On inner rail mark at 50mm forward of the leading edge of flanged hole in rail ii On outer rail continue mark from inner rail RIGHT SIDE ONL...

Page 334: ...Back to Index b Left side i On inner rail mark at 80mm forward of centerline of rear battery tray weld nut located on top of rail ii On outer rail continue mark from inner rail LEFT SIDE ONLY...

Page 335: ...Back to Index 7 Mark replacement part in same location 8 On left rail remove bracket located on inner rail...

Page 336: ...e on the inner rail at the forward edge of the section joint which may need to be recreated or restored ii Left rail section location When installation of new tip is complete there is a 10mm hole in b...

Page 337: ...Clip off the weld flanges top and bottom and dress edges These pieces will be the weld backer 12 Prepare welding equipment per the weld chart at the end of procedure 13 Install the weld backers into t...

Page 338: ...completed on both the inner and outer rail To avoid excessive heat buildup move between inner and outer rail during welding 15 Dress welds without removing any base material paying particular attentio...

Page 339: ...ll new or reposition the lower radiator crossmember and FESM structure and clamp in place and weld 18 Install new front rail cap panel 19 Clean all repaired areas and apply appropriate refinish and co...

Page 340: ...eed 90 110 Vertical 110 130 Vertical Down 245 250 Vertical Down inches per min 60 70 Flat Horizontal 70 90 Flat OH 210 225 Flat OH N A Approx Amperage Vertical Position 110 120 160 170 175 85 3 32 Dia...

Page 341: ...Back to Index...