Window Frame: Service and Repair

Windshield Frame Header Panel Replacement - Front

REMOVAL PROCEDURE

CAUTION: To avoid personal injury when exposed to welding flashes or to galvanized (Zinc Oxide) metal toxic fumes while grinding/cutting on any type of metal or sheet molded compound, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs, welding gloves, and protective clothing.




1. Disable the SIR system. Refer to SIR Disabling and Enabling Zones.
2. Disconnect the negative battery cable.
3. Remove all related panels and components.
4. Repair as much of the damaged area as possible. Refer to Dimensions - Body (Sedan) Dimensions - Body (Extended Sedan).
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary.

IMPORTANT: Note the number and location of the factory welds for installation of the header panel.

6. Locate and drill out all the necessary factory welds.




7. Remove the header panel.

INSTALLATION PROCEDURE

IMPORTANT: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart.




1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
2. Prepare all mating surfaces as necessary.
3. Apply 3M(R) Weld-Thru coating P/N 05916 or equivalent to all mating surfaces.
4. Position the header panel to the vehicle using 3-dimensional measuring equipment. Clamp the front header panel in place.




5. Plug weld accordingly.
6. Clean and prepare all of the welded surfaces.
7. Install all of the related panels and components.
8. Apply the sealers and anti-corrosion materials to the repair area, as necessary.
9. Paint the repaired area. Refer to Basecoat/ Clearcoat Paint Systems in General Information.
10. Connect the negative battery cable.
11. Enable the SIR system. Refer to SIR Disabling and Enabling Zones.