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Home >> Saab >> 2011 >> 9-5 Turbo4, Standard >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Adjustment Replacement >> Front Compartment Front Inner Side Rail Extension Replacement >> Installation Procedure

Installation Procedure

  1. Prepare battery tray support bracket in the area (1).

    4x slots 6x20 mm (0.2x0.7 in) 

  2. Prepare the new front compartment front inner side rail extension in the areas:
    Fig 1: Identifying Battery Tray Support Bracket
    G09437631Courtesy of SAAB-SCANIA OF AMERICA, INC.
    1. 2.1. 2x slots 8x24 mm (0.3x0.9 in) 
    2. 2.2. 2x slots 8x24 mm (0.3x0.9 in) 
  3. Prepare the new front compartment front outer side rail in the area (1).
    Fig 2: Identifying Front Compartment Front Outer Side Rail
    G09437632Courtesy of SAAB-SCANIA OF AMERICA, INC.
  4. Cut the new front compartment front outer side rail section in the corresponding locations to fit the original panel. The sectioning joint should be trimmed to allow min. 1 times the metal thickness at the sectioning joint (1).
  5. Apply bodywork repair through structural adhesive to body (1). Refer to STRUCTURAL ADHESIVE BODY REPAIRS .
    Fig 3: Identifying Bodywork Repair Through Structural Adhesive To Body
    G09437633Courtesy of SAAB-SCANIA OF AMERICA, INC.
  6. Position the front compartment front inner side rail extension onto the vehicle.
    Fig 4: Positioning Front Compartment Front Inner Side Rail Extension Onto Vehicle
    G09437634Courtesy of SAAB-SCANIA OF AMERICA, INC.
  7. Verify the fit of the front compartment front inner side rail extension.
  8. Clamp the front compartment front inner side rail extension into position.
  9. NOTE: Refer to WELDED, BRAZED, AND RIVETED JOINT SPECIFICATIONS .

    Spot weld (1) the front compartment front inner side rail extension accordingly.

    Fig 5: Identifying Spot Weld Area On Front Compartment Front Inner Side Rail Extension
    G09437635Courtesy of SAAB-SCANIA OF AMERICA, INC.
  10. MIG-braze (2) the front compartment front inner side rail extension.
  11. Position the front compartment front outer side rail.
    NOTE: Refer to WELDED, BRAZED, AND RIVETED JOINT SPECIFICATIONS .
    Fig 6: Positioning Front Compartment Front Outer Side Rail
    G09437636Courtesy of SAAB-SCANIA OF AMERICA, INC.
  12. Verify the fit of the front compartment front outer side rail.
  13. Clamp the front compartment front outer side rail into position.
  14. MIG-braze (1) the front compartment front outer side rail.
  15. Grind all MIG-brazed seams.
  16. NOTE: Refer to WELDED, BRAZED, AND RIVETED JOINT SPECIFICATIONS .

    Spot weld (1) the front compartment front outer side rail accordingly.

    Fig 7: Identifying Spot Weld Area On Front Compartment Front Outer Side Rail
    G09437637Courtesy of SAAB-SCANIA OF AMERICA, INC.
  17. Install the front wheelhouse front panel. Refer to FRONT WHEELHOUSE FRONT PANEL REPLACEMENT .
  18. NOTE: Refer to WELDED, BRAZED, AND RIVETED JOINT SPECIFICATIONS .

    Position the battery tray support bracket.

    Fig 8: Positioning Battery Tray Support Bracket
    G09437638Courtesy of SAAB-SCANIA OF AMERICA, INC.
  19. Verify the fit of the battery tray support bracket.
  20. Clamp the battery tray support bracket into position.
  21. MIG-braze (1) the battery tray support bracket.
  22. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to ANTI-CORROSION TREATMENT AND REPAIR (BASE) or ANTI-CORROSION TREATMENT AND REPAIR (CORROSION PROTECTION) .
  23. Install all related panels and components.
  24. Install the front wheelhouse rear liner. Refer to FRONT WHEELHOUSE REAR LINER REPLACEMENT .
  25. Install the front wheelhouse front liner. Refer to FRONT WHEELHOUSE FRONT LINER REPLACEMENT .
  26. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION .
  27. Enable the SIR system. Refer to SIR DISABLING AND ENABLING .
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