Crossmember Bolt Replacement, Rear (Front)

Rear Crossmember Bolt Replacement (Front Bolt): Removal Procedure:

REMOVAL PROCEDURE
1. Remove the nut from the rear crossmember front bolt that is to be replaced.
2. Access the rear compartment.
3. Remove the rear compartment floor carpet.

Rear Crossmember Bolt Replacement (Front Bolt): Removal Procedure:

4. Locate the scribed marks (2) labeled XMBR B0LT in the floor which identifies the area directly over the front bolt to be replaced.

Rear Crossmember Bolt Replacement (Front Bolt): Removal Procedure:

IMPORTANT: When drilling the access hole through the floor, restrict the drilling depth to 6 mm (15/64 in) so as not to damage the fuel system components under the floor.

5. Drill an access hole with a 50 mm (2 In) hole saw directly over the bolt.

Rear Crossmember Bolt Replacement (Front Bolt): Removal Procedure:

6. Drill out the anti rotation device rivet with a 6 mm (15/16 in) drill bit.
7. Remove the bolt.

Rear Crossmember Bolt Replacement (Front Bolt): Installation Procedure:

INSTALLATION PROCEDURE

IMPORTANT: Check the new bolt against the old bolt for proper length. There are four different length crossmember bolts.

1. Install the crossmember bolt.
2. Install a rivet to the bolt anti rotation device.

Rear Crossmember Bolt Replacement (Front Bolt): Installation Procedure:

3. Install the nut to the bolt.

Tighten
Tighten the crossmember bolt nut to 110 N.m (81 lb in).

Rear Crossmember Bolt Replacement (Front Bolt): Installation Procedure:

4. Cut a suitable piece of galvanized steel or fiber reinforced plastic sized to cover the hole in the floor with at least a 25 mm (1 in) overlap on all sides.

IMPORTANT: Do not use rivets, screws or do any drilling to attach the cover over the hole. Damage to the fuel system components under the floor could result.

5. Lightly scuff sand the bonding surfaces of both the panel and the cover.
6. Wipe each bonding surface with alcohol.
7. Apply a 3 to 6 mm (1/8 to 1/4 in) bead of adhesive around the periphery of the cover.

Rear Crossmember Bolt Replacement (Front Bolt): Installation Procedure:

8. Install the cover over the hole in the floor. Apply pressure to the cover to squeeze out the adhesive to form a consistent leak proof seal.

IMPORTANT: Make sure there is a leak proof seal so that exhaust and fuel fumes can not enter the vehicle.

9. Smooth out the adhesive around the cover making sure there are no skips or gaps.
10. Allow the bonding adhesive to cure.

Rear Crossmember Bolt Replacement (Front Bolt): Installation Procedure:

11. Install the rear compartment carpet.