Rear Crossmember Bolt Replacement Forward Bolt

1. Using HAND TOOLS 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. Refer to Rear Compartment Floor Panel Carpet Replacement in Interior Trim.



4. Locate the scribed marks (2) labeled XMBR BOLT in the floor which identifies the area directly over the front bolt to be replaced. The scribed marks are located approximately 230 mm (9 in) inward from the rear compartment side panel and 255 mm (10 in) rearward of the intermediate panel.




Important: There are fuel system components under the cargo compartment floor. When drilling the access hole restrict the drilling depth to 6 mm (15/64 in).

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



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

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.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install a new nut to the crossmember bolt and tighten the nut with HAND TOOLS.

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




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: There are fuel system components under the cargo compartment floor. Do not use rivets or screws to attach the cover over the hole.

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 perimeter of the cover.



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.



11. Install the rear compartment carpet. Refer to Rear Compartment Floor Panel Carpet Replacement in Interior Trim.

Rear Crossmember Bolt Replacement Rearward Bolt

1. Using HAND TOOLS remove the nut from the rear crossmember rear bolt that is to be replaced.
2. Access the rear stowage compartment.
3. Remove the rear compartment floor carpet. Refer to Rear Compartment Floor Panel Carpet Replacement in Interior Trim.



4. Locate the raised area (1) over the rear bolt. The raised area is approximately 23 mm (9 in) inboard from the wheelhouse and approximately 31 mm (12 in) forward of the rear compartment vertical panel.



5. Cut out an access hole over the rear bolt.

•	Cut on a 45 degree angle or less to aid in using the piece for a patch.

•	Cut out a 100 x 150 mm (2 x 3 in) section forming an access hole.

•	Save the cut out piece so it can be used to patch the hole.




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

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.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install a new nut to the crossmember bolt and tighten with HAND TOOLS.

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




4. Lightly scuff sand the bonding surfaces of both the panel and the patch.
5. Wipe each bonding surface with alcohol.
6. Apply a generous amount of adhesive bonding material to the underside and complete perimeter of the patch.



7. Position the patch to its original position and press the patch firmly in place squeezing out the adhesive to form a leak proof seal.

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

8. Add additional adhesive if necessary and smooth out to insure a leak proof seal.
9. Allow the bonding adhesive to cure.
10. Install the rear compartment carpet. Refer to Rear Compartment Floor Panel Carpet Replacement in Interior Trim.