Rear Crossmember Bolt Replacement Front Bolt

Important: Use hand tools when removing and installing a crossmember bolt nut.

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 Exterior/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.




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.



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 used on the vehicle depending on the position.

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




Important: Each time a crossmember bolt nut is removed it must be replaced with a new nut.

3. Using hand tools install and tighten a NEW NUT to the crossmember bolt.

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: 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.



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 Exterior/Interior Trim.

Rear Crossmember Bolt Replacement Rear Bolt

Important: Use HAND TOOLS to remove and install the crossmember bolt nuts.

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 Exterior/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 securing the bolt to the anti rotation device.




Important: Each time a crossmember bolt nut is removed it must be replaced with a new nut.

3. Using hand tools Install and tighten a NEW crossmember bolt nut.

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. Clean each bonding surface by wiping with alcohol.
6. Apply a generous amount of adhesive bonding material to the underside and complete periphery 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 Exterior/Interior Trim.