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Side panel 4D

Side panel 4D

Removing


If the roof is undamaged, the side panel can be cut and joined further down the C-pillar. Damage to the paintwork on the roof can be avoided when the new side panel is welded on.


1. Position the car in an aligning bench and cross-measure if necessary.

Important

The C-pillar must only be cut as described below. Otherwise, there is a risk of damaging the reinforcement inside the C-pillar.


2. Cut the outer sheet of the C-pillar 50 mm from the rear top edge and 140 mm from the front top edge. Be careful not to damage the underlying reinforcement.

3. Drill out the spot-welds holding the outer side panel by the door opening.

4. Drill out the spot-welds on the upper section of the moulding retainer and knock it out.

5. Drill out the spot-welds holding the outer side panel by the wheel housing, rear plate and rear window.


6. Knock away the side panel and straighten any deformed metalwork.


Fitting



1. Cut the spare part so that it overlaps the joint by approximately three centimetres.

2. Drill holes for plug-welding in the spare part.

3. Fit the spare part and fixate with a couple of welding clamps.

4. Cut through the spare part and the body together so that the joint can be welded edge-to-edge. Be careful no to damage the underlying reinforcement.

5. Remove the spare part and grind clean its surfaces and those on the body that are to be welded.

6. Apply welding primer on the surfaces to be plug and spot-welded. Use Teroson Zinkspray.

7. Fit the spare part and fixate with a couple of welding clamps.

8. Plug and spot-weld the spare part.

9. Spot-weld the spare part at the door frame and sill.


10. All-weld the joints.

11. Plug-weld the moulding retainer in the door opening.

12. Smooth off the welds.

13. Remove any remaining welding primer. Welding primer reduces adhesion of paint, filler and sealant.

14. Apply primer to all bare metal surfaces.

15. Seal joints and seams with sealant.

16. Seal the joints at the water channel with Terostat 1K-PUR T 226.

17. Apply anti-corrosion agent to the interior of the side panel. Use Terotex HV 400 or Mercasol 1.