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Side panel 5D, part of side panel

Side panel 5D, part of side panel

Certain weld joints on the car may be MIG brazed whereby the filler material is bronze rod. The characteristic sign of MIG brazing is that the joint is gold coloured. MIG brazing must always be replaced with new MIG brazing.

Warning

Repairs to MIG brazing using conventional welding methods and normal filler material are forbidden. Cracks can arise which can impair performance in a collision.


Removing


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. Measure 240mm from the upper edge of the C-pillar outer panel and make a mark. Make a mark where the rear side panel radius begins. Cut the outer panel between these points. Take care not to damage the underlying reinforcement.


3. Cut the D-pillar where the rear side panel radius begins. If the lower section of the D-pillar is damaged it must be cut higher up, see point 4.


4. If the lower section of the D-pillar is damaged, it must be cut 140-190mm from the point on the rear upper section of the rear wing.


5. Drill out the spot welds securing the outer side panel by the door opening and door sill.


6. Drill out the spot welds securing:

• outer side panel by wheel housing and rear side window


• rear bumper abutment

Grind away any seam weld. Note that the seam weld may be MIG brazed.


• the D-pillar

Grind away any seam weld. Note that the seam weld may be MIG brazed.


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


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


Fitting


1. Cut and align the spare part.

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

3. Grind clean the surfaces on the body and the spare part that are to be welded.

4. Apply welding primer on the surfaces to be plug and spot-welded. Use Teroson Zink spray.

5. Fit the spare part in place and fix it with a few welding clamps.

6. Plug weld and spot weld the spare part in place at the:

Warning

Repairs to MIG brazing using conventional welding methods and normal filler material are forbidden. Cracks can arise which can impair performance in a collision.


• the D-pillar

Replace any seam weld.


Warning

Repairs to MIG brazing using conventional welding methods and normal filler material are forbidden. Cracks can arise which can impair performance in a collision.


• rear bumper abutment

Replace any seam weld.


• outer side panel, wheel housing and rear side window


7. Spot weld the door aperture and sill and all weld the joints in the C-pillar and the D-pillar.


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

9. Smooth off the welds.

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

11. Apply primer to all bare metal surfaces.

12. Seal joints and seams with sealant.

13. Apply anti-corrosion agent to internal surfaces of the side panel after painting. Use Terotex HV 400.