Body Lock Pillar Outer Panel Reinforcement Replacement
Body Lock Pillar Outer Panel Reinforcement Replacement |
Removal Procedure |
Refer to Approved Equipment for Collision Repair Warning .
Refer to Glass and Sheet Metal Handling Warning .
1. |
Disable the SIR system. Refer to
SIR Disabling and Enabling
.
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2. |
Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
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3. |
Visually inspect the damage. Repair as much of the damage as possible.
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4. |
Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to
Anti-Corrosion Treatment and Repair (Base)
Anti-Corrosion Treatment and Repair (Corrosion Protection)
.
|
5. |
Create cut lines on the body lock pillar outer panel. |
6. |
Create cut line
10 mm (0.4 in)
on the upper front side panel (1).
|
7. |
Cut 80 mm in front of the luggage carrier side rail front support reinforcement and 150 mm in front of the luggage carrier side rail rear support reinforcement.
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8. |
Cut out the body lock pillar outer panel roughly.
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9. |
Locate and drill out all of the necessary factory welds.
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10. |
Create cut lines on the body lock pillar outer panel reinforcement (1). |
11. |
Cut out the body lock pillar outer panel reinforcement roughly.
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12. |
Drill out the necessary factory welds (1). |
13. |
Remove the luggage carrier side rail front support reinforcement (2). Refer to
Luggage Carrier Side Rail Front Support Reinforcement Replacement
.
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14. |
Drill out the necessary factory welds (1) on the center pillar inner panel lower reinforcement.
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15. |
Drill out the necessary factory welds (2) on the center pillar inner panel.
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16. |
Remove the damaged body lock pillar outer panel reinforcement.
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Installation Procedure |
1. |
Create cut lines on the body lock pillar outer panel (1). |
2. |
Cut the body lock pillar outer panel in corresponding locations to fit the original panel. The sectioning joint should be trimmed to allow min. 1 times the metal thickness at the sectioning joint.
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3. |
Prepare new body lock pillar outer panel in the area (1).
1 x slots (5 x 18 mm / 0.2 x 0.7 in) |
4. |
Prepare new body center pillar inner panel in the area (1).
14 x slots (8 x 24 mm / 0.3 x 0.9 in) |
5. |
Position and measure (1) from the front hinge pillar body to the center pillar inner panel
1191 mm (48.9 in)
on to the vehicle.
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6. |
Verify the fit of the center pillar inner panel.
|
7. |
Clamp the center pillar inner panel into position.
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8. |
Spot weld the center pillar inner panel (1) accordingly. |
9. |
MIG-braze the center pillar inner panel (2).
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10. |
Grind MIG brazed seams.
|
11. |
Prepare new body lock pillar outer panel reinforcement in the area (1).
Drill out the necessary slots. 9 x slots (8 x 24 mm / 0.3 x 0.9 in) |
12. |
Prepare new body lock pillar outer panel reinforcement in the area (2).
9 x slots (8 x 24 mm / 0.3 x 0.9 in) |
13. |
Clean and prepare the attaching surfaces for welding.
|
14. |
Apply bodywork repair through structural adhesive to body (1). Refer to
Structural Adhesive Body Repairs
.
|
15. |
Position and measure (1) from the front hinge pillar body to the rear hinge pillar body
1090 mm (43 in)
on to the vehicle.
|
16. |
Verify the fit of the body lock pillar outer panel reinforcement.
|
17. |
Clamp the body lock pillar outer panel reinforcement into position.
|
18. |
Spot tack-weld the body lock pillar outer panel reinforcement (1). |
19. |
MIG-braze the body lock pillar outer panel reinforcement (2).
|
20. |
MIG-braze full seam interrupted 9 times
30 mm (1.2 in)
the body lock pillar outer panel reinforcement (3).
|
21. |
MIG-braze full seam interrupted 5 times
30 mm (1.2 in)
the body lock pillar outer panel reinforcement (4).
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22. |
Grind MIG-brazed seams.
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23. |
Install the sound deadener (1).
|
24. |
Install the luggage carrier side rail front support reinforcement. Refer to
Luggage Carrier Side Rail Front Support Reinforcement Replacement
.
|
25. |
Clean and prepare the attaching surfaces for welding.
|
26. |
Apply bodywork repair through structural adhesive to body (1). Refer to
Structural Adhesive Body Repairs
.
|
27. |
Apply 1K-Adhesive bead on the sound deadener (2). Refer to
Chemical Products
.
|
28. |
Position the body lock pillar outer panel on the vehicle.
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29. |
Verify the fit of the roof outer panel.
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30. |
Clamp the body lock pillar outer panel into position.
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31. |
Spot weld the body lock pillar outer panel (1) accordingly. |
32. |
MIG-braze the body lock pillar outer panel (2).
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33. |
Grind MIG brazed seams.
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34. |
Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to
Anti-Corrosion Treatment and Repair (Base)
Anti-Corrosion Treatment and Repair (Corrosion Protection)
.
|
35. |
Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
|
36. |
Enable the SIR system. Refer to
SIR Disabling and Enabling
.
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