Body Side Outer Panel Replacement
Body Side Outer Panel 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 . |
2. |
Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
|
3. |
Repair as much of the damaged area as possible. Refer to
Dimensions - Body
.
|
4. |
Remove all related panels and components.
|
• |
Remove the rear side door. Refer to
Rear Side Door Replacement
.
|
• |
Remove the rear side door weatherstrip - body side. Refer to
Rear Side Door Weatherstrip Replacement
.
|
• |
Remove the rear compartment floor panel carpet. Refer to
Rear Compartment Floor Panel Carpet Replacement
.
|
• |
Remove rear window. Refer to
Rear Window Replacement (Sedan)
.
|
• |
Remove the rear compartment lid. Refer to
Rear Compartment Lid Replacement
|
• |
Remove the rear compartment lid weatherstrip. Refer to
Rear Compartment Lid Weatherstrip Replacement
.
|
• |
Remove the rear bumper fascia. Refer to
Rear Bumper Fascia Replacement
.
|
5. |
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)
.
|
6. |
Cut out the body side outer panel. |
7. |
Locate and drill out all of the necessary factory welds.
|
8. |
Cut out the body side outer panel. |
9. |
Locate and drill out all of the necessary factory welds.
|
11. |
Remove the damaged body side outer panel.
|
Installation Procedure |
1. |
Cut the replacement body side outer panel section 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. |
2. |
Prepare inner rocker panel (1) with reinforcement (PSO). |
3. |
Position the new body side outer panel on the vehicle.
|
4. |
Verify the fit of the new body side outer panel.
|
5. |
Remove new quarter outer panel.
|
6. |
Apply bodywork repair through structural adhesive to body (2). Refer to
Structural Adhesive Body Repairs
.
Adhesive on Sound Deadener (1) Apply glue (3) to the inside of the reinforcement plate. |
7. |
Apply 1K-Adhesive on the sound deadener (1). Refer to
Chemical Products
.
|
8. |
Position the new body side outer panel on the vehicle.
|
9. |
Verify the fit of the new body side outer panel.
|
10. |
Clamp the new body side outer panel into position.
|
11. |
Spot weld (1) the body side outer panel accordingly. |
12. |
Spot weld (SPP) the body side outer panel (1) accordingly. |
13. |
MIG-braze (1) the body side outer panel.
|
14. |
Pre-flange wheel housing.
Using a suitable hammer, bend over the flanged edge 45° (1), at the same time holding a small mallet or block against it. Use structural adhesive in the area (2). |
15. |
Bend the wheel arch.
Apply excess adhesive as a seam seal and corrosion protection using a spatula or flat paintbrush. Use structural adhesive in area (1). |
16. |
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)
.
|
17. |
Install all related panels and components.
|
• |
Install the rear side door. Refer to
Rear Side Door Replacement
.
|
• |
Install the rear side door weatherstrip - body side. Refer to
Rear Side Door Weatherstrip Replacement
.
|
• |
Install the rear compartment floor panel carpet. Refer to
Rear Compartment Floor Panel Carpet Replacement
.
|
• |
Install the rear window. Refer to
Rear Window Replacement (Sedan)
.
|
• |
Install the rear compartment lid. Refer to
Rear Compartment Lid Replacement
|
• |
Install the rear compartment lid weatherstrip. Refer to
Rear Compartment Lid Weatherstrip Replacement
.
|
• |
Install the rear bumper fascia. Refer to
Rear Bumper Fascia Replacement
.
|
18. |
Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
|
19. |
Enable the SIR system. Refer to
SIR Disabling and Enabling
.
|