Body Side Outer Upper Panel Replacement
Body Side Outer Upper 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. |
Remove the roof outer panel. Refer to
Roof Outer Panel Replacement
.
|
4. |
Visually inspect the damage. Repair as much of the damage as possible.
|
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. |
Create cut lines (1) on the body side outer upper panel. |
7. |
Cut the body side outer upper panel where sectioning is to be performed.
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8. |
Locate and mark all the necessary factory welds of the body side outer upper panel.
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9. |
Drill all factory welds. Note the number and location of welds for installation of the service assembly.
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10. |
Remove the body side outer upper panel.
|
11. |
Remove the luggage carrier side rail front support reinforcement (1). Refer to
Luggage Carrier Side Rail Front Support Reinforcement Replacement
.
|
12. |
Remove the luggage carrier side rail rear support reinforcement (1). Refer to
Luggage Carrier Side Rail Rear Support Reinforcement Replacement
.
|
Installation Procedure |
1. |
Clean and prepare the attaching surfaces for welding (1).
|
2. |
Apply bodywork repair through structural adhesive to body (1). Refer to
Structural Adhesive Body Repairs
.
|
3. |
Apply 1K-Adhesive on the sound deadeners. Refer to
Chemical Products
.
|
4. |
Install the luggage carrier side rail front support reinforcement (1). Refer to
Luggage Carrier Side Rail Front Support Reinforcement Replacement
.
|
5. |
Install the luggage carrier side rail rear support reinforcement (1). Refer to
Luggage Carrier Side Rail Rear Support Reinforcement Replacement
.
|
6. |
Position the body side outer upper panel (1) on the vehicle.
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7. |
Verify the fit of the body side outer upper panel.
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8. |
Clamp the body side outer upper panel into position.
|
9. |
Spot weld the body side outer upper panel (1) accordingly. |
10. |
MIG-braze the body side outer upper panel (2).
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11. |
Grind MIG-brazed seams.
|
12. |
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)
.
|
13. |
Install the roof outer panel. Refer to
Roof Outer Panel Replacement
.
|
14. |
Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
|
15. |
Enable the SIR system. Refer to
SIR Disabling and Enabling
.
|