SAAB WIS ONLINE

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.
Note

Do not damage any inner panels or reinforcements.


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.

8. Locate and mark all the necessary factory welds of the body side outer upper panel.

9. Drill all factory welds. Note the number and location of welds for installation of the service assembly.

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.


7. Verify the fit of the body side outer upper panel.

8. Clamp the body side outer upper panel into position.

9.
Note

Refer to Welded, Brazed, and Riveted Joint Specifications .


Spot weld the body side outer upper panel (1) accordingly.


10. MIG-braze the body side outer upper panel (2).

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 .