Quarter Outer Panel Replacement
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Quarter Outer Panel Replacement
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Refer to
Approved Equipment for Collision Repair Warning
.
Refer to
Glass and Sheet Metal Handling Warning
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1.
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Note
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Section in specified areas only. Sectioning outside of these areas may compromise the structural integrity of the vehicle. The sectioning procedures have been developed as a more cost-effective alternative to complete replacement.
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Disable the SIR system. Refer to
SIR Disabling and Enabling
.
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3.
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Remove all related panels and components.
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5.
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Note
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Do not damage any inner panels or reinforcements.
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Note
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Note the number and location of the welds for installations of the service part.
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Cut out the quarter outer panel.
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6.
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Locate and drill out all of the necessary factory welds.
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7.
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Note
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Do not damage any inner panels or reinforcements.
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Note
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Note the number and location of the welds for installations of the service part.
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Cut out the quarter outer panel.
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8.
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Locate and drill out all of the necessary factory welds.
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9.
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Note
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Note the number and location of the welds for installations of the service part.
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Locate and drill out all of the necessary factory welds.
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10.
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Remove the damaged quarter outer panel.
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1.
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Note
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Refer SPP, PSO welding parameters for resistance spot welding. See TIS Newsletter for equipment recommendations.
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Cut the replacement quarter 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.
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2.
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Note
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Pre-spot operation: The number of spots is specified in the documentation from the welding equipment manufacturer.
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Prepare inner rocker panel (1) with reinforcement (PSO).
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3.
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Prepare new quarter outer panel in the area (1).
7 slots (5x18 mm / 0.2x0.7 in)
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4.
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Prepare new quarter outer panel in the area (2).
6 slots (5x18 mm / 0.2x0.7 in)
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5.
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Position the new body side outer panel on the vehicle.
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6.
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Verify the fit of the new body side outer panel.
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7.
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Clamp the new body side outer panel into position.
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8.
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Drill fastening holes (1) for waterproof rivets.
4 holes
(4 mm / 0.16 in)
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9.
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Remove new quarter outer panel.
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11.
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Position the quarter outer panel on the vehicle.
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12.
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Verify the fit of the roof outer panel.
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13.
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Clamp the quarter outer panel into position.
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14.
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Spot weld (1) the quarter outer panel accordingly.
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15.
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Spot weld (SPP) the quarter outer panel (2) accordingly.
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16.
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MIG-braze (1) the quarter outer panel.
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17.
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Rivet (3) on the quarter outer panel.
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18.
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MIG-braze (1) the quarter outer panel.
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19.
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MIG-braze (1) the quarter outer panel.
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20.
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Grind MIG brazed seams.
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21.
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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).
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22.
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Bend the wheel arch.
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22.1.
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Apply excess adhesive as a seam seal and corrosion protection using a spatula or flat paintbrush. Use structural adhesive in area (1).
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23.
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Install all related panels and components.
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