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Rocker Panel > < Roof Front Frame

Streetka 2003.5 (01.2003-07.2005)

Side Panel Sheet Metal Repairs - A-Pillar Outer Panel Section and Reinforcement Streetka 2003.5 (01/2003-07/2005)
Removal and Installation

General Equipment
Measurement and alignment angle system
  1. Repair parts
    • A-pillar outer panel
    • A-pillar reinforcement
    • Upper and lower door hinges

Removal

NOTE:
NOTE:In order to prevent body distortion while performing repairs, the body must be stabilised on an alignment angle system.
  1. General Notes
    • The fender, fender apron panel reinforcement, rocker panel and roof front frame are removed before commencing the repair.
    • Move carpets and wiring out of the working area.

  1. Door hinges
    • Grind out the weld seams.

  1. Outer A-pillar
    1. Rough cut location.
    1. Grind out the weld seams.
    1. Mill out the spot welds.

  1. A-pillar reinforcement
    1. Mill out the spot welds.
    1. Grind out the weld seams.

Installation

NOTE:
NOTE:Before resistance spot welding of body panels with a total panel thickness of 3 mm and greater, the welding equipment instructions contained in sub-section 501-25A must be followed.
  1. A-pillar reinforcement
    • Drill holes for puddle welding (diameter: 10 mm).

  1. NOTE:
    NOTE:Only tack-weld the A-pillar reinforcement at the windshield and door cutout. The final weld joint is made with the outer A-pillar installed.
    A-pillar reinforcement
    1. Resistance spot weld.
    1. Puddle weld.
    1. Intermittent MIG weld.

  1. Outer A-pillar
    • Drill holes for puddle welding (diameter: 10 mm).

  1. NOTE:
    NOTE:For added strength, a cluster of resistance spot welds must be made around the upper and lower hinge mountings.
    Outer A-pillar
    1. Resistance spot weld.
    1. Puddle weld.
    1. Intermittent MIG weld.

  1. Door hinges
    • Continuous MIG weld.

Rocker Panel > < Roof Front Frame