Body Side Inner Panel Sectioning (5-Door Hatchback 68)
Note: According to
different corrosion warranties, only the regional mandatory joining
methods are allowed.
Removal Procedure
| 3. |
Remove all related panels and
components. |
| 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.
|
| 6. |
Create cut lines on the body
lock pillar center reinforcement (1). |
|
Note: Do not damage
any other panels or reinforcements.
|
| 7. |
Cut the body lock pillar
center reinforcement (1) where sectioning is to be
performed. |
| 8. |
Locate and mark all the
necessary factory welds of the body lock pillar center
reinforcement (1). |
| 9. |
Drill all factory welds. Note
the number and location of welds for installation of the service
assembly. |
| 10. |
Remove the damaged body lock
pillar center reinforcement (1). |
| 11. |
Create cut lines on the body
side inner panel (1). |
|
Note: Do not damage
any other panels or reinforcements.
|
| 12. |
Cut the body side inner panel
(1) where sectioning is to be performed. |
| 13. |
Locate and mark all the
necessary factory welds of the body side inner panel (1).
|
| 14. |
Drill all factory welds. Note
the number and location of welds for installation of the service
assembly. |
| 15. |
Remove the damaged body side
inner panel (1). |
Installation Procedure
| 1. |
Cut the body side inner panel
(1) in corresponding locations to fit the remaining original panel.
The sectioning joint should be trimmed to allow a gap of
one-and-one-half-times the metal thickness at the sectioning
joint. |
| 2. |
Prepare all mating surfaces as
necessary. |
| 3. |
Align the body side inner
panel. |
| 4. |
Create 6 x 20 mm (4/16 x 12/16
in) slots for MIG-brazing in locations where you can not apply a
ressistance spot welder. |
| 5. |
Clean and prepare the
attaching surfaces of the body side inner panel (1) for spot
welding and brazing. |
| 6. |
Apply structural adhesive to
all attaching surfaces |
|
Note: In MIG-brazing
areas 50 mm (2 in) must be kept clear of structural adhesive.
|
| 7. |
Position the body side inner
panel (1). |
| 8. |
Verify the fit of the
panel. |
| 9. |
Clamp the body side inner
panel into position. |
| 10. |
Braze the body side inner
panel (1) accordingly. |
| 11. |
Spot weld the body side inner
panel (1) accordingly |
| 12. |
To create a solid braze with
minimum heat distortion, make 25 mm (1 in) stitch brazes along the
seam with 25 mm (1 in) gaps between them. Then go back and complete
the stitch braze. |
| 13. |
Remove the body lock pillar
upper reinforcement (1) from the body lock pillar center
reinforcement (2). |
| 14. |
Cut the body lock pillar
center reinforcement (1) in corresponding locations to fit the
remaining original panel. The sectioning joint should be trimmed to
allow a gap of one-and-one-half-times the metal thickness at the
sectioning joint. |
| 15. |
Prepare all mating surfaces as
necessary. |
| 16. |
Align the body lock pillar
center reinforcement. |
| 17. |
Create 6 x 20 mm (4/16 x 12/16
in) slots on the body lock pillar center reinforcement (1) for
MIG-brazing in locations where you can not apply a ressistance spot
welder. |
| 18. |
Clean and prepare the
attaching surfaces for spot welding and brazing. |
| 19. |
Apply structural adhesive to
all attaching surfaces |
|
Note: In MIG-brazing
areas 50 mm (2 in) must be kept clear of structural adhesive.
|
| 20. |
Position the body lock pillar
center reinforcement (1). |
| 21. |
Verify the fit of the
panel. |
| 22. |
Clamp the body lock pillar
center reinforcement into position. |
| 23. |
Braze the body lock pillar
center reinforcement (1) accordingly. |
| 24. |
Spot weld the body lock pillar
center reinforcement (1) accordingly. |
| 25. |
Apply the sealers and
anti-corrosion materials to the repair area, as necessary.
|
| 26. |
Paint the repaired
area. |
| 27. |
Install all related panels and
components. |
|
