Quarter Outer Panel Sectioning (5-Door Wagon 35)
Special Tools
| • |
BO-6392
Flanging Tool Kit |
For equivalent regional tools, refer to
Special Tools .
Removal Procedure
Warning: Refer to
Approved Equipment for Collision Repair
Warning .
Warning: Refer to
Collision Sectioning Warning .
Warning: Refer to
Glass and Sheet Metal Handling
Warning .
| 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
quarter outer panel (1). |
|
Note: Do not damage
any inner panels or reinforcements.
|
| 7. |
Cut the quarter outer panel
(1) where the sectioning is to be performed. |
| 8. |
Open the wheelhouse flanging
of the quarter outer panel (1). |
| 9. |
Locate and mark all the
necessary factory welds of the quarter outer panel (1).
|
| 10. |
Drill all factory welds. Note
the number and location of welds for installation of the service
assembly. |
| 11. |
To remove the damaged quarter
outer panel (1) cut the adhesive (2) with an appropriate
tool. |
Installation Procedure
| 1. |
Cut the quarter outer 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. |
Clean and prepare the
attaching surfaces for spot welding. |
| 4. |
Create 20x 5 x 18 mm
(4/16 x 11/16 in) (1) slots for MIG-brazing to the quarter
outer panel (2). |
| 5. |
Clip in a new sound barrier to
body side outer panel reinforcement rear reinforcement.
|
| 6. |
Apply one-part urethane
adhesive (1) to the sound barrier (2). |
| 7. |
Apply structural adhesive to
body side inner panel (1) and rocker outer panel rear reinforcement
(2). |
| 8. |
Only right side! Apply
structural adhesive to body side inner panel filler (1).
|
| 9. |
Position the quarter outer
panel (1) on the vehicle. |
| 10. |
Verify the fit of the quarter
outer panel. |
| 11. |
Clamp the quarter outer panel
into position. |
| 12. |
Spot weld the quarter outer
(1) accordingly. |
| |
• |
Quarter outer panel to rocker
panel (2) - 7 spotwelds. |
| |
• |
Flange door opening (3) - 21
spotwelds. |
| |
• |
Flange window opening (4) - 14
spotwelds. |
| 13. |
Braze the quarter outer panel
(1) accordingly. |
| |
• |
Quarter outer panel / D-Pillar
(2) - 220 mm . |
| |
• |
Quarter outer panel / rocker
panel (3) - 350 mm . |
| |
• |
Quarter outer panel / C-Pillar
(4) - 160 mm . |
| 14. |
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.
|
| 15. |
Pre-flanging the flange with
BO-6396 pliers and BO-6392 tool kit
. |
| 16. |
Finish closing the wheelhouse
flanging. |
| 17. |
Apply the sealers and
anti-corrosion materials to the repair area, as necessary.
|
| 18. |
Paint the repaired
area. |
| 19. |
Install all related panels and
components. |
|
