| Removal and Installation | | -
Replacement parts - Upper water drain panel reinforcement
- Lower water drain panel reinforcement
| Removal | | -
General Notes - Remove the following components before starting the repairs: quarter panel, rear panel with reinforcement and luggage compartment water drain panel.
- Reposition the carpeting and the wiring harness away from the working area.
| NOTE:The revised cut locations in the upper area need to be taken into account when installing the water drain panel and the quarter panel. | | -
Lower water drain panel reinforcement - Mill out the spot welds.
- Mill out the spot welds (two panel thicknesses).
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Lower water drain panel reinforcement (inside view) | NOTE:The upper quarter panel only needs to be cut out if it is necessary to fully expose the upper water drain panel reinforcement. | | -
NOTE:The cutting dimensions for the quarter panel cut must be accurately met in order to obtain access to the upper water drain panel reinforcement. Upper quarter panel - Cut location.
- Rough cut location.
- Mill out the spot welds.
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- When making the cut at position 1 it is also necessary to cut through the outer area of the roof.
- The spot weld in position 3 is covered by the roof. In order to accurately locate it, you need to slightly lift up the roof sealing flange.
Residual part of the upper quarter panel - Cut location (through two panel thicknesses).
- Mill out the spot welds (two panel thicknesses).
- Mill out the spot weld (two panel thicknesses).
| NOTE:The upper water drain panel only needs to be cut out if it is necessary to fully expose the upper water drain panel reinforcement. | | -
Residual part of the upper water drain panel - Cut location.
- Grind out the spot welds.
- Warm the area (to about 170° C) and release the NVH elements.
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Upper water drain panel reinforcement - Cut location.
- Mill out the spot welds.
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NOTE:Working from the passenger compartment, heat up the NVH element and detach it. The NVH element is also secured to the water drain panel reinforcement from the inside by means of plastic clips. Upper water drain panel reinforcement - Mill out the spot welds.
- Grind out the spot welds.
- Heat the area (approx. 170° C) and detach the NVH element from the inner quarter panel.
| Installation 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 501-25 must be followed. | | -
NOTE:Working from the inside, insert the NVH element at the water drain panel reinforcement using PU window adhesive and secure it with the two plastic clips. Upper water drain panel reinforcement - Apply PU glass adhesive to the NVH element.
- Continuous MIG weld seam.
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NOTE:Only tack-weld the water drain panel reinforcement to the tailgate aperture and the side window aperture. The final welded joint is made when the quarter panel is installed. Upper water drain panel reinforcement - Resistance spot weld.
- Resistance spot welding (tack-weld).
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- By drilling out the holes it is possible to weld all three layers of metal together.
- Only tack-weld the water drain panel reinforcement at the tailgate aperture and at the inner quarter panel. The final welded joint is made when the water drain panel and the quarter panel are installed.
Lower water drain panel reinforcement - Drill out by one panel thickness and puddle weld.
- Resistance spot weld.
- Resistance spot welding (tack-weld).
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Water drain panel, upper - Continuous MIG weld seam.
- Resistance spot weld.
- Apply PU glass adhesive to the NVH element and insert the NVH element from the inside into the water drain panel.
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NOTE:By drilling out the holes it is possible to weld all three layers of metal together. Upper quarter panel - Continuous MIG weld seam.
- Drill out by one panel thickness and puddle weld.
- Puddle welding.
- Resistance spot weld.
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