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Rocker Panel > < 501-29 Side Panel Sheet Metal Repairs|Specifications

S-MAX.Galaxy 2006.5 (03.2006-)

Side Panel Sheet Metal Repairs - A-Pillar Assembly S-MAX/Galaxy 2006.5 (03/2006-)
Removal and Installation

General Equipment
Measurement or alignment angle system
  1. Replacement parts
    • A-pillar outer panel
    • A-pillar inner panel
    • A-pillar reinforcement
    • Rocker panel reinforcement
    • NVH elements

Removal

  1. General Notes
    • The apron panel reinforcement needs to be removed before the repairs can be started.
    • Required removal operations: A-pillar trim panel, rocker panel trim and driver or passenger seat.
    • Reposition the carpeting and the wiring harness away from the working area.
NOTE:
NOTE:Due to the locations of inner reinforcements and NVH elements, it is very important that the dimensions quoted for the separating cuts on the outer A-pillar and on the rocker panel are accurately met.
  1. A-Pillar outer
      NOTE:
      NOTE:Take care not to damage the inner A-pillar reinforcement when making the separating cut on the front of the A-pillar.
    • Cut points.

  1. A-Pillar outer
    • Mill out the spot welds.

  1. A-Pillar outer
    • Mill out the spot welds (two panel thicknesses).

  1. A-Pillar outer
    • Mill out the spot welds.

  1. A-Pillar outer
    1. Grind out the MIG brazed joints.
    1. Heat the areas (approx. 170° C) and detach the NVH elements.

  1. A-pillar reinforcement
    1. Mill out the spot welds.
    1. Heat the areas (approx. 170° C) and detach the NVH elements.

  1. Rocker panel reinforcement
    1. Cut location.
    1. Mill out the spot welds.

  1. A-pillar inner panel
    1. Cut location.
    1. Mill out the spot welds (two panel thicknesses).

  1. A-pillar inner panel
    1. Mill out the spot welds.
    1. Grind out the spot welds.

  1. A-pillar inner panel
    • Mill out the spot welds.

  1. A-pillar inner panel
    1. Mill out the spot welds (two panel thicknesses).
    1. Grind out the spot welds.

  1. A-pillar, inner panel (inside view)
    • Mill out the spot welds.

  1. A-pillar, inner panel (inside view)
    • Heat the area (approx. 170° C) and release the NVH element.

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 501-25 must be followed.
  1. A-pillar inner panel
    • Drill out the holes for puddle welding (10 mm diameter).

  1. A-pillar inner panel
    • Drill a hole for puddle welding (10 mm diameter).

  1. A-pillar inner panel
    • Resistance spot weld.

  1. A-pillar inner panel
    • Puddle weld.

  1. A-pillar inner panel
      NOTE:
      NOTE:Once the A-pillar reinforcement and the A-pillar outer panel have been installed this area is no longer accessible.
    • Applu PU sealant to the outside and inside.

  1. A-pillar inner panel
    1. Puddle weld.
    1. Continuous MIG weld seam.

  1. A-pillar inner panel
    • Resistance spot weld.

  1. A-pillar inner panel
    1. Surface grind the MIG weld seams in the area of the welded flange.
      NOTE:
      NOTE:Once the A-pillar reinforcement and the A-pillar outer panel have been installed this area is no longer accessible.
    1. Apply self-adhesive sealing strip.

  1. NOTE:
    NOTE:Only tack-weld the rocker panel reinforcement at the top and bottom. The final welded joint is made when the rocker panel is installed.
    Rocker panel reinforcement
    1. Continuous MIG weld seam.
    1. Resistance spot welding (tack-weld).

  1. WARNING:
    WARNING:The A-pillar reinforcement is covered with a hot-dip aluminized coating on its entire surface. This coating needs to be fully ground off on the MIG welding flanges on the front using a fibre grinding disc. Any contamination due to parts of the coating in the welding bath will weaken the welded joint.
    A-pillar reinforcement
    • Clean the contact area.

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

  1. NOTE:
    NOTE:Working from the inside, insert the NVH element at the A-pillar reinforcement into the mounting tube for the instrument panel bracket.
    A-pillar, inner panel (inside view)
    • Apply PU glass adhesive to the NVH element.

  1. NOTE:
    NOTE:The PU window adhesive acts as noise insulation in the area of position 1.
    A-pillar reinforcement
    1. Apply PU window adhesive to the inside of the A-pillar.
    1. Apply PU glass adhesive to the NVH element.
    1. Puddle weld.

  1. NOTE:
    NOTE:Only tack-weld A-pillar reinforcement. The final welded joint is made when the outer A-pillar is installed.
    A-pillar reinforcement
    • Resistance spot welding (tack-weld).

  1. NOTE:
    NOTE:The MIG spot welds need to be surface ground so that the outer A-pillar fits correctly.
    A-pillar reinforcement
    • Surface grind the MIG spot welds.

  1. A-Pillar outer
    • Drill holes for puddle welding (10 mm diameter).
NOTE:
NOTE:
  • The factory-installed MIG brazed joints must be replaced by MIG welds in a different position if a repair is performed.
  • These MIG welds must not be carried out on or in the immediate vicinity of existing MIG brazed seams as even the smallest amount of brazing solder can result in a reduction in the strength of the weld seam.
  1. NOTE:
    NOTE:For the reasons described above, when preparing the outer A-panel the existing openings need to be enlarged by 10 mm (see illustration E77653).
    A-Pillar outer
    • Mill out the openings with a spherical cutter.

  1. NOTE:
    NOTE:The PU window adhesive acts as noise insulation in the area of positions 2.
    A-Pillar outer
    1. Apply PU glass adhesive to the NVH element.
    1. Apply PU window adhesive to the inside of the A-pillar.
    1. Continuous MIG weld seam.

  1. A-Pillar outer
    • Resistance spot weld.

  1. A-Pillar outer
    • Puddle weld.

  1. A-Pillar outer
    • Intermittent MIG weld.

  1. A-Pillar outer
    1. Resistance spot weld.
    1. Puddle weld.

Rocker Panel > < 501-29 Side Panel Sheet Metal Repairs|Specifications