Orlando

Body Hinge Pillar Outer Panel Sectioning - Welding

Note : According to different corrosion warranties, only the regional mandatory joining methods are allowed.

Warning : Refer to Approved Equipment for Collision Repair Warning in the Preface section.

Warning : Refer to Collision Sectioning Warning in the Preface section.

Warning : Refer to Glass and Sheet Metal Handling Warning in the Preface section.

1. Disable the SIR System. Refer to SIR Disabling and Enabling .
2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
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. Refer to Anti-Corrosion Treatment and Repair : Base .



6. Create cut lines on the body hinge pillar outer panel (1).




Note : Do not damage any inner panels or reinforcements.

7. Cut the body hinge pillar outer panel (1) where sectioning is to be performed.



8. Locate and mark all the necessary factory welds of the body hinge pillar outer panel (1).
9. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



10. Remove the damaged body hinge pillar outer panel (1).

1. Cut the body hinge pillar 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. Align the body hinge pillar outer panel (1).



4. Drill 8 mm (5/16 in) holes for plug welding on the body hinge outer pillar panel (1) where the spotwelder cannot be applied.
5. Clean and prepare the attaching surfaces for welding.



6. Position the body hinge pillar outer panel (1) on the vehicle.
7. Verify the fit of the body hinge pillar outer panel.
8. Clamp the body hinge pillar outer panel into position.



9. Weld the body hinge pillar outer panel (1) accordingly.



10. Spotweld the body hinge pillar outer panel (1) accordingly.
11. To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them. Then go back and complete the stitch weld.
12. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair : Base .
13. Paint the repaired area.
14. Install all related panels and components.
15. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
16. Enable the SIR system. Refer to SIR Disabling and Enabling .