Orlando

Rocker Inner Panel Replacement - Welding

Warning : Refer to Approved Equipment for Collision Repair 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 negative battery 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 side inner panel (1).



7. Cut the panel (1) where sectioning is to be performed.

Note : Do not damage any inner panels or reinforcements.




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



10. Remove the body side inner panel (1).



11. Locate and mark all the necessary factory welds of the rocker inner panel (1).
12. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



13. Remove the damaged rocker inner panel (1).

1. Align the rocker inner panel.



2. Drill 8 mm (5/16 in) for plug welding to sill inner panel (1).
3. Clean and prepare the attaching surfaces for welding.



4. Position the rocker inner panel (1) on the vehicle.
5. Verify the fit of the sill inner panel.
6. Clamp the rocker inner panel into position.



7. Weld the sill inner panel (1) accordingly.



8. Spotweld the sill inner panel (1) accordingly.



9. Weld the body side inner panel (1) accordingly.
10. 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.
11. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair : Base .
12. Paint the repaired area.
13. Install all related panels and components.
14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
15. Enable the SIR system. Refer to SIR Disabling and Enabling .