Orlando

Body Side Inner Panel Sectioning - Brazing

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 side inner panel (1).




Note : Do not damage any other panels or reinforcements.

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



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 damaged body side inner panel (1).

1. Cut the body side inner 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 side inner panel.



4. Create 6x20 mm (4/16 x 12/16 in) slots for brazing along the edges of the body side inner panel (1) where the spot welder cannot be applied.
5. Clean and prepare the attaching surfaces for spotwelding and brazing.



6. Apply structural adhesive (1).



7. Position the body side inner panel (1).
8. Verify the fit of the panel.
9. Clamp the body side inner panel into position.



10. Braze the body side inner panel (1) accordingly.



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