Orlando

Body Lock Pillar Upper Reinforcement Replacement - 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. Cut the tailgate opening drain gutter (1) where the sectioning is to be performed.



7. Locate and mark all the necessary factory welds of the tailgate opening drain gutter (1).



8. Remove the tailgate opening drain gutter (1).



9. Create cut lines on the body lock pillar upper reinforcement (1).
10. Remove the tailgate opening drain gutter (1).




Note : Do not damage any other panels or reinforcements.

11. Cut the body lock pillar upper reinforcement (1) where sectioning is to be performed.



12. Locate and mark all the necessary factory welds of the body lock pillar upper reinforcement (1).
13. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



14. Remove the damaged body lock pillar upper reinforcement (1).

1. Cut the body lock pillar upper reinforcement (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 lock pillar upper reinforcement.
4. Clean and prepare the attaching surfaces for spotwelding and brazing.



5. Apply structural adhesive (1) to body lock pillar upper reinforcement.



6. Position the body lock pillar upper reinforcement (1).
7. Verify the fit of the panel.
8. Clamp the body lock pillar upper reinforcement into position.



9. Spotweld the body lock pillar upper reinforcement (1) accordingly.
10. Use the drill holes on the tailgate opening drain gutter to create 6x20 mm (4/16 x 12/16 in) slots for brazing.



11. Position the tailgate opening drain gutter (1).



12. Braze the tailgate opening drain gutter (1) accordingly.



13. Spotweld the tailgate opening drain gutter (1) accordingly.
14. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair : Base .
15. Paint the repaired area.
16. Install all related panels and components.
17. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
18. Enable the SIR system. Refer to SIR Disabling and Enabling .