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Rear End Panel Replacement — Welding

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

Removal Procedure

    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 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 .

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  7. Locate and mark all the necessary factory welds of the rear end panel (1).
  8. Note : Note the number and location of welds for installation of the service assembly.

  9. Drill all factory welds.

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  11. Remove the rear end panel (1).

Installation Procedure


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    Note : If the location of the original plug weld holes cannot be determined, space the plug weld holes every 40 mm (1½ in).

  1. Drill 8 mm (5/16 in) for plug welding along the edges of the rear end panel (1) where the spot welder cannot be applied.
  2. Clean and prepare the attaching surfaces for welding.

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  4. Position the rear end panel (1) on the vehicle.
  5. Verify the fit of the rear end panel.
  6. Clamp the rear end panel into position.

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  8. Weld the rear end panel (1) accordingly.

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  10. Spotweld the rear end panel (1) accordingly.
  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 battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
  15. Enable the SIR system. Refer to SIR Disabling and Enabling .
   


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