Orlando

Rear End Panel Replacement — 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 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. Locate and mark all the necessary factory welds of the rear end panel (1).

Note : Note the number and location of welds for installation of the service assembly.

7. Drill all factory welds.



8. Remove the rear end panel (1).

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.



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



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



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