Orlando

Rocker Outer Panel Sectioning — Welding

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 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 rocker outer 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 rocker outer panel (1).
9. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



10. Remove the damaged rocker outer panel (1).

1. Cut the rocker outer panel 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 rocker outer panel.
4. Clean and prepare the attaching surfaces for welding.



5. Apply one-part urethane adhesive (1)



6. Position the rocker outer panel (1) on the vehicle.
7. Verify the fit of the rocker outer panel.
8. Clamp the rocker outer panel into position.



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