Orlando

Quarter Outer Panel Sectioning - Brazing

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

Special Tools

For equivalent regional tools, refer to Special Tools .

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 quarter outer panel (1).



7. Cut the quarter outer panel (1) where sectioning is to be performed.



8. Open the wheelhouse flanging of the quarter outer panel (1).



9. Locate and mark all the necessary factory welds of the quarter outer panel (1).
10. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



11. Remove the damaged quarter outer panel (1).

1. Cut the quarter outer 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 quarter outer panel.



4. Create 6x20 mm (4/16 x 12/16 in) slots for brazing along the edges (1) of the quarter outer panel where the spotwelder cannot be applied spaced apart every 40 mm (1 ½ in).
5. Clean and prepare the attaching surfaces for spotwelding and brazing.



6. Apply one-part windscreen urethane adhesive (1) as noted from the original panel.



7. Apply structural adhesive (1).
8. Position the quarter outer panel on the vehicle.
9. Verify the fit of the quarter outer panel.
10. Clamp the quarter outer panel into position.



11. Braze the quarter outer panel (1) accordingly.
12. To create a solid braze seam 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 braze seam.



13. Spotweld the quarter outer panel (1).
14. Pre-flanging the flange with BO-6396 pliers and BO-6392 tool kit.



15. Finish closing the wheelhouse flanging.
16. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair : Base .
17. Paint the repaired area.
18. Install all related panels and components.
19. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
20. Enable the SIR system. Refer to SIR Disabling and Enabling .