Orlando

Rear Floor Panel Sectioning — 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. Create cut lines on the rear floor panel outer extension (1).



7. Cut the rear floor panel outer extension (1) where sectioning is to be performed.



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



10. Remove the damaged rear floor panel outer extension (1).



11. Create cut lines on the rear floor panel (1).



12. Cut the rear floor panel (1) where sectioning is to be performed.



13. Locate and mark all the necessary factory welds of the rear floor panel (1).
14. Drill all factory welds. Note the number and location of welds for installation of the service assembly.



15. Remove the damaged rear floor panel (1).

1. Cut the rear floor panel (1) 50 mm (2 in) longer (2) then the old part.
2. Prepare all mating surfaces as necessary.
3. Align the rear floor panel.



4. Create 5x18 mm (4/16 x 11/16 in) for brazing along the edges (1) of the remaining rear floor panel and underbody cross sill bar.



5. Create 5x18 mm (4/16 x 11/16 in) for brazing along the edges (1) of the rear floor panel.
6. Clean and prepare the attaching surfaces for spotwelding and brazing.



7. Position the rear floor panel (1) on the vehicle.
8. Verify the fit of the rear floor panel.
9. Clamp the rear floor panel into position.



10. Braze the rear floor panel (1) accordingly.
11. To create a solid stitch braze 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 stitch braze.



12. Spotweld the rear floor panel (1).



13. Cut the rear floor panel outer extension (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.
14. Prepare all mating surfaces as necessary.
15. Align the rear floor panel outer extension.



16. Drill 8 mm (5/16 in) for plug welding along the edges (1) of the rear floor panel outer extension.
17. Clean and prepare the attaching surfaces for brazing.



18. Position the rear floor panel outer extension (1) on the vehicle.
19. Verify the fit of the rear floor panel outer extension.
20. Clamp the rear floor panel outer extension into position.



21. Braze the rear floor panel outer extension (1) accordingly.
22. To create a solid stitch braze 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 stitch braze.
23. Apply the sealers and anti-corrosion materials to the repair area as necessary. Refer to Anti-Corrosion Treatment and Repair : Base .
24. Paint the repaired area.
25. Install all related panels and components.
26. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
27. Enable the SIR system. Refer to SIR Disabling and Enabling .