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PRE-RELEASE

Body Lock Pillar Outer Panel Reinforcement Replacement

Body Lock Pillar Outer Panel Reinforcement Replacement

Removal Procedure

Refer to Approved Equipment for Collision Repair Warning .

Refer to Glass and Sheet Metal Handling Warning .


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 .

3. Visually inspect the damage. Repair as much of the damage as possible.

4. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (Base) Anti-Corrosion Treatment and Repair (Corrosion Protection) .

5.
Note

Do not damage any inner panels or reinforcements. Note the number and location of the welds for installations of the service part.


Create cut lines on the body lock pillar outer panel.


6. Create cut line 10 mm (0.4 in) on the upper front side panel (1).

7. Cut 80 mm in front of the luggage carrier side rail front support reinforcement and 150 mm in front of the luggage carrier side rail rear support reinforcement.

8. Cut out the body lock pillar outer panel roughly.

9. Locate and drill out all of the necessary factory welds.

10.
Note

Do not damage any inner panels or reinforcements.


Create cut lines on the body lock pillar outer panel reinforcement (1).


11. Cut out the body lock pillar outer panel reinforcement roughly.

12.
Note

Do not damage any inner panels or reinforcements. Note the number and location of the welds for installations of the service part.


Drill out the necessary factory welds (1).


13. Remove the luggage carrier side rail front support reinforcement (2). Refer to Luggage Carrier Side Rail Front Support Reinforcement Replacement .

Note

Do not damage any inner panels or reinforcements. Note the number and location of the welds for installations of the service part.



14. Drill out the necessary factory welds (1) on the center pillar inner panel lower reinforcement.

15. Drill out the necessary factory welds (2) on the center pillar inner panel.

16. Remove the damaged body lock pillar outer panel reinforcement.


Installation Procedure


1.
Note

Refer SPP, PSO welding parameters for resistance spot welding. See TIS Newsletter for equipment recommendations.


Create cut lines on the body lock pillar outer panel (1).


2. Cut the body lock pillar outer panel in corresponding locations to fit the original panel. The sectioning joint should be trimmed to allow min. 1 times the metal thickness at the sectioning joint.

3. Prepare new body lock pillar outer panel in the area (1).

1 x slots (5 x 18 mm / 0.2 x 0.7 in)

4. Prepare new body center pillar inner panel in the area (1).

14 x slots (8 x 24 mm / 0.3 x 0.9 in)


5. Position and measure (1) from the front hinge pillar body to the center pillar inner panel 1191 mm (48.9 in) on to the vehicle.


6. Verify the fit of the center pillar inner panel.

7. Clamp the center pillar inner panel into position.

8.
Note

Refer to Welded, Brazed, and Riveted Joint Specifications .


Spot weld the center pillar inner panel (1) accordingly.


9. MIG-braze the center pillar inner panel (2).

10. Grind MIG brazed seams.

11. Prepare new body lock pillar outer panel reinforcement in the area (1).

Drill out the necessary slots.

9 x slots (8 x 24 mm / 0.3 x 0.9 in)


12. Prepare new body lock pillar outer panel reinforcement in the area (2).

9 x slots (8 x 24 mm / 0.3 x 0.9 in)

13. Clean and prepare the attaching surfaces for welding.


14. Apply bodywork repair through structural adhesive to body (1). Refer to Structural Adhesive Body Repairs .

15. Position and measure (1) from the front hinge pillar body to the rear hinge pillar body 1090 mm (43 in) on to the vehicle.


16. Verify the fit of the body lock pillar outer panel reinforcement.

17. Clamp the body lock pillar outer panel reinforcement into position.

18.
Note

Refer to Welded, Brazed, and Riveted Joint Specifications .


Spot tack-weld the body lock pillar outer panel reinforcement (1).


19. MIG-braze the body lock pillar outer panel reinforcement (2).

20. MIG-braze full seam interrupted 9 times 30 mm (1.2 in) the body lock pillar outer panel reinforcement (3).

21. MIG-braze full seam interrupted 5 times 30 mm (1.2 in) the body lock pillar outer panel reinforcement (4).

22. Grind MIG-brazed seams.

23. Install the sound deadener (1).


24. Install the luggage carrier side rail front support reinforcement. Refer to Luggage Carrier Side Rail Front Support Reinforcement Replacement .

25. Clean and prepare the attaching surfaces for welding.


26. Apply bodywork repair through structural adhesive to body (1). Refer to Structural Adhesive Body Repairs .

27. Apply 1K-Adhesive bead on the sound deadener (2). Refer to Chemical Products .

28. Position the body lock pillar outer panel on the vehicle.


29. Verify the fit of the roof outer panel.

30. Clamp the body lock pillar outer panel into position.

31.
Note

Refer to Welded, Brazed, and Riveted Joint Specifications .


Spot weld the body lock pillar outer panel (1) accordingly.


32. MIG-braze the body lock pillar outer panel (2).

33. Grind MIG brazed seams.

34. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (Base) Anti-Corrosion Treatment and Repair (Corrosion Protection) .

35. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

36. Enable the SIR system. Refer to SIR Disabling and Enabling .


PRE-RELEASE