SAAB WIS ONLINE

PRE-RELEASE

Body Side Outer Panel Replacement

Body Side Outer Panel Replacement

Removal Procedure

Refer to Approved Equipment for Collision Repair Warning .

Refer to Glass and Sheet Metal Handling Warning .


1.
Note

Section in specified areas only. Sectioning outside of these areas may compromise the structural integrity of the vehicle. The sectioning procedures have been developed as a more cost-effective alternative to complete replacement.


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. Repair as much of the damaged area as possible. Refer to Dimensions - Body .

4. Remove all related panels and components.

• Remove the rear side door. Refer to Rear Side Door Replacement .

• Remove the rear side door weatherstrip - body side. Refer to Rear Side Door Weatherstrip Replacement .

• Remove the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement .

• Remove rear window. Refer to Rear Window Replacement (Sedan) .

• Remove the rear compartment lid. Refer to Rear Compartment Lid Replacement

• Remove the rear compartment lid weatherstrip. Refer to Rear Compartment Lid Weatherstrip Replacement .

• Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .

5. 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) .

6.
Note

Do not damage any inner panels or reinforcements.


Note

Note the number and location of the welds for installations of the service part.


Cut out the body side outer panel.


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

8.
Note

Do not damage any inner panels or reinforcements.


Note

Note the number and location of the welds for installations of the service part.


Cut out the body side outer panel.


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

10.
Note

Note the number and location of the welds for installations of the service part.


Locate and drill out all of the necessary factory welds.

Note

The side outer panel is glued to the fender edge and also to the inner reinforcement plate.



11. Remove the damaged body side outer panel.


Installation Procedure


1.
Note

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


Cut the replacement body side outer panel section 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.

2.
Note

Pre-spot operation. The number of spots is specified in the documentation from the welding equipment manufacturer.


Prepare inner rocker panel (1) with reinforcement (PSO).


3. Position the new body side outer panel on the vehicle.


4. Verify the fit of the new body side outer panel.

5. Remove new quarter outer panel.

6. Apply bodywork repair through structural adhesive to body (2). Refer to Structural Adhesive Body Repairs .

Adhesive on Sound Deadener (1)

Apply glue (3) to the inside of the reinforcement plate.


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

8. Position the new body side outer panel on the vehicle.


9. Verify the fit of the new body side outer panel.

10. Clamp the new body side outer panel into position.

11.
Note

Refer to Welded, Brazed, and Riveted Joint Specifications .


Spot weld (1) the body side outer panel accordingly.


12.
Note

Refer to Welded, Brazed, and Riveted Joint Specifications .


Spot weld (SPP) the body side outer panel (1) accordingly.


13. MIG-braze (1) the body side outer panel.


14. Pre-flange wheel housing.

Using a suitable hammer, bend over the flanged edge 45° (1), at the same time holding a small mallet or block against it. Use structural adhesive in the area (2).


15. Bend the wheel arch.

Apply excess adhesive as a seam seal and corrosion protection using a spatula or flat paintbrush. Use structural adhesive in area (1).


16. 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) .

17. Install all related panels and components.

• Install the rear side door. Refer to Rear Side Door Replacement .

• Install the rear side door weatherstrip - body side. Refer to Rear Side Door Weatherstrip Replacement .

• Install the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement .

• Install the rear window. Refer to Rear Window Replacement (Sedan) .

• Install the rear compartment lid. Refer to Rear Compartment Lid Replacement

• Install the rear compartment lid weatherstrip. Refer to Rear Compartment Lid Weatherstrip Replacement .

• Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement .

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

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


PRE-RELEASE