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Installation
1. Trim the excess from the upper part of the service panel.
2. Install the riv-nuts into the new rocker panel front section
as indicated.
3. CAUTION: Care should be taken not to cut through
into the inner panels.
NOTE: Temporarily install the front door and hinges to
aid alignment.
Offer up, align and clamp the new panel into position,
overlapping the old panel remnant. Cut through the new
panel, partially cutting the old panel at the points where
the butt joints are to be made.
4. Remove the front door and hinges and the new A-pillar outer panel. www.JagDocs.com
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9. Offer up the new panel and clamp into position. Check alignment, if
correct, proceed to next step, if not rectify and recheck before
proceeding.
10. Remove the new A-pillar outer panel.
11.
12. NOTE: Make sure the adhesive does not encroach into
the area of the MAG plug welds as it will contaminate the
weld (any unsealed areas must be sealed following the
repair).
Apply adhesive to the area as indicated.
Apply sealer adhesive to the NVH components as indicated.
13.
Offer up the new A-pillar outer panel, align and clamp into position.
14. Tack MIG braze the upper butt joint.
15. Tack MAG weld the lower butt joint.
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16.
17. NOTE: Spot welds must be installed 5mm away from
the originals and in the same quantities whenever this is
possible. Where this is not possible, spot welds should be
installed adjacent to the original. Where there is adhesive
in the original joint, spot welds should be installed through
the original.
Spot weld.
MAG plug weld.
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21. MAG weld the lower butt joint.
22.
Prepare the old and new panel joint surfaces of the fender apron panel
closing panel section.
23. NOTE: If a new fender apron panel closing panel is to be fitted the
section will not be required.
Tack MAG weld the fender apron panel closing panel section.
24. MAG plug weld and MAG weld the fender apron panel
closing panel section.
25. Dress all welded/brazed joints. www.JagDocs.com
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26. NOTE: It may be necessary to temporarily seal the
opening whilst the foam cures, to prevent it encroaching
into the hood hinge area.
Apply expanding foam into the A-pillar as indicated.
27. Make sure that any open or exposed panel joints are suitably sealed
following this procedure.
28. The installation of associated panels and components is the reversal of
removal procedure.
Tighten the hood hinge bolts to 17 Nm.
Tighten the upper and lower front door hinges to 30 Nm.
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(100-00 General Information, Description and Operation) /
Body Repairs (501-25A Body Repairs - General Information, Description and Operation) /
Corrosion Protection (501-25B Body Repairs - Corrosion Protection, Description and Operation) /
Body and Frame (501-26 Body Repairs - Vehicle Specific Information and Tolerance Checks, Description and Operation).
4. Disconnect the generator electrical connectors.
5. Remove the fender apron panel.
For additional information, refer to: Fender Apron Panel (501-27 Front End Sheet Metal Repairs, Removal and Installation).
6. Remove the A-pillar outer panel.
For additional information, refer to: A-Pillar Outer Panel (501-29 Side