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Panel Sheet Metal Repairs, Removal and Installation).
7. Remove the side air curtain module.
For additional information, refer to: Side Air Curtain Module (501-20B Supplemental Restraint System, Removal and Installation).
8. Remove the front seat.
For additional information, refer to: Front Seat (501-10 Seating, Removal and Installation).
9. Remove the floor covering.
10. If the passenger side A-pillar reinforcement is to be repaired, remove
the heater core and evaporator core housing.
For additional information, refer to: Heater Core and Evaporator Core Housing (412-01 Climate Control, Removal and Installation).
11. If the right-hand A-pillar reinforcement is to be repaired, remove the
central junction box.
For additional information, refer to: Central Junction Box (CJB) (418-00 Module Communications Network, Removal and Installation).
12. If the drivers side A-pillar reinforcement is to be repaired, remove the
pedal box.
13. Release and lay aside the insulating material at the inner bulkhead.
14. Release and position aside the inner bulkhead and floor panel wiring
harness.
15. NOTE: The NVH components may have already been
removed on the outer panel.
Remove the upper and lower NVH components and if
undamaged retain for reuse.
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18.
19.
20. NOTE: A drill bit suitable for drilling boron should be
used on the boron spot welds.
Drill out the boron spot welds as indicated.
NOTE: A drill bit suitable for drilling Dual Phase Steel,
600MPa, (DP600) should be used.
Drill out the spot welds as indicated.
From inside the vehicle, drill out the spot welds as
indicated. www.JagDocs.com
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21.
22. Cut a window in the old panel, above the front door lower
hinge reinforcement, to enable access to the spot welds as
indicated.
NOTE: The spot welds indicated should be drilled right
through, to enable MAG plug welding and a MIG braze slot
on installation. The MIG braze slot is required as the
original panel is MIG brazed in this area.
Drill out the spot welds as indicated.
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23.
24. Drill out the spot welds as indicated.
NOTE: Care should be taken not to cause damage to
remaining panels when separating joints containing
adhesive.
Separate the joints and remove the old panel, observing
the areas of NVH component and adhesive as indicated.
Installation
1. Offer up the new panel and clamp into position. Check alignment, if
correct, proceed to next step, if not rectify and recheck before
proceeding.
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10.
11. NOTE: Make sure the adhesive does not encroach into
the areas of the MAG plug welds as it will contaminate the
weld.
Apply adhesive to the area as indicated.
Apply adhesive to the area as indicated. www.JagDocs.com