- Note amount and location of spot welds. Remove doors, trim, seat belts and wiring from C-pillar.
- Remove sealer and drill spot welds from:
- Measure and cut service part at roof location 165 mm rearward and 165 mm forward of center pillar uppermost weatherstrip attachment hole. Measure and cut service part at rear rocker location 165 mm forward of the rear edge of part. Do not cut front edge of service part. Cut vehicle part to service part dimensions.
- Measure and align. Clamp in place.
- Use MIG to plug weld center pillar in place with the same amount and location of factory welds.
- Metal finish roof and rocker area.
- Install doors for final fitting and adjustment to restore proper function of the door assembly to the body side. Adjust hinges as necessary to ensure proper function of the door system.
- Clean all weld seams with a wire brush. Prime and seal all repair areas.
- Apply permanent underbody sealant.
- Prime with two-part catalyzed primer.
- Apply sealers and corrosion protection materials according to information in the "Body Paint" section of this service manual or paint manufacturer's recommendations.
Important: Sedan shown; wagon similar
Important: Some parts have structural weld-thru adhesive in the joint areas. It is necessary to replace this with additional spot welds at the attachment points. This can be accomplished by adding an additional weld between each factory weld in all areas.
Important: Sectioning should only take place in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle. The side door frame openings feature a unique modular build design to improve manufacturing quality. The side door frame openings are composed of pre-assembled components. Note the size and location of the precut service panel. Do not section the hinge reinforcement panel. If damage requires replacement of the body side inner door frame, it is available separately for service. The hinges supplied for the replacement parts must have final welding done when the door is fitted to the body after the new service part is installed
| • | Body side inner panel. |
| • | Rocker panel area. |
Important: To ensure a secure weld the sectioning joint should have a gap of approximately one and a half times the thickness of the metal. Trim the parts as necessary to achieve this.
Important: Door hinge body side straps must be finish welded on new replacement parts as shown in hinge welding procedure in the manual.
Important: Ensure that proper corrosion protection processes are used on all repair areas.
