Unibody: Service and Repair

Trustmark Authoring Standards (TAS) Repair Procedures

NOTE: TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.

A TAS removal and installation procedure uses a sequence of color illustrations to indicate the order to be followed when removing/disassembling or installing/assembling a component.

TAS Graphics

Colors used in the graphic are as follows:
- Blue - Component to be removed/installed or disassembled/assembled.
- Green and Brown - Additional components that need to be removed/installed or disassembled/assembled prior to the target component.
- Yellow - Component that is touched or affected in a way but remains in the vehicle. It may be detached, attached, moved, modified, checked, adjusted etc.
- Magenta - Electrical connectors and fasteners such as nuts, bolts, clamps and clips.
- Pale Blue - Special tool(s) and general equipment.

One illustration may have multiple steps assigned to it.

Numbered pointers are used to indicate the number of electrical connectors and fasteners such as nuts, bolts, clamps and clips.

Items in the illustration can be transparent or use cutouts to show hidden details.

TAS Symbols

Symbols are used inside the graphics and in the text area to enhance the information display.

Side Panel Sheet Metal Repairs - Side Panel

Removal and Installation

Removal

CAUTION: The side panel must be MIG slot brazed to its reinforcement, which contains DP600, (Dual Phase steel). MIG plug welds / spot welds, must not be used.

- NOTE:
- The side panel is serviced as a separate weld on panel, serviced less the fender mounting bracket, which is serviced separately.
- There are NVH elements attached inside this panel, they are not serviced on the new panel. If damaged, new element/s will be required.

1. The side panel is replaced in conjunction with:
- Front bumper cover
- Front fender
- Hood
- Front door
- Rear door
- Quarter glass
- Instrument panel
- Windshield glass
- Headliner
- Rear bumper cover

2. For additional information relating to the repair procedure, please see the following:
Body Dimensions
Standard Workshop Tolerances

3. Remove the hood.
4. Remove the front fender.
5. Remove the front door.
6. Remove the rear door.
7. Remove the headliner.
8. Remove the instrument panel.
9. Remove the windshield glass.
10. Remove the rear quarter glass.
11. Remove the rear bumper cover.
12. Remove the upper and lower door hinges from the A-Pillar, 4 x bolts.
13. Remove the upper and lower door hinges from the B-Pillar, 4 x bolts.
14. Remove the front door striker from the B-Pillar.
15. Remove the rear door striker from the C-Pillar.
16. Remove the roof moulding, front and rear sections.
17. Remove the side air curtain module.
18. Remove the front seat.
19. Remove the floor console.
20. Remove the RH & LH rocker panel inner trims.
21. Remove the rear seat cushion.
22. Remove the rear carpet section.
23. Remove the B-Pillar side impact sensor.
24. Remove the front safety belt retractor.
25. Remove the rear safety belt retractor.
26. Release and lay aside the front carpet section.
27. Remove the rear carpet section.
28. Remove the front wheel and tire. LINK
29. Remove the rear wheel and tire.
30. Remove the rocker panel outer moulding.
31. Remove the liftgate aperture weatherseal.
32. Remove the forced air extraction grille.
33. Release and lay aside the insulating material at the inner bulkhead.
34. Release and lay aside the insulating material at the inner quarter panel.
35. Release and lay aside the wiring harnesses at the A-Pillar, B-Pillar and rocker panel.
36. Release and lay aside the wiring harness along the inner quarter panel and back panel.
37. Release and lay aside the insulating material at the inner quarter panel.
38. RH side: Drain the fuel tank.
39. RH side: Remove the fuel tank filler pipe.

40. Remove the fender mounting bracket:
- Mill out 3 spot welds. If not re-using the mounting the upper spot weld does not have to be removed.
- Separate the mounting from the A-Pillar.
- Retain the mounting if it is being reused, if not, discard.

41. Saw cut the old panel at the A-Pillar and rear quarter panel, using the new panel for reference, ensuring that the new panel overlaps the panel remaining on the vehicle.

42. Saw cut the old panel at the B-Pillar, as illustrated, observe the measurements to allow access to the B-Pillar reinforcement.

44. Separate the joints and remove the old panel, also releasing the NVH elements.

Installation

1. Offer up and align the new panel and clamp into position, overlapping the old panel remaining on the vehicle. Check alignment, if correct, proceed to next step, if not, rectify and recheck before proceeding.
2. Saw cut the new and old panels at the A-Pillar and rear quarter panel, ensuring that the new panel overlaps the panel remaining on the vehicle.

3. Saw cut through the new and old panels at the B-Pillar, where the MIG butt joint is to be made.

4. Remove the new panel and the old remnants.

5. NOTE: MIG slots should be installed in accordance with the spacing shown in the illustration. Where this is not possible, due to the indents in the panel, the slot should be made in the location of the original spot weld.

Cut slots in the new panel ready for MIG brazing.

6. Drill holes in the new panel ready for MIG plug welding.

7. Prepare the old and new panel joint surfaces.
8. If necessary, renew the NVH element/s.
9. Apply sealer adhesive to the NVH element at the A-Pillar.