CAUTION: Rack Exterior Panel "A" must be hard soldered MIG to the amplifier, which is made of steel DP600 (duplex steel). MIG welding / spot welding must not be used.
NOTE: Rack Exterior Panel "A" serviced as a separate welded panel. The wing support bracket is serviced separately.
NOTE: NVH elements are attached inside this panel, they are not serviceable on the new panel. If damaged, a new item will be required (s).
Removing
1. Combined with rack outer panel "A" is replaced by:
- front bumper cover
- Hood
- Front fender
- Front door
- Dashboard
- Windshield
- headlining
2. For more information regarding this repair procedure, see: For more information, refer to the chapter: Body and frame (501-26 Body Repairs - Vehicle Special Information and Approval Checks, Description and Operation) / Standard techniques used at the service station (100-00 General information, Description and principle of operation).
3. Remove the hood.
4. Remove the front fender.
5. Remove the front door. For more information, see chapter: Front door (501-03 Lockable body elements, Removal and installation).
6. Remove an upholstery of a ceiling. For more information, see chapter: Top trim - Vehicle not included: Tilting sunroof (501-05 Interior trim, Removal and installation) / Upper Trim - Included with the vehicle: Sunroof with tilting roof (501-05 Interior trim, Removal and installation).
7. Remove the instrument panel. For more information, please refer to the chapter: Control panel - 2.2L Duratorq - Td4 (501-12 Instrument panel and console, Removal and installation).
8. Remove the windshield. For more information, see the chapter: Windshield (501-11 Glass, frames and mechanisms, Removal and installation).
9. Remove the top and bottom hinges of a door from a rack, turn out 4 bolts.
10. Remove the bottom trim panel interior trim.
11. Remove the side curtain airbag module. For more information, refer to the chapter: Curtain side airbag module (501-20B Secondary restraint system, Removal and installation).
12. Remove a forward wheel in gathering with the tire. For more information, see the chapter: Wheel and tire (204-04 Wheels and tires, Removal and installation).
13. Remove the bottom trim panel outer molding.
14. Loosen and set aside the front carpet section.
15. Remove the rear carpet section.
16. Remove the roof molding, front and rear sections.
17. Loosen and lay aside the wiring harnesses that run along the inside of the rack "A" and the inside of the bottom trim panel.
18. Loosen and place aside the insulating material on the inner baffle.
19. Remove the wing support bracket:
- Mill 3 spot welds. If the fastener is not reused, the top weld point does not need to be removed.
- Separate the mount from the rack "A".
- Save the mount if it will be reused, if not, discard it.
20. Cut off the old panel at the points shown, using the new panel as a guide, making sure the new panel will overlap the panel remaining on the vehicle.
21. Mill out the weld points.
22. Separate the connections and remove the old panel, also disconnect the NVH element.
Installation
1. Attach the new panel, align it and lock it in place, overlapping the old panel remaining on the vehicle. Cut through the new and old panels at the points where the MIG butt joints are to be made.
2. Remove the new panel and the remains of the old one.
3. Prepare the connecting surfaces of the old and new panels.
4. Cut holes in the new MIG braze plate.
NOTE: The holes for MIG brazing must be made according to the gaps shown in the illustration. Where this is not possible due to recesses in the panel, the hole should be made in place of the original spot weld.
5. Attach the new panel and lock it in place. Check the reconciliation, if correct, go to the next step, if not, correct and check again before proceeding to the next step.
6. Remove the new panel.
7. Apply adhesive to the areas shown.
8. If necessary, replace the NVH element.
9. Apply sealing adhesive to the NVH element.
10. Attach the new panel and lock it in place.
11. Tie butt joints.
12. Carry out MIG brazing.
13. Clean the tack welds.
14. Perform welding of butt joints using MIG technology.
15. Install the wing support bracket using the wing for alignment.
16. Clean all welds.
17. Reverse the removal procedure to install the appropriate panels and mechanicals.
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