Contents: Removal ⇩ Installation ⇩
CAUTION: The bottom rail panel must be MIG brazed to the internal bottom rail panel reinforcement which is made of DP600 steel (dual phase steel). MIG/spot welding must not be used.
NOTE: The bottom trim panel is serviced as a separate weld-on panel.
Removal
1. In combination with the lower trim panel, the following is replaced:
- Front bumper trim
- Front wing
- Front door
- Back door
2. For additional information regarding this repair procedure, refer to: For additional information, refer to: Body and Frame (501-26 Body Repairs - Special Vehicle Information and Tolerance Checks, Description and Operation) / Standard Service Station Techniques (100-00 General Information, Description and Operation).
3. Remove the wing.
4. Remove the front door. For more information, refer to the chapter: Front Door (501-03 Lockable Body Parts, Removal and Installation).
5. Remove the rear door. For more information, refer to the chapter: Rear Door (501-03 Lockable Body Parts, Removal and Installation).
6. Remove the front wheel. For more information, refer to the chapter: Wheel and tire (204-04 Wheels and tires, Removal and installation).
7. Remove the rear wheel. For more information, refer to the chapter: Wheel and tire (204-04 Wheels and tires, Removal and installation).
8. Left side: Remove the hood release handle.
9. Remove the front seat. For more information, refer to the chapter: Front Seat (501-10 Seat, Removal and Installation).
10. Remove the floor console. For more information, refer to the chapter: Floor Console (501-12 Instrument Panel and Console, Removal and Installation).
11. Remove the front door opening seal.
12. Remove the rear door opening seal.
13. Remove the door jamb trim panel. For more information, refer to the chapter: Front Door Jamb Trim Panel (501-05 Interior Trim, Removal and Installation).
14. Remove the B-pillar upper trim panel. For more information, refer to the chapter: Upper B-pillar trim panel (501-05 Interior Trim, Removal and Installation).
15. Remove the right and left B-pillar lower trim panels. For more information, refer to the chapter: Lower B-pillar trim panel (501-05 Interior Trim, Removal and Installation).
16. Remove the rear quarter trim panel. For more information, refer to the chapter: Rear Quarter Trim Panel (501-05 Interior Trim, Removal and Installation).
17. Remove the interior trim of the right and left lower trim panels.
18. Remove the lower trim panel outer molding.
19. Remove the rear panel interior trim.
20. Remove the rear seat cushion. For more information, refer to the chapter: Rear Seat Cushion (501-10 Seat, Removal and Installation).
21. Remove the front seat belt retractor. For more information, refer to the chapter: Front Seat Belt Retractor (501-20A Seat Belt System, Removal and Installation).
22. Remove the rear carpet section.
23. Release and position aside the front carpet section.
24. Remove the side impact sensor from the B-pillar. For additional information, refer to the chapter: Side Impact Sensor B-Pillar (501-20B Supplemental Restraint System, Removal and Installation).
25. Remove the side impact sensor from the rear pillar. For additional information, refer to the chapter: Pillar Side Impact Sensor (501-20B Supplemental Restraint System, Removal and Installation).
26. Release and place aside the internal insulation of the partition.
27. Release and position aside the wiring harnesses running along the inside of the lower trim panel.
28. Cut the old panel where it meets the "A" post, "B" post, and rear side panel, leaving an allowance for overlapping the new panel. Use the new panel as a reference.
29. Mill out the weld spots.
30. Separate the connections and remove the old panel.
Installation
1. Place the new panel, align it and fix it in place, overlapping it onto the old panel remaining on the car.
2. Cut through the new and old panels at the A-post, B-post, and rear side panel where MIG butt joints are to be made.
3. Remove the new panel and the remains of the old one.
4. Cut holes in the new panel for MIG welding.
NOTE: Holes should be made for MIG brazing at the intervals shown in the illustration. Where this is not possible due to recesses in the panel, a hole should be made at the original weld location.
5. Prepare the connecting surfaces of the old and new panels.
6. Apply the new panel and fix it in place. Check the alignment, if correct, proceed to the next step, if not, correct and check again before proceeding to the next step.
7. Tack the butt joints.
8. Perform MIG welding.
(The original text was published on the website LRman.ru)
9. Clean the tack welds.
10. Perform butt welding using MIG technology.
11. Clean all welded joints.
12. To install the relevant panels and mechanical components, perform the removal procedure in reverse order.
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