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Home >> Saab >> 2005 >> 9-5 Linear, Automatic >> Repair and Diagnosis (Single Page) >> Accessories & Equipment >> Interior/Exterior Trim >> Body - 9-5 >> Adjustment-Replacement >> Outer sill >> Fitting

Outer sill: Fitting

Fig 1: Illustration For Step 3,7-8
G03865664Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. Roughly cut the sill.
  2. Position the new sill and cut it so that it is located edge-to-edge with the existing joints on the body.
  3. Drill holes in the bottom edge of the sill and by the front hinge for plug-welding.
  4. Grind clean the surfaces on the sill and body that are to be welded.
  5. Apply welding primer to the surfaces that are to be spot-welded and plug-welded.
  6. Position the sill and fix it with a few welding clamps.
  7. Plug-weld and spot-weld the sill.
  8. All-weld the joints.
  9. Smooth off the welds.
  10. Remove any remaining welding primer. Welding primer reduces adhesion of paint, filler and sealant.
  11. Apply primer to all bare metal surfaces. Use Standox 1K Fullprimer.
  12. Seal joints and sheet metal flanges with sealant. Use Terostat 1K-PUR.
    IMPORTANT: Because the sill consists of a number of reinforcements and sections, it is important that the anti-corrosion agent penetrates into all the sections.
  13. Apply anti-corrosion agent to internal surfaces after painting. Use Terotex HV 400 or Mercasol 1.
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