A-Pillar Reinforcement, Replacing - Partial Replacement: Procedure

• A-pillar removed. Refer to A-PILLAR, REPLACING .

Separating Points

-- Transfer the separation cut -2- according to the dimension -a- onto the A-pillar reinforcement and perform using the Edge Milling Unit.

Dimension -a- = 55 mm

-- Remove the bolt -3-.

-- Loosen the original joint using Spot Weld Breaker and One-Handed Angle Grinder.

-- Remove the A-pillar reinforcement -1- from the body and remove.

Courtesy of AUDI OF AMERICA, LLC

-- Transfer the separation cut -2- according to the dimension -a- onto the A-pillar reinforcement and perform using the Edge Milling Unit.

Dimension -a- = 40 mm

-- Loosen the original joint using Spot Weld Breaker and One-Handed Angle Grinder.

-- Remove the A-pillar reinforcement remainder -1- from the body and remove.

Courtesy of AUDI OF AMERICA, LLC

-- Remove the foam residue -2- as much as possible before sanding.

-- Loosen the original joint using Spot Weld Breaker and One-Handed Angle Grinder.

-- Remove the hinge reinforcement partial section -1- from the body.

Courtesy of AUDI OF AMERICA, LLC

-- Remove the remaining material using the One-Handed Angle Grinder.

-- Grind down the welding surfaces to bare metal using the One-Handed Angle Grinder.

-- Completely remove any residual adhesive and grind down the adhesive surface to bare metal using the One-Handed Angle Grinder.

Courtesy of AUDI OF AMERICA, LLC

Replacement Parts

• A-Pillar Reinforcement
• Connecting Plate
• Hinge Reinforcement
• Molded Foam Part
• Two-Part Body Adhesive :D 180 003 M3 
• Silicone Remover :LVM 020 000 A5 

New Part, Preparing

-- Transfer the separation cut -2- onto the A-pillar reinforcement -1- and perform using the Edge Milling Unit.

-- Transfer the separation cut -4- onto the connecting plate -3- and perform using the Edge Milling Unit.

-- Transfer the amount and position of holes for the gas-shielded arc plug weld seam from the removal onto the A-pillar reinforcement -1-.

-- Drill 8 mm diameter holes for the gas-shielded arc plug weld seam using the Drill.

-- Grind down the adhesive and welding surfaces at the A-pillar reinforcement -1-, connecting plate -3- and hinge reinforcement -5- using the One-Handed Angle Grinder down to bare metal.

-- Clean the adhesive surfaces using Silicone Remover :LVM 020 000 A5  .

Courtesy of AUDI OF AMERICA, LLC

Welding

-- Clean the adhesive surfaces using Silicone Remover :LVM 020 000 A5  .

-- Apply Two-Part Body Adhesive :D 180 003 M3  on the entire surface using the Double Cartridge Gun.

-- Fit the new part to the vehicle with Portal Gauge resting on the Alignment Bracket Set and secure.

-- Check the fit with attachments.

-- Weld the hinge reinforcement -1- with a straight-line spot weld seam using a Resistance Spot Welder.

-- Install the bolt -3- and tighten to tightening specification.

-- Install the molded foam part -2-. Refer to MOLDED FOAM PARTS .

Tightening Specifications 

• Screw  . Bolt.

Courtesy of AUDI OF AMERICA, LLC

-- Fit and secure the connecting plate -1- on the vehicle while it is standing on the Alignment Set.

-- Check the fit with attachments.

-- Weld the separation cut with a gas-shielded arc continuous weld seam using a Gas-Shielded Welder.

Courtesy of AUDI OF AMERICA, LLC

-- Clean the adhesive surfaces using Silicone Remover :LVM 020 000 A5  .

-- Apply Two-Part Body Adhesive :D 180 003 M3  on the entire surface using the Double Cartridge Gun.

Courtesy of AUDI OF AMERICA, LLC

-- Fit and secure the new part on the vehicle while it is standing on the Alignment Set.

-- Check the fit with attachments.

-- Weld in the A-pillar reinforcement -1- with a straight-line spot weld seam using a Resistance Spot Welder.

-- Weld in the A-pillar reinforcement -1- with a gas-shielded arc plug weld seam using a Gas-Shielded Welder.

-- Weld the separation cut with a gas-shielded arc continuous weld seam using a Gas-Shielded Welder.

Courtesy of AUDI OF AMERICA, LLC

-- Install the A-pillar. Refer to A-PILLAR, REPLACING .