A-Pillar, Replacing: Procedure

Separating Points

Permitted Separation Cuts on Entire Side Wall Frame. Refer to PERMITTED SEPARATION CUTS ON ENTIRE SIDE WALL FRAME .

-- Perform the separation cut -2- and -3- using the Edge Milling Unit.

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

-- Remove the A-pillar -1- from the body.

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-- Remove the foam residue -1- as much as possible before sanding.

-- 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.

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Replacement Parts

• A/B-Pillar Sub-Part with Side Sill
• Molded Foam Parts
• Two-Part Body Adhesive :D 180 003 M3 
• Silicone Remover :LVM 020 000 A5 

New Part, Preparing

-- Transfer the separation cuts to the new part and perform with a Edge Milling Unit.

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

-- Grind the adhesive surfaces and welding surfaces on the new part -1- using One-Handed Angle Grinder down to the bare metal.

-- Lightly grind the adhesive surfaces -1- from the inside.

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

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Welding

-- Install the molded foam part -1-. Refer to MOLDED FOAM PARTS .

-- 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.

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-- Fit the new part to the vehicle resting on its wheels or on the Alignment Set and secure.

-- Check the fit with attachments.

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

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

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

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