Outer Side Sill, Replacing: Procedure

Separating Points

CAUTION:

Risk of injury due to flying metal shavings.

Irritation and injury to skin and eyes possible.

- Wear protective eyewear.

- Wear safety gloves.

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

CAUTION:

Do not damage the underlying reinforcements when performing the separation cuts.

- Re-welding the reinforcements is not permitted due to safety reasons.

- Perform the separation cuts using the Edge Milling Unit.

-- Perform the separation cuts -2- using the Edge Milling Unit.

-- Separate the outer edge at the wheel arch using the Edge Milling Unit.

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

-- Remove the outer side sill -1- from the body.

Fig 1: Outer Side Sill, Separation Cut And Bonded Area Components Location

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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

New Part, Preparing

-- Transfer the separation cuts to the new part -1- and perform with a Edge Milling Unit.

-- Use the One-Handed Angle Grinder to sand the adhesive surfaces and welding surfaces to bare metal.

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

-- Lightly sand the adhesive surfaces in the area of the wheel arch.

-- 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 in the outer side sill -1- with a straight-line spot weld seam using a Resistance Spot Welder.

-- Weld in the outer side sill -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.

-- Reform the wheel arch flange.

-- Remove leaking adhesive and seal the wheel arch.

Courtesy of AUDI OF AMERICA, LLC