Side Panel Reinforcement, Replacing, Crash Bolster: Procedure
- A-pillar removed. Refer to A-PILLAR, REPLACING .
- B-pillar removed. Refer to B-PILLAR, REPLACING .
- Outer side sill is removed. Refer to OUTER SIDE SILL, REPLACING .
- A-pillar reinforcement removed. Refer to A-PILLAR REINFORCEMENT, REPLACING - PARTIAL REPLACEMENT .
- B-pillar reinforcement is removed. Refer to B-PILLAR REINFORCEMENT, REPLACING .
- Side sill reinforcement removed. Refer to SIDE SILL REINFORCEMENT, REPLACING .
Separating Points
Risk of injury due to flying metal shavings.
Irritation and injury to skin and eyes possible.
- Wear protective eyewear.
- Wear safety gloves.
-- Loosen the original joint using Spot Weld Breaker and One-Handed Angle Grinder.
-- Remove the side panel reinforcement -1- from the body.
-- 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.
Replacement Part
- Side Panel Reinforcement (Crash Bolster)
- Two-Part Body Adhesive :D 180 003 M3
- Silicone Remover :LVM 020 000 A5
New Part, Preparing
Steel shavings can lead to aluminum contact corrosion.
- Cover aluminum parts when sanding or welding steel parts.
- Immediately remove the steel shavings on the aluminum cast parts.
- Use tools for either steel or aluminum.
- Use the Aluminum Tool Set :V.A.G 2010/2A and Collision Tool Trolley :V.A.G 2010/2A-1 .
-- Grind the adhesive surfaces and welding surfaces on the new part -1- using One-Handed Angle Grinder down to the bare metal.
-- Clean the adhesive surfaces using Silicone Remover :LVM 020 000 A5 .
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 and secure the new part on the vehicle while it is standing on the Alignment Set.
-- Check the fit with attachments.
-- Weld the side panel reinforcement -1- using a Resistance Spot Welder with a straight-line spot weld seam.
-- Install the side sill reinforcement. Refer to SIDE SILL REINFORCEMENT, REPLACING .
-- Install the B-pillar reinforcement. Refer to B-PILLAR REINFORCEMENT, REPLACING .
-- Install the A-pillar reinforcement. Refer to A-PILLAR REINFORCEMENT, REPLACING - PARTIAL REPLACEMENT .
-- Outer Side Sill, Installing. Refer to OUTER SIDE SILL, REPLACING .
-- B-Pillar, Installing. Refer to B-PILLAR, REPLACING .
-- Install the A-pillar. Refer to A-PILLAR, REPLACING .