Side Sill Reinforcement, Replacing: 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 .

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.

CAUTION:

Do not damage the reinforcements below.

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

-- Remove the bolts -2-, -3- and -4-.

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

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

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CAUTION:

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 .

-- 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 Part

New Part, Preparing

-- 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 .

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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.

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

-- Check the fit with attachments.

-- Install the bolts -2-, -3- and -4- and tighten to tightening specification.

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

Tightening Specifications

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-- Install the B-pillar reinforcement. Refer to B-PILLAR REINFORCEMENT, REPLACING .

-- 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 .