41 21 510 Replacing Front Left Door Post (Front Side Panel Removed)
Read contents of BODY, GENERAL .
Spot-weld bonding is used on this vehicle. Observe specific procedure . See 41 00... SPOT-WELD BONDING STEEL COMPONENTS or 41 00... OPENING BONDED CONNECTIONS .
Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.
Use only approved SPOT-WELDING APPARATUS for repairs.
Place vehicle on straightening bench.
Following new body parts are required (see CONSUMABLES ):
- (1) A-pillar, outer
- (2) Reinforcement, A-pillar, inner
- (3) Door hinges
- (4) Carrier support, outer wheel arch section
- (5) Shaped part, carrier support, wheel arch (not shown)
- (4) Inner A-pillar shaped parts (not shown)
Door post removal
Mark severance cuts in accordance with specified dimensions and cut.
Dimension a = approx. 130 mm from edge of rectangular hole.
Dimension b = approx. 200 mm from center of a bore hole with Ø12 mm.
Open welded connections in areas (1).
Undo and remove sections of the cavity sealing (2).
Installation note:
Right side of vehicle only:
Drill through the area (1) around holder (2) and carrier support (3) and MAG weld.
Mark severance cuts in accordance with specified dimensions and cut.
Dimensions a = approx. 150 mm from roof edge.
Dimension b = approx. 100 mm below severance cut a.
Dimension c = approx. 130 mm before centerpoint of Ø 20 mm hole.
Open welded connections in areas (1).
Installation note:
Panel section (2) is needed to close the cowl panel.
Mark severance cut (1) according to the specified dimension.
Dimensions a = approx. 180 mm from roof edge.
Cut a 20x50 mm hole in area (2).
Pull away the water drain hose (3) of the slide/tilt sunroof from the panel using a wire loop.
Carry out severance cut (1).
Undo the welded connection in this area (1).
Undo the welded connection in this area (1).
Undo the welded connection in this area (1).
Open BONDED CONNECTIONS in areas (2).
Take off door post.
New part preparation
Mark severance cuts on new parts according to severance cuts on vehicle and sever.
Prepare REINFORCEMENT PLATES at severance cuts.
Insert inner A-pillar reinforcement (1) into outer A-pillar (2) and weld.
Prepare . See 41 00... BONDING STEEL ON STEEL or 41 00... NOTES ON ADHESIVE K1 bonding surfaces (2).
Installation note:
Apply sealing compound to cavity sealing . See 41 00... INSTALLING CAVITY SEALING (EXPANDED) or 41 00... INSTALLING CAVITY SEALING (NOT EXPANDED) (1).
Adjust new part to fit with set of attachments or universal mount.
Door post installation
Apply K1 adhesive to bonding surfaces.
Install new parts and reinforcement plates with alignment bracket or universal mount and weld.
MAG weld hinges in areas (2).