Removal of front door post

Open welded connections in areas (1).

LOOSEN spot-welded adhesive joints in areas (2).

Roughly cut side frame connection along lines (3).

Remove side frame connection.

Open remaining welded connections in areas (3).

Fig 1: Identifying Welded Connections Area And Side Frame Connection Lines

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Fig 2: Identifying Roof Edge, Severance Cut And Centrepoint Of Hole

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Mark severance cuts in accordance with specified dimensions and cut.

IMPORTANT: Cut outer panel only for following severance cuts.

Dimension a = 200 mm from roof edge.

Dimension b = 120 mm below severance cut a.

Measurement c = approx. 170 mm before centrepoint of hole dia. 20 mm.

Dimension d = 120 mm before severance cut c.

Open welded connections in areas (1).

Remove sheet sections (2).

NOTE: Cut-out metal sections (2) are required again for sealing.

IMPORTANT: For following severance cut, do not damage slide/tilt sunroof water drain hose.

Cut outer panel only.

Mark severance cut (1) in accordance with specified dimension and cut.

Dimension a = approx. 260 mm from roof edge.

Fig 3: Identifying Dimension From Severance Cut To Roof Edge

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Mark severance cut (1) in accordance with specified dimension and cut.

IMPORTANT: Cut outer panel only.

Measurement a = approx. 235 mm before centrepoint of 20 mm dia. hole.

Fig 4: Identifying Dimension From Severance Cut To Centrepoint Of Hole

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Fig 5: Identifying Welding Connection Area And Sealing Area

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Open welded connections in areas (1).

Open spot-weld bonded joints in areas (2).

Open bonded connection in area (3).

Remove cavity sealing (4).

Installation note:

Replace glued joint in area (3) with MAG weld seam.

View from below.

Open weld joint (1).

Fig 6: Identifying Weld Joint

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View from inside.

Open weld joint (1).

Feed out water drain hose (2) for slide/tilt sunroof.

Fig 7: Identifying Water Drain Hose And Weld Joint

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Remove holder (1) for side wall.

Mark severance cuts (2) in accordance with schematic diagram and cut.

Cut out A-pillar metal section and A-pillar reinforcement underneath.

Remove cavity acoustic baffle (3).

Fig 8: Identifying Cavity Acoustic Baffle, Holder And Severance Cuts

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Fig 9: Identifying Welded Connection Areas

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Drill through 2 welded connections in areas (1) with 6.8 mm dia. drill.

Installation note:

In areas (1), joining is performed using bonding-riveting technology.

Fig 10: Identifying Additional Rivet Installation Area

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Additional rivet positions are required for installation in areas (1) for strengthening reasons.

Additional rivet positions (black, number 2)
Welded connections ex works (grey, number 2)

Drill additional rivet positions with 6.8 mm dia. drill in accordance with schematic drawing.

Open remaining areas of welded connections (grey, number 2) through grinding.

Release bonded connections in areas (1) and remove A-pillar.