Removing entrance cover with door post

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Mark severance cuts in accordance with specified dimensions and cut.

IMPORTANT: Cut outer panel only for following severance cuts.

Measurement a = approx. 270 mm from center point of 25 mm dia. hole.

Dimension b = approx. 140 mm after cut a.

Measurement c = approx. 100 mm from roof edge.

Measurement d = approx. 80 mm below cut c.

Measurement e = approx. 40 mm from center-point of 25 mm dia. hole.

OPEN spot-welded adhesive joints in areas (1).

Open welded connections in areas (2).

NOTE: Cut-out metal sections (3) and (4) are required again for sealing.

Fig 1: Identifying Entrance Cover With Door Post And Cutting Dimensions

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Mark severance cut in accordance with specified dimension and cut.

IMPORTANT: Cut outer metal plate only for following severance cut.

Measurement a = approx. 340 mm from center point of 25 mm dia. hole.

Open welded connections in area (1).

Installation note:

Apply repair welding spots in area (1) to existing welding spots on new part / vehicle.

Fig 2: Identifying Welding Spots Repair Area

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This is necessary because the adhesive between the spot flanges acts as an insulator.

Open welded connections in areas (1).

Perform severance cut (2) according to illustration.

Tilt metal section (3) forwards to gain access to the 4 weld joints underneath.

Open the 4 weld joints.

Installation note:

Apply repair welding spots in area (1) to existing welding spots on new part / vehicle.

Fig 3: Identifying Welded Connections Areas, Severance Cut And Severance Cut

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IMPORTANT: Open spot-welded adhesive joints in area (1)
Open welding spots from outside. Do not damage inside panel!

Open bonded connection in area (2).

Fig 4: Identifying Spot-Welded Adhesive Joints Area And Bonded Connection Area

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Mark severance cut in accordance with specified dimension and cut.

IMPORTANT: Cut outer metal plate only for following severance cut.

Dimension a =140 mm from the edge of roof frame.

Open weld joint (1).

Remove cover for side member with B-pillar.

Fig 5: Identifying B-Pillar Weld Joint

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New part preparation

Mark severance cuts on B-pillar in accordance with severance cuts on the vehicle and cut.

IMPORTANT: Do not cut through support (3) for B-pillar reinforcement.

(2) B-pillar reinforcement outer skin
(1) B-pillar outer skin

Fig 6: Identifying B-pillar Reinforcement Support, B-Pillar Reinforcement Outer Skin And B-Pillar Outer Skin
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Mark severance cut (1) and other severance cuts according to the severance cuts on the vehicle and cut.

Partially release metal section (2) as described in removal and tilt forwards.

Open weld joints in area (3) and remove cover for side member (4).

Prepare REINFORCEMENT PLATES at severance cuts.

NOTE: After welding in new part, tilt metal section (2) closed again and weld up.

Fig 7: Identifying Severance Cut, Metal Section, Weld Joints Area And Cover Side Member

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Set 3 6.8 mm Ø bore holes for blind rivets in area (1). Drill from passenger compartment.

Fig 8: Identifying Blind Rivets Area And Metal Section

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IMPORTANT: Structure bonding!
OBSERVE preparation of bonding surfaces (1).

Adjust new part to fit with set of attachments or universal mount.

Fig 9: Identifying Bonding Surfaces

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