41 21 003 Replacing A-Pillar With Reinforcement On Left (Hybrid)
Compliance with the following points is mandatory before beginning work:
- De-energize the HIGH-VOLTAGE SYSTEM .
- Observe SAFETY INFORMATION for working with electric vehicles.
Procedure OBSERVE repair stage 3!
Read contents of BODY, GENERAL .
Spot-weld bonding is used on this vehicle. Observe specific PROCEDURE .
Use only approved SPOT-WELDING APPARATUS for repairs.
Place vehicle on straightening bench.
Following new body parts are required (refer to ELECTRONIC PARTS CATALOGUE ):
- (1) A-pillar, outer
- (2) Connection, side frame
- (3) Shaped part, carrier support, wheel arch, front (not shown)
- (4) Shaped part, carrier support, wheel arch (not shown)
Following CONSUMABLES are required:
| Material | Quantity |
|---|---|
| Adhesive K1 | 1 |
| Blind rivets N7 | 3 |
| Blind rivets N3 | 2 |
| Cleaning agent R1 | 1 |
| Sealant D1 | |
| Cavity wax remover |
Removing the A-pillar with reinforcement
Roughly cut side frame connection along lines (1).
LOOSEN spot-welded adhesive joints in areas (2).
Open welded connections in areas (3).
Release side frame connection from cavity sealing (4) and remove.
Open remaining welded connections in areas (1).
Mark severance cuts in accordance with specified dimensions and cut.
Dimension a = 200 mm from roof edge.
Dimension b = 100 mm below severance cut a.
Dimension c = approx. 165 mm before center of hole dia. 15 mm.
Dimension d = 140 mm before severance cut c.
Open welded connections in areas (1).
Remove sheet sections (2).
Cut outer panel only.
Mark severance cut (1) in accordance with specified dimension and cut.
Dimension a = approx. 250 mm from roof edge.
Mark severance cut (1) in accordance with specified dimension and cut.
Dimension a = approx. 235 mm before center of 15 mm dia. hole.
View from below.
Open weld joint (1).
Open weld joint (1).
Open spot-welded adhesive joint (2).
Release bonded connection (3).
Open welded connections in areas (1).
Open spot-weld bonded joints in areas (2).
Open bonded connection in area (3).
Release and remove A-pillar from cavity sealings (4).
Installation note:
Replace glued joint in area (3) with MAG weld seam.
New part preparation
Mark severance cuts on new parts in accordance with severance cuts on vehicle and cut.
Prepare REINFORCEMENT PLATES at severance cuts.
Adjust new parts to fit with alignment bracket or universal mounting.
Create bore holes (2) to (3) for blind rivets N7 as per specified dimensions:
(2): Dia. 6.8 mm bore hole in accordance with dimension a = 10 mm from component edge.
(3): Dia. 6.8 mm bore hole in accordance with dimension b = 55 mm from bore hole (2).
Create bore holes (1) and (2) for blind rivets N7 and N3 in accordance with schematic diagram:
- Bore hole dia. 6.8 mm.
- Bore holes dia. 4.2 mm.
In areas (1) and (2) prepare body for plug/spot welding.
Remove new parts and deburr bore holes.
OBSERVE preparation of bonding surfaces.
Installing the A-pillar with reinforcement
Clean bonding surfaces (1) with cleaning agent R1.
Apply sealant to cavity sealing . See 41 00... INSTALLING CAVITY SEALING (EXPANDED) or 41 00... INSTALLING CAVITY SEALING (NOT EXPANDED) (2).
Apply adhesive to bonding surfaces.
Install new parts and reinforcement plates with alignment bracket or universal mount.
At the same time, make sure water drain hose of slide/tilt sunroof is correctly fitted.
In areas (1), rivet new part with blind rivets N7.
Weld new part in area (2).
Install side frame connection new part and rivet with blind rivets.
| Area | Blind rivet N7 | Blind rivet N3 |
|---|---|---|
| 1 | 1 | |
| 2 | 2 |
Weld new parts in the remaining joint areas.
MAG-weld new part in areas (1).
To do so, apply 10 mm long fillet welds at spacing of 15 mm.
Weld the new parts in the remaining joint areas.