Preparing New Parts

• Remove adhesive residue on the vehicle joining areas.
• Remove the unnecessary components (1)  and (2)  from the new part.

  Release the respective welded connections from the side of the unnecessary components.

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• Detach the welded connections (1)  .

  Be aware that the crash reinforcement (2)  will be reused.

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• Make the separating cut (1)  according to the presentation and remove the crash reinforcement (2)  .
  NOTE: TECHNICAL INFORMATION 
  For additional information see: 41 00...
  Welding in reinforcement plates (sheet steel)
• Make a reinforcement plate for the separating cut (1)  .

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• Adjust the new part using an alignment bracket or a universal fixture and secure it.
• Prepare areas (1)  and (2)  for joining by welding.
  NOTE: TECHNICAL INFORMATION 
  For additional information see: 41 00...
  Spot-weld bonding steel components
• In the areas (2)  , observe the procedure for replacing spot-welded adhesive joints for the series production.

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• Prepare areas (1)  for joining by welding.

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• Prepare areas (1)  for joining by welding.

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  NOTE: To provide a better overview: Schematic diagram with partially hidden components.
• Prepare areas (1)  for joining by welding.

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  NOTE: To provide a better overview: Schematic diagram with partially hidden components.
• Prepare areas (1)  for joining by welding.

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  NOTE: To provide a better overview: Schematic diagram with partially hidden components.
• Prepare areas (1)  to (3)  for joining by welding.

  For better clarity, the joint plate (5)  is not shown.

• Prepare the area (3)  so that the repair spot-weld can be placed on the production spot-weld.
• Mind the bonded connections located behind it in area (4)  .

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• Prepare the repair spot-weld (2)  for plug welding (from the inside).
• Prepare areas (1)  for joining by welding.

  Observe the procedure for replacing spot-welded adhesive joints for the standard production.

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• Prepare areas (1)  and (2)  for joining by welding.
• Prepare the areas (2)  so that the repair spot-welds can be set on the production spot-welds.
• Mind the bonded connections located behind it in areas (3)  .

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• Prepare areas (1)  and (2)  for joining by welding.
• In the areas (1)  , observe the procedure for replacing spot-welded adhesive joints for the standard production.
• Prepare the area (2)  so that the repair spot-weld can be placed on the production spot-weld.
• Mind the bonded connections located behind it in areas (3)  .

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  NOTE: To provide a better overview: Schematic diagram with partially hidden components.
• Adjust the new part of the crash reinforcement and prepare in areas (1)  to (3)  for joining by welding.

  For better clarity, the bulkhead (4)  is not shown.

• In the area (2)  , observe the procedure for replacing spot-welded adhesive joints for the series production.
• Prepare the area (3)  so that the repair spot-weld can be placed on the production spot-weld.
• Mind the bonded connections located behind it in area (4)  .

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• Make a reinforcement plate (5)  for the separating cut.
  NOTE: TECHNICAL INFORMATION 
  For additional information see: 41 00...
  Welding in reinforcement plates (sheet steel)
• Mark the separating cuts (1)  and (2)  on the new part according to the separating cuts on the vehicle and cut.
• For severance cuts (1)  and (2)  , prepare reinforcement plates.

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• Fit in new part.
  NOTE: TECHNICAL INFORMATION 
  For additional information see: 41 00...
  Spot-weld bonding steel components
• Prepare the new part and the reinforcement plate in areas (1)  to (4)  for joining by welding.
• In the areas (1)  to (3)  , observe the procedure for replacing spot-welded adhesive joints from standard production.

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• Prepare the reinforcement plate and areas (1)  and (2)  for joining by welding.
• In the area (2)  , observe the procedure for replacing spot-welded adhesive joints for the series production.

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Renew T-bolt 

• Take the quantity and position from the component to be renewed.
• Renew T-bolts (1)  .

  Parts:  T-bolt

• Weld the T-bolt (1)  onto the new part.

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