Removal of front door post

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).

Fig 1: Identifying Side Frame Connection Lines, Spot-Welded Adhesive Joints Areas And Welded Connections Areas

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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).

Fig 2: Identifying Welded Connections Areas And Spot-Welded Adhesive Joints Areas

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

Dimension a = approx. 250 mm from roof edge.

Fig 3: Identifying Severance Cut Mark

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

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

Fig 4: Identifying Severance Cut Mark

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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.

Fig 5: Identifying Welded Connections Areas, Spot-Weld Bonded Joints Areas, Bonded Connection Area And Cavity Sealing

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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 Weld Joint And Water Drain Hose

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Roughly mark severance cut (1).

Cut out A-pillar metal section (2) and A-pillar reinforcement underneath.

Fig 8: Identifying Severance Cut Mark And A-Pillar Metal Section

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Release bonded connection (1).

Fig 9: Identifying Bonded Connection

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Remove holder (1) for side wall.

Roughly mark severance cut (2).

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

Remove cavity acoustic baffle (3).

Fig 10: Identifying Side Wall Holder, Severance Cut Mark And Cavity Acoustic Baffle

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

Fig 11: Identifying Front Left Door Post Joined Areas

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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.

Fig 12: Identifying Rivet Positions Installation Areas

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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).

Fig 13: Identifying A-Pillar Joining Area And Bore Holes

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Create bore holes (1) and (2) for blind rivets N1 and N3 in accordance with schematic diagram:

1. Bore hole dia. 6.8 mm.
2. Bore holes dia. 4.2 mm.

Fig 14: Identifying Blind Rivets Bore Holes

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Transfer bore holes (1) created during removal to new part.

Also drill new part through holes (1) with drill Ø 6.8 mm.

Remove new parts and deburr bore holes.

Fig 15: Identifying Bore Holes

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