41 21 003 Replacing A-Pillar With Reinforcement On Left
Observe procedure for 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.
The following new body parts are required:
- (1) A-pillar, outer
- (2) Reinforcement, side frame
- (3) Connection, side frame
- (4) Support, A-pillar
- (5) Shaped part, carrier support, wheel arch, front (not shown)
- (6) Shaped part, carrier support, wheel arch (not shown)
Following CONSUMABLES are required:
| Material | Quantity |
|---|---|
| Adhesive K1 | 1 |
| Blind rivets N3 | 3 |
| Blind rivets N1 | 9 |
| Blind rivets N2 | 6 |
| Cleaning agent R1 | 1 |
| Cavity sealing wax remover | 1 |
| Sealant D1 |
Removing the A-pillar with reinforcement
Roughly mark severance cuts (1) and cut.
Open welded connections in areas (2).
LOOSEN spot-welded adhesive joints in area (3).
Loosen side frame from cavity sealing (4) and remove.
Remove cavity acoustic baffle (4).
Mark severance cut in accordance with dimension and cut.
Dimension "a" = approx. 80 mm before center point of 25 mm dia. hole.
Open welded connections in areas (1).
Mark severance cuts (1) in accordance with schematic diagram and cut.
Severance cuts are at the same height as hinge attachment points.
Remove panel sections and detach welded connections (2).
View of passenger compartment:
Open weld joint (1).
Mark severance cut in accordance with dimension and cut.
Dimension "a" = 300 mm from corner of roof outer skin.
Open welded connections in areas (1).
Open spot-weld bonded joints in areas (2).
Release A-pillar from cavity sealings (3) and remove.
Mark severance cut (1) in accordance with dimension and cut.
Dimension "a" = approx. 100 mm from previous separation cut.
Open welded connections in areas (2).
Mark severance cut (1) in accordance with dimension and cut.
Dimension "a" = approx. 100 mm from previous separation cut.
Open welded connections in areas (2).
Drill through 6 welded connections in areas (1) with 6.8 mm dia. drill.
Additional rivet positions are required for installation in areas (1) for strengthening reasons.
- Additional rivet positions (black, number 5)
- Former welded connections (grey, number 6)
Drill additional rivet positions with 6.8 mm dia. drill in accordance with schematic drawing.
Open remaining areas of welded connections (grey, number 6) through grinding.
Detach bonded connections in areas (1) and remove hinge reinforcements.
New part preparation
Mark severance cuts on new parts in accordance with severance cuts on vehicle and cut.
Prepare REINFORCEMENT PLATES at severance cuts.
Release spot-welded adhesive joints in areas (1) and (2).
Remove A-pillar support and side frame connection.
No holes are to be drilled in the A-pillar in areas (1) and (2).
Adapt A-pillar new parts, side frame reinforcement and A-pillar support with alignment bracket or universal mount and secure.
In area (1) create 5 holes for blind rivets.
(2) = bore holes 4.2 mm dia. for blind rivets N3 .
(3) = bore holes 6.8 mm dia. for blind rivets N1 .
In area (1) create 2 bore holes 6.8 mm dia. for blind rivets N1 .
Transfer bore holes (1) created during removal to new part.
Also drill new part through holes (1) with drill Ø 6.8 mm.
In area (1) prepare new part for plug welding.
In all other joint areas, prepare new parts and body for joining by welding.
Remove new parts again and deburr holes.
Installing the A-pillar with reinforcement
Clean all bonding surfaces (1) on the vehicle and on the new part with cleaning agent R1.
Apply adhesive K1 to bonding surfaces (1) to new part and vehicle.
Coat CAVITY SEALINGS with sealant.
Install new parts and reinforcement plates with alignment bracket or universal mount and secure.
In areas (1) to (8) rivet new parts with blind rivets.
| Area | Blind rivet N1 | Blind rivet N2 |
|---|---|---|
| 1 | 1 | |
| 2 | 1 | |
| 3 | 1 | |
| 4 | 2 | |
| 5 | 2 | |
| 6 | 2 | |
| 7 | 1 | |
| 8 | 1 |
In areas (1), rivet new part with blind rivets N1 and N3.
Weld new part in area (2).
Weld new part in area (1).
Shown without A-pillar support for purposes of clarity.
Avoid applying excessive heat to the neighboring adhesive areas.
MAG-weld new part in areas (1).
To do so, apply 10 mm long fillet welds at spacing of 15 mm.