41 21 003 Replacing A-pillar with reinforcement on left

Read contents of SAFETY INFORMATION and BODY, GENERAL .

Procedure OBSERVE repair stage 3.

Remove or cover those vehicle components in the repair area which are susceptible to heat or dust.

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 body new parts are required:

(1) Side frame, outer
(2) Outer wheel arch carrier support
ADHESIVE K1 (MATERIALS INFORMATION)

Also, observe NOTES ON ADHESIVE K1 .

Fig 1: Identifying Outer Side Frame And Wheel Arc Carrier Support

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Removing the A-pillar with reinforcement

Open welded connections in areas (1).

OPEN spot-welded adhesive joints in area (2).

Remove the carrier support.

Fig 2: Identifying Carrier Support Welded Connection Areas

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Mark severance cuts in accordance with specified dimensions and cut.

IMPORTANT: Cut outer panel only for following severance cuts.

Dimension "a"= 95 mm from center point of 8 mm dia. hole.

Dimension "b" = 120 mm below severance cut a.

Open welded connections in areas (1).

Remove sheet section.

Fig 3: Identifying A-Pillar Severance Cut Dimensions

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NOTE: Cut out metal section is needed again for sealing.

IMPORTANT: For following severance cut, do not damage slide/tilt sunroof water drain hose.
Cut outer panel only.

Fig 4: Identifying A-Pillar Severance Cut Dimension

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Mark severance cut in accordance with specified dimension and cut.

Dimension "a"= 155 mm from center point of 8 mm dia. hole.

Open welded connections in areas (1).

(2) = Cavity sealing

Fig 5: Identifying A-Pillar Cavity Sealing And Welded Connection Areas

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Mark severance cut in accordance with specified dimension and cut.

IMPORTANT: Cut outer panel only.

Dimension "a" = approx. 260 mm before center of 8 mm dia. hole.

Open spot-welded adhesive joints in area (1)

Open welded connections in areas (2) and (3).

Open bonded connections in areas (4).

Release A-pillar from cavity sealing (5) and remove.

NOTE: To release the bonded connections in areas (4) it may be necessary to remove the outer skin in this area.

See "Installing the A-pillar with reinforcement " for further schematic diagram of bonded connections.

Area (3) must be sealed according to standard after welding of new part.

New part preparation

Mark severance cuts on new part 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.

IMPORTANT: Structure bonding .
OBSERVE preparation of bonding surfaces.

Installing the A-pillar with reinforcement

Apply adhesive to areas (1) K1.

Apply sealant to CAVITY SEALING .

Fig 6: Identifying Adhesive Application Areas

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Install new parts and reinforcement plates with alignment bracket or universal mount and weld analogue to series standard.