41 32 101 Replacing top cowl panel and A-pillar, complete left

WARNING: This page is about a different variant/trim than selected.

Read contents of BODY, GENERAL .

Spot-weld bonding is used on this vehicle. See SPOT-WELD BONDING STEEL COMPONENTS and OPENING BONDED CONNECTIONS .

Use only approved SPOT-WELDING APPARATUS for repairs.

Place vehicle on straightening bench.

Observe procedure of REPAIR STAGE 3 .

Following new body parts are required:

(1) Cowl panel, top
(2) Cowl panel, bottom
(3) Carrier support, wheel arch, front,
(4) A-pillar, outer
(5) Attachment, sill

Fig 1: Identifying Upper Cowl Panel, Lower Cowl Panel, Carrier Support, Outer A-Pillar, And Sill Attachment

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Following CONSUMABLES are required:

Material	Quantity
Adhesive K5a	1
Blind rivets N1	14
EMC screws	1
Cavity sealing wax remover
Cleaning agent R1	1
Sealant D1

Removing the A-pillar with cowl panel

Open welded connections in areas (1).

Fig 2: Identifying A-Pillar Welded Connections Areas

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Open welded connections in areas (1).

Remove support carrier.

Fig 3: Identifying Welded Connections Areas

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Open welded connections in areas (1).

Installation note:

Position sill attachment after painting on body.

Fig 4: Identifying Body Sill Attachment Welded Connections Areas

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Open spot-welded adhesive joints in area (1) and welded connections in area (2).

Fig 5: Identifying Spot-Welded Adhesive Joints Area

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Separate MAG-welded joints in area (1) and remove door hinge (2).

Fig 6: Identifying Door Hinge MAG-Welded Joints Area

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Separate 2 welded joints in area (1) of the hinge mounting surface.

Installation note:

Replace welded connections in area (1) by 3 additional plug welding welds in area (2).

Fig 7: Identifying Areas Of Welded Connections And Plug Welds

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Open welded connections in area (1).

Fig 8: Identifying Welded Connections Area

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Open welded connections in area (1).

Fig 9: Identifying Welded Connections Area

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Open welded connections in area (1).

Fig 10: Identifying Welded Connections Area

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Open welded connections in areas (1).

Take off door post.

Fig 11: Identifying Door Post Welded Connections Areas

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New part preparation

Adjust new parts to fit with alignment bracket or universal mounting.

Repair stage 2:

Adjust new support beam to fit and secure.

Set eleven 6.7 mm dia. holes for blind rivets in area (1).

Fig 12: Identifying Area For Blind Rivet Bore Holes

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Set 3 6.7 mm dia. bore holes for blind rivets in area (1).

Remove new part again and deburr bore holes.

Fig 13: Identifying Areas For Blind Rivet Bore Holes

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IMPORTANT: Do not grind/sand new part in area of bonding surfaces.

Installing the A-pillar with cowl panel

Adjust new parts with alignment bracket or universal mount and weld.

Repair stage 2:

Clean all bonding surfaces on new part and on vehicle with cleaning agent R1.

Apply adhesive to bonding surfaces (1).

Fig 14: Identifying Bonding Surfaces

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Mount support carrier and rivet with blind rivets (1).

Fig 15: Identifying Riveting Area

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Rivet support carrier with blind rivets (1).

After adhesive has hardened in area (1), fit an EMC SCREW .

Fig 16: Identifying Riveting Area

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