41 21 930 Replacing inside left side frame (B-pillar reinforcement)

Read contents of BODY, GENERAL .

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 procedures for SPOT-WELD BONDING STEEL COMPONENTS  and OPENING BONDED CONNECTIONS .

Use only approved SPOT-WELDING APPARATUS  for repairs.

Place vehicle on straightening bench.

Carry out work in connection with replacing the side wall 41 35 101 .

Side panel and B-pillar reinforcement are fitted as a composite unit.

The following new body parts are required:

• (1) Side frame, outer (including B-pillar reinforcement)
• Reinforcement plate, side sill
• Reinforcement plate, C-pillar
• Reinforcement plate, D-pillar
• Reinforcement plate, universal
• Cavity sealing, B-pillar, top, inner
• Cavity sealing, B-pillar bottom, inner

Fig 1: Identifying Outer Side Frame

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The following CONSUMABLES  are required:

Removal 

Mark severance cut in accordance with specified dimension and cut.

Fig 2: Identifying Roof Outer Skin Edge Dimension

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Dimension a = approx. 120 mm from component edge of roof outer skin.

Open welded connections in areas (1).

Rest of procedure same as for removal of side panel in 41 35 101 .

After removal of side wall:

Mark severance cut in accordance with dimension and cut.

Dimension a = approx. 50 mm below side panel severance cut.

Open welded connections in areas (1).

Fig 3: Identifying Severance Cut Area And Welded Connections Areas

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Extend severance cut (1) to lower edge of entrance.

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

Open BONDED CONNECTION  in area (4).

Remove B-pillar reinforcement with entrance part section.

Fig 4: Identifying Severance Cut Area, Welded Connections Areas, And Bonded Connection Area

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

Remove jacking point.

Fig 5: Identifying Spot-Welded Adhesive Joints Area And Bonded Connections Areas

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New part preparation 

Mark severance cut (1) in accordance with severance cut on body and cut.

Mark severance cut (2) approx. 100 mm from below severance cut (1) and cut.

Open welded connections in areas (3) and remove panel section (4).

Installation note: 

Metal section (4) is needed again for sealing side panel.

Fig 6: Identifying Metal Section, Severance Cut Areas, And Welded Connections Areas

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Prepare REINFORCEMENT PLATES  (welded) for severance cuts in this area.

Mark severance cut (1) in accordance with severance cut on body and cut.

Fig 7: Identifying Severance Cut Area

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In area (1) prepare new part for plug-weld.

Prepare new part for spot-weld in areas (2).

Fig 8: Identifying Spot-Weld Areas And Plug Weld Area

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Prepare new part for spot-weld in areas (1).

Prepare new part for joining by adhesive in areas (2). (STRUCTURE BONDING )

Remove foamed material from cavity sealing in area (3).

Fig 9: Identifying Spot-Weld Areas, Adhesive Areas, And Cavity Sealing Area

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New part preparation in the remaining joining areas in the same way REPLACEMENT OF SIDE PANEL .

Adjust new part to fit with set of attachments or universal mount.

Installation 

Clean bonding surfaces with CLEANING AGENT R1 .

Apply sealant to cavity sealings (1). See INSTALLING CAVITY SEALING (EXPANDED) , INSTALLING CAVITY SEALING (NOT EXPANDED) , and INSTALLING A CAVITY SEALING WITH 2-COMPONENT PU CAVITY FOAM .

Fit cavity sealings.

Fig 10: Identifying Cavity Sealings

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Apply ADHESIVE K1  in areas (1).

Apply sealant to cavity sealing (2).

Comply with installation of SIDE PANEL .

Install new part to fit with set of attachments or universal mount.

Fig 11: Identifying Adhesive Areas And Cavity Sealing

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Overview of joining methods:

(1) = welding

(2) = adhesive

Avoid applying excessive heat to the neighboring adhesive areas!

Fig 12: Identifying Welding Areas And Adhesive Areas

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