Installing side section

WARNING: Risk of damage if the processing time is not observed!

The quality of the joint will be affected if the adhesive processing time is not observed.

→ The new part must be welded within 30 minutes in the area of the adhesive, otherwise the adhesion of the adhesive will be affected.

Fig 1: Fitting the seal

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1. Installing seal

1.1. Apply a triangular bead of body sealant measuring -dimension X = approx. 12 mm- high all around the seal. Position seal on inside of side section and press on firmly. See Fig 1.

Check dimension -Y= 20 mm- with respect to roof reinforcement. See Fig 1.

Fig 2: Applying adhesive to the inside of the side section

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2. Apply adhesive on the inside of the side section

2.1. Apply a triangular bead of Betamate 2096 adhesive measuring -dimension X = approx. 8 mm- in height to the joint between the light housing and the inside of the side section. The light frame must lie flush with the inside of the side section. See Fig 2.

Fig 3: Applying adhesive to the side section

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3. Applying adhesive to the side section

3.1. Apply a triangular bead of adhesive (Teromix-6700) measuring -dimension X = approx. 8 mm- to the inside of the side section, along the wheel arch up as far as the start of the door sill. See Fig 3.

NOTE: Determine the position of the new part and secure with tensioning clamps.

When butt welding body sheet panels with a sheet thickness of > 1.5 mm, there must be a welding slit width s = 1 x sheet thickness to guarantee the required welding quality (welding through).

Fig 4: Fitting the side section to the body

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4. Fitting the side section to the body

4.1. Secure the side section with tensioning clamps. Use test gauge 9748 .

4.2. Tack-weld the side section.

Fig 5: Welding in the side section

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5. Welding in the side section

5.1. Resistance spot-weld the side section in area -A- . See Fig 5.

Fig 6: Welding in the side section

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6. Welding in the side section

6.1. Resistance spot-weld the side section in area -A- . See Fig 6.

Fig 7: Welding in the side section

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7. Welding in the side section

7.1. Resistance spot-weld the side section in area -A- . See Fig 7.

WARNING: Welding in body components

Danger of injury and material damage

→ Once the spare parts have been fixed in place, repair spotwelds must be placed on the old spotwelds because there is no current flow possible in areas with a hardened adhesive layer. Welding procedures other than resistance spot-welding are not permitted since the thermal effect would destroy the bonded joint over a wide area. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

Fig 8: Welding in the side section