Removing side section

Installation Location:

Fig 1: Side Section Component Location

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NOTE:

Separation points on the side section can only be at the marked areas A and B .

Fig 2: Determining the cut

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1. Determining the cut

1.1. Determine separation point on C-pillar -A- to the dimension -X = 18 mm- , then mark the cut. See Fig 2.

1.2. Position cut on lower side member -B- so that the replacement body part overlaps the lower side member by approx. 60 mm, then mark the cut. See Fig 2.

Fig 3: Cutting the lower side member

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2. Cutting through the lower side member

2.1. Cut through the side section at the marked separation point in the lower side member -A- using the oscillating body saw. See Fig 3.

CAUTION: Separating side section

Risk of damage to roof reinforcement and/or internal body parts.

→ Only separate parts using the oscillating body saw.

→ In the event of damage: Repair affected area by applying inert-gas welds.

Fig 4: Cutting the C-pillar

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3. Cutting the C-pillar

3.1. Cut through the side section at the marked separation point in the C-pillar -A- using the oscillating body saw. Do not damage internal components when doing this. See Fig 4.

Fig 5: Milling off spotwelds

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4. Milling off spotwelds

4.1. Mill off spotwelds in area -A- using a spotweld cutter. See Fig 5.

Fig 6: Milling off spotwelds

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5. Milling off spotwelds

5.1. Mill off spotwelds in area -A- using a spotweld cutter. See Fig 6.

Fig 7: Separating spotwelds

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6. Separating spotwelds

6.1. Separate spotwelds in area -A- using a parting grinder. See Fig 7.

Fig 8: Milling off spotwelds

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7. Milling off spotwelds

7.1. Mill off spotwelds in area -A- using a spotweld cutter. See Fig 8.

Fig 9: Milling off spotwelds

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8. Milling off spotwelds

8.1. Mill off spotwelds in area -A- using a spotweld cutter. See Fig 9.

Fig 10: Milling off spotwelds

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9. Milling off spotwelds

9.1. Mill off spotwelds in areas -A, B, D- using a spotweld cutter. See Fig 10.

9.2. Mill off spotwelds in areas -E- and -C- using a spotweld cutter (2 plate thicknesses). See Fig 10.

Fig 11: Cutting and milling off spotwelds

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10. Separating and milling off spotwelds

10.1. Separate spotwelds in areas -A- and -B- using a parting grinder. See Fig 11.

10.2. Mill off spotwelds in area -C- using a spotweld cutter. See Fig 11.

Fig 12: Cutting and milling off spotwelds

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11. Separating and milling off spotwelds

11.1. Mill off spotwelds in area -A- using a spotweld cutter. See Fig 12.

11.2. Separate spotwelds in areas -B- using a parting grinder. See Fig 12.

Fig 13: Separating spotwelds

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12. Separating spotwelds

12.1. Separate spotwelds in area -A- using a parting grinder. See Fig 13.

Fig 14: Cutting the spotwelds

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13. Milling off spotwelds

13.1. Mill off spotwelds in area -A- using a spotweld cutter. See Fig 14.

Fig 15: Bending up side section

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14. Bending up the side section

14.1. Bend side section up in area -A- until the internal spotwelds are accessible. See Fig 15.

Fig 16: Milling off spotwelds

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15. Milling off internal spotwelds

15.1. Mill off spotwelds in area -A- using a spotweld cutter. See Fig 14.

NOTE: Removing expanded sealant

The outer side section is factory-sealed to the inner side section with expanded sealant in area -Y- . See Fig 17.
The expanded sealant will be destroyed when you change the side section and must be replaced.

Fig 17: Expanded sealant

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NOTE: Separating body parts

In the case of bonded panel joints with a hardened bonded layer on the outer panel, apply a generous amount of heat to heat up the outer panel in the area of the spotwelds. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .
After removing the loosened body part, old adhesive must be removed and any uneven spots sanded down. The flange area must then be pre-treated for bonding. For the procedure see: Information on the use of structural adhesive in vehicle manufacturing Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

Fig 18: Loosening bonded joints

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16. Separating bonded joints and removing expanded sealant

16.1. Heat up bonded joints in the areas -A, B, C- between the side section and body using the Leister Elektron hot-air gun; see Gr. 3.5, Workshop Equipment Manual 00000 and remove side section. See Fig 18.