Installing Outer Hinge Pillar

→ Press on joint immediately after applying adhesive. Otherwise the adhesive bead must be removed and pre-treatment of the surface and application of the adhesive must be repeated.

→ Do not apply pressure to bonded parts until hardening is complete.

Information 

• In areas in which bonded flanges are spot-welded in an unhardened state, suction devices must be used due to combustion products. 
• Areas that can only be accessed from one side must be joined with MAG plug-welds or MAG welded seams. In these cases, no adhesive can be used in the vicinity of the welded seam because this would burn and would have a negative effect on the joint. 
• Welding procedures other than resistance spot-welding are not permitted since the thermal effect would destroy the bonded joint over a wide area. 
• The areas without adhesive must be protected using appropriate anti-corrosion and sealing measures. 

Fig 1: Identifying Bonded Seam Lengths

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1. 530 mm
2. 550 mm
3. 1, 500 mm
4. 2, 070 mm

1. Apply structural adhesive to body parts
   1. 1.1. Using the bonding gun, apply structural adhesive to the body in areas -A-  and -B-  as an adhesive bead measuring -X= approx. 3 mm-  .

      See: Working with body structural adhesive → Information On The Use Of Structural Adhesives In Vehicle Construction

      Fig 2: Identifying Structural Adhesive Applying Dimension On Body Parts

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      Information 

      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).

2. Fit outer hinge pillar on the body
   1. 2.1. Fit the outer hinge pillar to the body and fix in place with tensioning clamps.
3. Fastening outer hinge pillar
   1. 3.1. Tighten fastening screws -1-  .
   Fig 3: Locating Outer Hinge Pillar Mounting Screw

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   Information 

   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.

4. Welding in outer hinge pillar
   1. 4.1. Resistance spot-weld the outer hinge pillar in areas -A-  and -B-  .
   Fig 4: Identifying Outer Hinge Pillar Welding Area (A And B)

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5. Welding in outer hinge pillar
   1. 5.1. Resistance spot-weld the outer hinge pillar in area -A-  .
   Fig 5: Identifying Outer Hinge Pillar Welding Area (A)

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6. Welding in outer hinge pillar
   1. 6.1. Apply a full weld to the outer hinge pillar in areas -A-  and -B-  using inert gas.
   Fig 6: Identifying Outer Hinge Pillar Welding Area (A And B)

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7. Welding in outer hinge pillar
   1. 7.1. Apply a full weld to the outer hinge pillar in areas -A-  and -B-  using inert gas.
   Fig 7: Identifying Outer Hinge Pillar Welding Area (A And B)

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8. Welding in outer hinge pillar
   1. 8.1. Plug-weld the outer hinge pillar in areas -A, B, C, D-  using inert gas.
   Fig 8: Identifying Outer Hinge Pillar Welding Area (A And B)

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9. Welding in outer hinge pillar
   1. 9.1. Plug-weld the outer hinge pillar in area -A-  using inert gas.
   Fig 9: Identifying Outer Hinge Pillar Welding Area (A And B)

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10. Welding in outer hinge pillar
    1. 10.1. Braze the outer hinge pillar in area -A-  .
    Fig 10: Identifying Outer Hinge Pillar Welding Area (A)

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11. Create surface contour on outer hinge pillar connection with respect to the cowl panel.
    1. 11.1. Create surface contour -A-  using a parting grinder and a 1-mm thick cutting disc. Make sure the surface contour to be created (approx. 25 mm long) does not run into the rounded areas.
    Fig 11: Identifying Outer Hinge Pillar Connection Surface Contour On Cowl Panel

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