Removing Outer Lower Side Member

Fig 1: Outer Lower Side Member Component Location

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Information 

• All straightening work on the body in the connection area of the sheetmetal parts to be replaced must be completed before the damaged parts are removed. 

1. Cut off the lower side member near the pillars.
   1. 1.1. Cut the lower side member in the areas -F-, -G and H-  using the oscillating body saw. Observe the dimensions -X-  → Cut dimension, old part: 320 mm, -Y- → Cut dimension, old part: 90 mm  and -Z- → Cut dimension, old part: 100 mm  . Do not damage the internal components.
      Fig 2: Identifying Lower Side Member In Areas (F)

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      Fig 3: Cutting Lower Side Area Dimensions (X)

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      Fig 4: Cutting Lower Side Area Dimensions (Y And Z)

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   2. 1.2. Cut the laser welded joint between the lower side member and inner lower side member using the parting grinder (areas -A-, -B and C-  ).
      Fig 5: Cutting Laser Welded Joint Between Lower And Inner Lower Side Member Dimension

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      Fig 6: Cutting Laser Welded Joint Between Inner Lower Side Member Areas (B And C)

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   3. 1.3. Mill off the welded joint on the lower side member using the spotweld cutter (areas -D-, -E-, -K-, -I and J-  ).
      Fig 7: Identifying Welded Joint On Lower Side Member Area (F)

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      Fig 8: Identifying Welded Joint On Lower Side Member Area (G)

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      Fig 9: Identifying Welded Joint On Lower Side Member Area (K)

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      Fig 10: Identifying Welded Joint On Lower Side Member Area (J)

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2. Remove lower side member.
   1. 2.1. In series production, the lower side member is sealed in the area of the pillars and wheel arch with expanded foam sealing parts. These seals are destroyed when the lower side member is removed and must be replaced when the member is reinstalled.
3. Shorten wing fastening rail.
   1. 3.1. Shorten wing fastening rail by the dimension -W-  → Overlap: 50 mm  .
      Fig 11: Identifying Wing Fastening Rail Dimension

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   2. 3.2. Mill off the welded joint on the remaining piece of the fastening rail using the spotweld cutter.
   3. 3.3. Remove the remaining piece of the fastening rail.