Removing Side Section

Fig 1: Side Section Component Location

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Information 

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

Information 

Remove expanded sealant

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

Fig 2: Identifying Expanded Sealant Area

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1. Determine the cut
   1. 1.1. Determine separation point on C-pillar -A-  to the dimension -X = 18 mm-  , then mark the cut.
   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.
   Fig 3: Identifying Cut On Lower Side Member

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2. Cut through the lower side member
   1. 2.1. Cut through the side section at the marked separation point in the lower side member -A-  using the oscillating body saw.
   Fig 4: Cutting Lower Side Member Area

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   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.

3. Cut the C-pillar
   1. 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.
   Fig 5: Cutting C-Pillar Area

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4. Mill off spotwelds
   1. 4.1. Mill off spotwelds in area -A-  using a spotweld cutter.
   Fig 6: Identifying Spotwelds Area

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5. Mill off spotwelds
   1. 5.1. Mill off spotwelds in area -A-  using a spotweld cutter.
   Fig 7: Identifying Spotwelds Area

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6. Separate spotwelds
   1. 6.1. Separate spotwelds in area -A-  using a parting grinder.
   Fig 8: Separating Spotwelds Area

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7. Mill off spotwelds
   1. 7.1. Mill off spotwelds in area -A-  using a spotweld cutter.
   Fig 9: Identifying Spotwelds Area (A)

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8. Mill off spotwelds
   1. 8.1. Mill off spotwelds in area -A-  using a spotweld cutter.
   Fig 10: Identifying Spotwelds Area (A)

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9. Mill off spotwelds
   1. 9.1. Mill off spotwelds in areas -A, B, D-  using a spotweld cutter.
   2. 9.2. Mill off spotwelds in areas -E-  and -C-  using a spotweld cutter (2 plate thicknesses).
   Fig 11: Identifying Spotwelds Area (A, B, C, D And E)

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10. Separate and mill off spotwelds
    1. 10.1. Separate spotwelds in areas -A-  and -B-  using a parting grinder.
    2. 10.2. Mill off spotwelds in area -C-  using a spotweld cutter.
    Fig 12: Separating Spotwelds Area (A And B)

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11. Separate and mill off spotwelds
    1. 11.1. Mill off spotwelds in area -A-  using a spotweld cutter.
    2. 11.2. Separate spotwelds in areas -B-  using a parting grinder.
    Fig 13: Separating Spotwelds Area (B)

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12. Separate spotwelds
    1. 12.1. Separate spotwelds in area -A-  using a parting grinder.
    Fig 14: Separating Spotwelds Area (A)

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13. Mill off spotwelds
    1. 13.1. Mill off spotwelds in area -A-  using a spotweld cutter.
    Fig 15: Identifying Spotwelds Area (A)

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14. Bend up the side section
    1. 14.1. Bend side section up in area -A-  until the internal spotwelds are accessible.
    Fig 16: Bending Up Side Section Area

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15. Mill off internal spotwelds
    1. 15.1. Mill off spotwelds in area -A-  using a spotweld cutter.
    Fig 17: Identifying Spotwelds Area (A)

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    Information 

    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. →  Diagram Of Body Bonding Points And Sealing Elements 
    • 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 →  Information On The Use Of Structural Adhesives In Vehicle Construction 
16. Separate bonded joints and remove expanded sealant
    1. 16.1. Heat up bonded joints in areas -A, B, C-  between the side section and body using the Leister Electron hot-air gun/V.A.G. 1416 WE 1119  and remove side section.
    Fig 18: Loosening Bonded Joints Area

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