Fitting And Installing Front Side Section

→ Weld in the new part within 30 minutes.

Fig 1: Overview Of Side Section - Outside

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1. Fit front side section to the body.
   1. 1.1. Fit front side section to the body and align it using the locating holes you drilled for installing the B-pillar reinforcement. Fix front side section in place with tapping screws and tensioning clamps.

      Check contours and gaps between the doors and side member again according to the adjustment values. → WM 5000IN Diagram - body gap dimensions

2. Fit front side section to the A-pillar connection point.
   1. 2.1. Use the oscillating body saw to cut through the two sheetmetal panels close to the overlap between the front side section and A-pillar (area -A-  ). Do not damage the internal components.
      Fig 2: Exacting A-Pillar Cut

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      Fig 3: Overview Of B-Pillar - Outside

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3. Fit front side section to the B-pillar connection point.
   1. 3.1. Use the oscillating body saw to cut through the two sheetmetal panels close to the overlap between the front side section and B-pillar (area -A-  ). Do not damage the internal components.
      Fig 4: Exacting B-Pillar Cut

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      Fig 5: Overview Of C-Pillar - Outside

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4. Fit front side section to the C-pillar connection point.
   1. 4.1. Use the oscillating body saw to cut through the two sheetmetal panels close to the overlap between the front side section and C-pillar (area -A-  ). Do not damage the internal components.
      Fig 6: Exacting C-Pillar Cut

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5. Remove front side section.
   1. 5.1. Remove front side section and remaining pieces from the pillars.
      Fig 7: Overview Of A- And B-Pillar

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6. Apply body sealing adhesive to the A-pillar reinforcement.
   1. 6.1. On the lower door hinge flange area -A- Teromix-6700 two-component adhesive  must be applied sparingly.
      Fig 8: Applying Body Sealing Adhesive

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      Fig 9: Overview Of A- And B-Pillar

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7. Apply body sealing adhesive to the B-pillar.
   1. 7.1. On the two door hinge flanges and on the catch bar mounting point in areas -A, B and C- Teromix-6700 two-component adhesive  must be applied sparingly.
      Fig 10: Applying Body Sealing Adhesive

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      Fig 11: Overview Of Body Sealing Adhesive - Outside

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8. Apply body sealing adhesive to the wheel arch flange.
   1. 8.1. On the wheel arch flange in area -A- Teromix-6700 two-component adhesive  → Application depth: 6 mm  must be applied. Observe the application depth -X10-  .
      Fig 12: Applying Body Sealing Adhesive

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      Fig 13: Identifying Application Depth For Body Sealing Adhesive

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9. Install front side section.
   1. 9.1. Fit front side section to the body. Adjust the contours and gap dimensions according to the previous fitting process. Fix front side section in place with tapping screws and tensioning clamps.
      Fig 14: Overview Of Front Side Section - Outside

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10. Weld in front side section at the A-pillar.
    1. 10.1. Weld the front side section in area -A-  using inert gas.
       Fig 15: Identifying Welded Joints On A-Pillar

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    2. 10.2. Resistance spot-weld the front side section in areas -B and C-  .
       Fig 16: Overview Of Front Side Section - Outside

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11. Weld in front side section at front side member.
    1. 11.1. Plug-weld the front side section in area -A-  using inert gas.
       Fig 17: Identifying Welded Joints On Front Side Member

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    2. 11.2. Resistance spot-weld the front side section in area -A-  .
       Fig 18: Identifying Welded Joints On Side Member

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       Fig 19: Overview Of B-Pillar - Outside

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12. Weld in front side section at the B-pillar.
    1. 12.1. Weld the front side section in area -A-  using inert gas.
       Fig 20: Identifying Welded Joints On Top Of B-Pillar

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    2. 12.2. Resistance spot-weld the front side section in areas -B and C-  .
    3. 12.3. Resistance spot-weld the front side section in areas -A, B and C-  .
       Fig 21: Identifying Welded Joints On B-Pillar

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       Fig 22: Overview Of C-Pillar - Outside

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13. Weld in front side section at the C-pillar.
    1. 13.1. Weld the front side section in area -A-  using inert gas.
       Fig 23: Identifying Welded Joints On C-Pillar

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    2. 13.2. Resistance spot-weld the front side section in areas -B and C-  .
    3. 13.3. Resistance spot-weld the front side section in area -A-  .
       Fig 24: Identifying Welded Joints On Rear Side Member

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14. Weld locating holes on B-pillar.
    1. 14.1. Plug-weld locating holes from outside and inside in areas -A and B-  using inert gas.
       Fig 25: Identifying Welding Locating Holes

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15. Grind the MIG seams until smooth.