Installing Deformation Element

Information 

The following work is only required if a deformation element was installed on the removed body front section.

Information 

Due to changes in spare parts, the component is installed differently to the vehicle delivery status.

1. Mark position for bore holes.
   1. 1.1  Mark the centre line of the indentations on the longitudinal member for the wheel housing upper section.

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      Centre line marking

   2. 1.2  Identify the centre line for the bore holes on the underside of the deformation element and transfer to the upper side.

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      Centre line (shown from below)

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      Marking (shown from above, without upper part of deformation element)

   3. 1.3  Position deformation element on the body.

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      Positioning (shown without upper part of deformation element)

      1. 1.3.1  Place the deformation element in the indentations.
      2. 1.3.2  Move the deformation element forward in a longitudinal direction as far as it will go -arrow A-  .
      3. 1.3.3  Set the marking -1-  .
      4. 1.3.4  Move the deformation element backward in a longitudinal direction as far as it will go -arrow B-  .
      5. 1.3.5  Set the marking -2-  .
      6. 1.3.6  Align deformation element evenly in a longitudinal direction between markings -1-  and -2-  .
      7. 1.3.7  Align lateral deformation element with the centre line markings.
      8. 1.3.8  Mark bore hole centre point -3-  .
2. Remove deformation element.
3. Drill holes.

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   Marking

   1. 3.1  Drill holes for rivets at the marked positions using a > with a diameter of 6.6 mm  Drill bit diameter 6.6 mm.
4. De-burr the bore holes.
5. Prime the bare surfaces.
6. Secure the deformation element.
   1. 6.1  Once the painting work is complete, rivet in the deformation element using blind rivets > BLIND RIVET 999.190.229.01  .

Subsequent work for body repairs (with straightening system) 

1. Release and remove vehicle from the straightening system.
2. Clean joint areas and sheetmetal flanges with a wire brush.
3. Prime joint areas and sheetmetal flanges with 2K primer.
4. Restore standard seal with body sealant

   > 5X00IN42 SEAM SEALING - SECTION ON "INFORMATION"

   Also seal the repair area carefully.

5. Paint repair area and adjacent surfaces, if necessary.
6. Restore standard underbody protection with underbody sealant

   > 5X00IN43 UNDERBODY PROTECTION - SECTION ON "INFORMATION"

7. Apply standard cavity preservation

   > 5X00IN44 CAVITY PRESERVATION - SECTION ON "INFORMATION"

   Also carefully apply cavity preservation to the repair area.

8. Install removed accessories in the repair area.