Installing Side Panel

Information 

• Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive. 
• The bonding process can only be carried out reliably when a smooth and swift sequence of operations is guaranteed. 
• Do not begin bonding work until all materials and tools necessary for later repair work are available. 

1. Bond in molded part.
2. Apply foam filler to the side panel. → WM 5X00IN WORKING WITH BODY FOAM FILLER - section on "Installing"

   Make sure that all openings and gaps are closed off with the sealing compound.

   The gap between the inner side section and the side panel must be closed when fitting it on the body.

   Fig 1: Identifying Side Panel Foam Filler Area

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3. Apply adhesive as shown in the illustrations. → Application Depth: 3.0 mm 

   Working with structural body adhesive. → WM 5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE

   Green	Resistance Spot-Welding
   Blue	Bonding
   Yellow	Resistance Spot-Welding + Bonding

Fig 2: Identifying Side Panel Adhesive Applying Area (1 Of 2)
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Fig 3: Identifying Side Panel Adhesive Applying Area (2 Of 2)
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4. Working with body structural adhesive → WM 5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE
5. Fit and secure the side panel. Check gap dimensions. → WM 5X00IN GAP DIMENSIONS - body gap dimensions
   Fig 4: Fitting And Securing Side Panel

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6. Resistance spot-weld the side panel in the door aperture area.
   Fig 5: Identifying Side Panel Resistance Spot-Welding Area (Door Aperture)

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7. Resistance spot-weld the side panel in the hood compartment area.
   Fig 6: Identifying Side Panel Resistance Spot-Welding Area (1 Of 6)

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   Fig 7: Identifying Side Panel Resistance Spot-Welding Area (2 Of 6)

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   Fig 8: Identifying Side Panel Resistance Spot-Welding Area (3 Of 6)

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   Fig 9: Identifying Side Panel Resistance Spot-Welding Area (4 Of 6)

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   Fig 10: Identifying Side Panel Resistance Spot-Welding Area (5 Of 6)

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   Fig 11: Identifying Side Panel Resistance Spot-Welding Area (6 Of 6)

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8. Plug-weld the side panel in the side member area.
   Fig 12: Identifying Side Panel Plug-Welding Area

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9. Apply a full weld to the side panel in the side pillar joint area using inert gas.
   Fig 13: Identifying Side Panel Weld Area

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10. 10. Flange edge of wheel arch.

Fig 14: Flanging Edge Of Wheel Arch

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