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. Install side panel with wheel housing and check that it fits perfectly. Check gap dimensions. →  5X00IN DIAGRAM - BODY GAP DIMENSIONS  . 
2. Apply foam filler to the body → 5X00IN22 WORKING WITH BODY FOAM FILLER .

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3. Apply foam filler to the side panel. → 5X00IN22 WORKING WITH BODY FOAM FILLER .

   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.

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4. Adhesive is applied as shown. → Application depth: 3.0 mm 

   Working with structural body adhesive. → 5X00IN21 WORKING WITH STRUCTURAL BODY ADHESIVE .

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   Green	Resistance spot-welding
   Yellow	Resistance spot-welding + bonding

5. Apply adhesive to the wheel housing. → Application depth: 3.0 mm 

   Working with body structural adhesive. → 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE .

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6. Fit wheel housing on the side panel using pliers and fix in place.

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7. Fit and secure rear side section.

   Check gap dimensions. →  5X00IN DIAGRAM - BODY GAP DIMENSIONS  . 

8. Resistance spot-weld the rear side section in area -A-  .
   1. 8.1. Plug-weld area -B, C-  of the rear side section.

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9. Resistance spot-weld the water drain area.

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10. Resistance spot-weld the light housing area.

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11. Resistance spot-weld the side window area.
    1. 11.1. Apply a full weld to the C-pillar using inert gas →  .

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12. Resistance spot-weld the air intake area -A-  .

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13. Plug-weld.

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14. Resistance spot-weld.

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