Removing Front Side Members

Information 

• All straightening work on the body in the connection area of the sheetmetal parts to be replaced must be completed before the damaged parts are removed. 

Fig 1: Front Side Members Component Location

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1. Cut off side member for wheel housing upper inner section.
   1. 1.1. Cut side member for the wheel housing upper section in the area -E-  using the oscillating body saw. Maintain the dimension -X1- → cut dimension, old part: 80 mm. 
      Fig 2: Identifying Cutting Off Top Inner Side Member

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      Fig 3: Identifying Side Member Cutting Area On Wheel Housing Upper Section

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2. Cut off side member for wheel housing upper outer section.
   1. 2.1. Cut out the laser welded joint on the side member for the wheel housing upper section in the area of the cut offset -X2-  using the parting grinder (area -A1-  ).
   2. 2.2. Cut the side member for the wheel housing upper section in the area -B1-  using the oscillating body saw. Maintain the dimension -X2- → cut offset: 80 mm.  Do not damage the internal components.
      Fig 4: Identifying Cutting Off Top Outer Side Member

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      Fig 5: Identifying Spring Strut Mount Welded Joints

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3. Separate welded joints at the upper spring strut mount.
   1. 3.1. Mill off the welded joints in area -A, D-  using a spotweld cutter.
   2. 3.2. Grind off the welded joints in area -B, C-  using a parting grinder.
      Fig 6: Separating Welded Joints At Spring Strut Mount

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      Fig 7: Identifying Spring Strut Mount Reinforcement Welded Joint Area

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4. Separate welded joints at the reinforcement for the spring strut mount.
   1. 4.1. Mill off the welded joints in area -F-  using a spotweld cutter.
      Fig 8: Separating Welded Joints At Reinforcement For Spring Strut Mount

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      Fig 9: Identifying Firewall Welded Joint Area

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5. Separate welded joints at the firewall.
   1. 5.1. Mill off the welded joints in area -H, G-  using a spotweld cutter.
      Fig 10: Separating Welded Joints At Firewall

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      Fig 11: Identifying Firewall Lower Section Welded Joint Area

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6. Separate welded joints at the firewall lower section.
   1. 6.1. Mill off the welded joints in area -J-  using a spotweld cutter.
      Fig 12: Separating Welded Joints At Firewall Lower Section

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      Fig 13: Identifying Floor Inner Section Welded Joint Area

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7. Separate welded joints at the floor inner section.
   1. 7.1. Mill off the welded joints in area -I-  using a spotweld cutter.
      Fig 14: Separating Welded Joints At Floor Inner Section

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      Fig 15: Identifying Lower Side Member Welded Joint Area

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8. Separate welded joints at the lower side member.
   1. 8.1. Mill off the welded joints in area -K-  using a spotweld cutter.
      Fig 16: Separating Welded Joints At Lower Side Member

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      Fig 17: Identifying Lower Side Member Welded Joint Area

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9. Separate welded joints at the lower side member.
   1. 9.1. Mill off the welded joints in area -L-  using a spotweld cutter.
      Fig 18: Separating Welded Joints At Lower Side Member

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      Fig 19: Identifying Side Member Bracket Joint

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10. Separate bracket for side member.
    1. 10.1. Using a parting grinder, separate the bracket on the side member in the area -M-  .
       Fig 20: Separating Bracket For Side Member (M)

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       Fig 21: Identifying Side Member Bracket Joint

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11. Separate bracket for side member.
    1. 11.1. Using a parting grinder, separate the bracket on the side member in the area -N-  .
    2. 11.2. Remove bracket.
       Fig 22: Separating Bracket For Side Member (N)

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       Fig 23: Identifying Firewall Lower Section Welded Joint Area (O)

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12. Separate welded joints at the firewall lower section.
    1. 12.1. Using a drill, drill the spotwelds in area -O-  through to the passenger compartment.
       Fig 24: Separating Welded Joints At Firewall Lower Section

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       Fig 25: Identifying Firewall Upper Section Welded Joint Area

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13. Separate welded joints at the firewall upper section.
    1. 13.1. Mill off the welded joints in area -P-  and -U-  using a spotweld cutter.
       Fig 26: Separating Welded Joints At Firewall Upper Section (P)

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       Fig 27: Separating Welded Joints At Firewall (U)

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    2. 13.2. Grind off the welded joints in area -Q-  using a parting grinder.
       Fig 28: Separating Welded Joints At Firewall Upper Section (Q)

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       Fig 29: Identifying Web Plate Welded Joint Area

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14. Separate welded joints at the web plate.
    1. 14.1. In area -R-  cut out a lid from the floor with a parting grinder.
       Fig 30: Cutting Out Lid On Floor

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    2. 14.2. Mill off the welded joints in area -S-  using a spotweld cutter.
       Fig 31: Separating Welded Joints At Web Plate (S)

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    3. 14.3. Grind off the welded joints in area -T-  using a parting grinder.
       Fig 32: Separating Welded Joints At Web Plate (T)

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       Fig 33: Identifying Side Member Lower Section Welded Joint Area

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15. Separate welded joints at the side member lower section.
    1. 15.1. Mill off the welded joints in area -V-  using a spotweld cutter.
       Fig 34: Separating Welded Joints At Side Member Lower Section (V)

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    2. 15.2. Grind off the welded joints in area -W-  using a parting grinder.
       Fig 35: Separating Welded Joints At Side Member Lower Section (W)

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       Fig 36: Identifying Side Member Lower Section Welded Joint Area

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16. Separate welded joints at the side member lower section.
    1. 16.1. Mill off the welded joints in area -Y-, -Y-  and -Y-  using a spotweld cutter.
       Fig 37: Separating Welded Joints At Firewall Lower Section (Y)

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       Fig 38: Separating Welded Joints At Firewall (Y And Z)

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       Fig 39: Separating Welded Joints At Side Member Lower Section (Y And Z)

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    2. 16.2. Grind off the welded joints in area -Z-  and -Z-  using a parting grinder.
       Fig 40: Separating Welded Joints At Firewall (Y And Z)

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       Fig 41: Separating Welded Joints At Side Member Lower Section (Y And Z)

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17. Remove side member.