Preparing Front Panel For Installation

Information 

• Some of the repair illustrations show only one side of the vehicle or a similar component. 
• Naturally, some steps also have to be performed on the opposite side of the vehicle as well. 

Information 

Remove component carefully.

The removed component must be re-used during installation.

1. Loosen upper cross member.
   1. 1.1  Drill through punch rivets -A and B-  .

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      Loosening cross member

   2. 1.2  Grind off rear punch rivets.

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      Grinding off punch rivets

   3. 1.3  Heat bonding areas.

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      Loosening cross member

   4. 1.4  Remove cross member.
2. Fit front panel and secure it to the body.
   1. 2.1  Position front panel.
      1. 2.1.1  Bend sheetmetal flange in slightly on one side.

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         Fitting sheetmetal flange

      2. 2.1.2  Insert front panel.

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      Inserting front panel

   2. 2.2  Drill bores for the rivets through the existing holes. > Diameter 6.5 mm 
3. Drill new holes in the areas shown. > Diameter 6.5 mm 

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   Drilling new holes

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   Drilling new holes

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   Drilling new holes

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   Drilling new holes

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   Drilling new holes

4. Fit upper cross member.
   1. 4.1  On the cross member, drill new holes through the existing holes on the body.

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   Removing front panel

5. Countersink the bores shown for installing countersunk rivets. > Nr.202 - Countersink 

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   Counterbores

6. Remove cross member and front panel.
7. De-burr the bores.
8. Prepare connection areas for bonding.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE

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   Preparing connection areas for bonding

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   Preparing connection areas for bonding

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   Preparing connection areas for bonding

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   Preparing connection areas on the cross member for bonding