Installing Body Front Section

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 body front section and check that it fits perfectly. Check gap dimensions.

   > 5X00IN DIAGRAM - BODY GAP DIMENSIONS

2. Apply adhesive. > Application depth 3.0 mm 

   Working with body structural adhesive

   > 5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE

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   Preparing body front section

3. Rivet in body front section in upper longitudinal member area. > BLIND RIVET 999.190.229.01 

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   Upper longitudinal member area

4. Rivet in body front section in wheel housing area. > BLIND RIVET 999.190.229.01 

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   Body front section, wheel housing area

5. Weld and rivet in body front section in inner bulkhead area.
   1. 5.1  Apply a full weld to the body front section area -A -  using inert gas.
   2. 5.2  Rivet in body front section area -B -  . > BLIND RIVET 999.190.229.01 

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   Body front section, inner bulkhead area

6. Rivet in body front section in the bulkhead area. > BLIND RIVET 999.190.229.01 

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   Body front section, bulkhead area

7. Rivet in body front section in the underbody area. > BLIND RIVET 999.190.230.01 

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   Body front section, underbody area

   1. 7.1  Do not use rivets at the position shown.

      Once installation is complete, use a ground connection at this position.

8. Rivet in body front section in the footwell area. > BLIND RIVET 999.190.230.01 

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   Body front section, footwell area

9. Rivet in body front section in the footwell area. > BLIND RIVET 999.190.229.01 
   1. 9.1  Screw in (self-tapping) fastening screws -1-  . > TORX SCREW 999.073.541.01 

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   Body front section, footwell area

10. Install cowl panel.
11. Apply adhesive. > Application depth 3.0 mm 

    Working with body structural adhesive

    > 5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE

    1. 11.1  Fit and secure the cowl panel.

       Check gap dimensions.

       > 5X00IN DIAGRAM - BODY GAP DIMENSIONS

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    Installing cowl panel

12. Apply foam filler to area -1-  .

    > 5X00IN22 WORKING WITH BODY FOAM FILLER - section on "Installing"

    Make sure that all openings and gaps are closed off with the foam filler.

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    Preparing connection areas on cowl panel

13. Resistance spot-weld the cowl panel.
    1. 13.1  Apply a full weld to area -A -  using inert gas.

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       Installing cowl panel

14. Prepare connection areas on bracket for longitudinal member for wheel housing.

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    Connection areas on bracket for longitudinal member for wheel housing

15. Straighten sealing surface and connection areas of the body.
16. De-burr connection areas and prepare for welding.
17. Prepare marked areas for welding and bonding.
18. Fit bracket for longitudinal member for wheel housing.
    1. 18.1  For better positioning of the bore holes, fit the wing holder -2-  .
    2. 18.2  Drill holes for rivets in the marked areas -1-  using a drill bit with > Diameter 6.6 mm  Drill bit diameter of 6.6 mm.

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    Drilling holes

19. Apply adhesive. > Application depth 3.0 mm 

    Working with body structural adhesive

    > 5X00IN WORKING WITH BODY STRUCTURAL ADHESIVE

    1. 19.1  Fit and secure supporting plate for longitudinal member for wheel housing.

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    Applying adhesive

20. Rivet in bracket for longitudinal member for wheel housing in area -B -  . > BLIND RIVET 999.190.230.01 
    1. 20.1  Resistance spot-weld bracket for longitudinal member for wheel housing in area -A -  .

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    Supporting plate

21. Make ground connections using a through bolt.

    >MAKING GROUND CONNECTIONS

    1. 21.1  Make a ground connection -1-  on both sides of the vehicle.

       Check screw-in direction.

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       Making ground connection

    2. 21.2  Between the two rivets -2 and 3-  , make a ground connection -1-  .

       Check screw-in direction.

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       Making ground connection

       Countersunk screw > COUNTERSUNK SCREW 999.073.549.01 

       Hexagon nut > HEXAGON NUT 900.377.003.01 

    3. 21.3  Tighten threaded joint to the specified torque. > Tightening torque 15 (11 ftlb.) Nm 
    4. 21.4  Seal threaded joint.