Installing A-Pillar Reinforcement (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. Position reinforcement plates -1-  centrally from inside to the body in the area of the A-pillar reinforcement and pin them.

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   Welding pins

2. Apply adhesive to entire bonding area -B -  of the body.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   >Application depth 0.5 mm 

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   Bonding areas

3. Apply adhesive to entire bonding area -B -  of the A-pillar reinforcement (section).

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   >Application depth 0.5 mm 

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   Bonding areas

   1. 3.1 Also apply a bead of adhesive all around the bonding surface.

      >Application depth 3 mm 

4. Apply body foam filler all the way around the bulkhead part -1-  in the marked area and clip bulkhead part into the body.

   > 5X00IN22 WORKING WITH BODY FOAM FILLER

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   Body foam filler

5. Install A-pillar reinforcement (section) and fix in position.
6. Pin A-pillar reinforcement (section) -1-  to reinforcement plates.

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   Welding pins

7. Screw in and tighten self-tapping screws.

   > 5X00IN24 SETTING SELF-TAPPING SCREWS

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   Self-tapping screws

8. Resistance spot-weld the A-pillar reinforcement (section).

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   Resistance spot-welding

9. Plug-weld A-pillar reinforcement (section).

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   Plug-welding

10. Plug-weld reinforcement plates to body and A-pillar reinforcement (section).

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    Plug-welding

11. Apply a full steel weld to the A-pillar reinforcement (section).

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    Weld seam cut

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    Welded seams

12. Screw in self-tapping screws on the outer side member until the adhesive has hardened.

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    Self-tapping screws on outer side member

13. Check that the marked area is flat and that the outer side member can lie flat. Grind them level if necessary.

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    Level contact surface