Preparing Outer Side Member For Installation (When Replacing Side Member Reinforcement)

Information 

If the side member reinforcement was replaced (

> 514955 REPLACING SIDE MEMBER REINFORCEMENT 

), the outer side member must be prepared and installed differently.

1. Only in the front section area:  Dismantle the wing rail (section) from outer side member (front section).

   Information 

   Only make cuts in the top plate. Make sure not to damage the plate underneath when doing this.

   1. 1.1 Mark and make cut.

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      Cut

   2. 1.2 Drill out penetrated joints.

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      Penetrated joints

   3. 1.3 Heat bonding areas with >V.A.G 1416 - hot-air blower  and remove wing rail (section) -1-  .

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      Bonding areas

2. Fit in outer side member.
   1. 2.1 Cut outer side member at the point where it joins the body, leaving an overlap of 30 mm.
   2. 2.2 Fit in outer side member and secure it to the body.

      > 5X00IN GAP DIMENSIONS

   3. 2.3 Make cuts through the outer side member and body in the overlap areas.

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      Cuts

3. Adjust outer side member to additional reinforcement plate.

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   Cut

4. Cut sheetmetal insert used as a welding backing strip for the weld areas from the old outer side member.
5. Remove outer side member.
6. Prepare outer side member for bonding.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

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   Bonding areas on outer side member

7. Prepare connection areas for applying a full aluminum weld.

   > 5X00IN10 WELDING ALUMINIUM

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   Connection areas