Installing A-Pillar Reinforcement

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. 

Information 

• Apply adhesive evenly over the entire bonding surface. 

1. Apply adhesive on bonding areas -A -  of the body.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   > Application depth 0.5 mm 

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   Bonding area

   Information 

   • Apply adhesive evenly over the entire bonding surface. 
2. Apply adhesive to bonding area -A -  of the A-pillar reinforcement.

   > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE PAH.071.781.00

   > Application depth 0.5 mm 

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   Bonding area

   1. 2.1  Also apply a bead of adhesive all around the bonding surface.

      > Application depth 3 mm 

3. 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

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

   > 5X00IN22 Working with body foam filler

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   Body foam filler

5. Install A-pillar reinforcement.
6. Secure A-pillar reinforcement.

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   Blind rivets

   1. 6.1  Rivet in A-pillar reinforcement in area -A -  .

      > BLIND RIVET 999.190.229.01 

   2. 6.2  Resistance spot-weld the A-pillar reinforcement in area -B -  .
7. Secure A-pillar reinforcement.

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   Blind rivets

   1. 7.1  Resistance spot-weld the A-pillar reinforcement in area -B -  .
   2. 7.2  Plug-weld the A-pillar reinforcement in area -A -  .
8. Screw in and tighten self-tapping screws -1-  .

   > 5X00IN24 SETTING SELF-TAPPING SCREWS

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   Self-tapping screws

9. Secure A-pillar reinforcement.

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   Joints

   1. 9.1  Rivet in A-pillar reinforcement.

      > BLIND RIVET 999.190.229.01 

   2. 9.2  Screw in and tighten self-tapping screws -1-  .

      > 5X00IN24 SETTING SELF-TAPPING SCREWS

10. Screw in and tighten self-tapping screws.

    > 5X00IN24 SETTING SELF-TAPPING SCREWS

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    Self-tapping screws

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

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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