Preparing Front Panel For Installation

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IMPORTANT:

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.

IMPORTANT: Remove component carefully.
The removed component must be re-used during installation.

Loosen upper cross member.

1.1 Drill through punch rivets -A and B- .

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Loosening cross member

1.2 Grind off rear punch rivets.

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Grinding off punch rivets

1.3 Heat bonding areas.

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Loosening cross member

1.4 Remove cross member.

Fit front panel and secure it to the body.

2.1 Position front panel.

2.1.1 Bend sheetmetal flange in slightly on one side.

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Fitting sheetmetal flange

2.1.2 Insert front panel.

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Inserting front panel

2.2 Drill bores for the rivets through the existing holes. > Diameter 6.5 mm

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

Fit upper cross member.

4.1 On the cross member, drill new holes through the existing holes on the body.

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Removing front panel

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

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Counterbores
Remove cross member and front panel.
De-burr the bores.
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