Installing Side Member Outer

Information 

• Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive. 
• Bonding 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. Tack on sheet metal insert > Sheetmetal insert  used as a welding backing strip on the body.

   > 5X00IN10 WELDING ALUMINIUM

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   Sheetmetal insert

   Information 

   • Apply adhesive evenly over the entire bonding surface. 
2. Apply adhesive on bonding area > Bonding area  of the body. > Application depth 0.5 mm 

   Apply body structural adhesive

   > 5X00IN21 PROCESS BODY STRUCTURAL ADHESIVE - section on "Information"

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   Bonding area

   Yellow	Bonding and resistance spot-welding > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE
   Orange	Bonding and riveting > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE

   Information 

   • Apply adhesive evenly over the entire bonding surface. 
3. Apply adhesive in the marked area > Outer side member (internal view).  > Application depth 0.5 mm 

   Apply body structural adhesive

   > 5X00IN21 PROCESS BODY STRUCTURAL ADHESIVE - section on "Information"

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   Outer side member (internal view)

   Yellow	Bonding and resistance spot-welding > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE
   Orange	Bonding and riveting > 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE

   1. 3.1  Also apply a bead of adhesive all around the bonding surface. > Application depth 3 mm 
4. Fit and secure side member outer.

   Check gap dimensions.

   > 5X00IN GAP DIMENSIONS

5. Apply a full aluminium weld to the outer side member in areas -A, B and. C-  using inert gas.

   > 5X00IN10 WELDING ALUMINIUM

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   Outer side member and body

6. Install outer side member.
   1. 6.1  Resistance spot-weld the outer side member in area -A-  .

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      Front side member rivet areas

   2. 6.2  Rivet in the outer side member in area -B-  . > FLOW-FORM RIVETS 9A7.008.606.00 

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      Front side member rivet areas

   3. 6.3  Resistance spot-weld the outer side member in area -A-  .

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      Rear side member rivet areas

   4. 6.4  Rivet in the outer side member in areas -B-  . > FLOW-FORM RIVETS 9A7.008.473.00 

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      Rear side member rivet areas

   5. 6.5  Rivet in the outer side member in area -C-  . > FLOW-FORM RIVETS 9A7.008.606.00 

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      Rear side member rivet areas

7. Flare edges -1-  in the front door aperture using > VAS 6635/5 - crimping pliers  .

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   Edges in door apertures