Installing Outer Side Member (Front Section)

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 > Sheet metal insert  for use as a welding backing strip on the body.

   > 5X00IN10 WELDING ALUMINIUM

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   Sheet metal 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 

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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 (front section).  > Application depth 0.5 mm 

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   Outer side member (front section)

   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 in and secure the outer side member (front section).

   Check gap dimensions.

   > 5X00IN GAP DIMENSIONS

5. Join A-post.

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   Joint zones

   1. 5.1  Weld aluminium in areas -A-  .

      > 5X00IN10 WELDING ALUMINIUM

   2. 5.2  Bond and join areas -B-  .

      > 5X00IN21 WORK WITH BODY STRUCTURAL ADHESIVE

   3. 5.3  Fully steel-continuous-seam weld area -C- 
6. Install outer side member (front section).

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   Joint areas

   1. 6.1  Resistance spot-weld the outer side member (front section) in area -A-  .
   2. 6.2  Rivet in the outer side member (front section) in area -B-  . > FLOW-FORM RIVETS 9A7.008.606.00 
7. Flange the edge -1-  in the front door aperture using > VAS 6635/5 - crimping pliers  .

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   Edge in door aperture