Removing Outer Side Member (Front Section)

Information 

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

Information 

Mark cuts to match the new part. Make sure that there is an overlap of approx. 30 mm to the body.

1. Mark and make cut -A-  . > Distance 210 mm 

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   Cut A

   Information 

   Mark cuts to match the new part. Make sure that there is an overlap of approx. 30 mm to he body.

2. Mark and make cut -D-  . > Distance 113 mm 

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   Cut D

   1. 2.1  Cut outer side member -1-  and flange -2-  . Do not damage door sill reinforcement -3 and 4-  .
3. Disconnect connection points.
   1. 3.1  Drill out spotwelds in the area -A-  .

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      Punch rivets

   2. 3.2  Remove punch rivets in area -B-  using > VAS 852 001 - aluminium body dent removal system  and > VAS 6790 - compact booster  .

      > 5X00IN23 REPLACE PUNCH RIVETS AND CLINCHING POINTS

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      Punch rivets

4. Bend up edge -1-  in door aperture.

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   Edge in door aperture

   1. 4.1  Heat bonding areas using > V.A.G 1416 - hot-air blower  .
   2. 4.2  Bend up edge -1-  in door aperture using > VAS 6635 - crimping pliers set, 4-piece  .
5. Heat bonding areas > Bonding areas  using > V.A.G 1416 - hot-air blower  .

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   Bonding areas

6. Remove outer side member (front section).
7. Mark and make cut -E-  . > Distance approx. 20 mm 

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   Stepped cut

   1. 7.1  Cut through outer side member -1-  only. Do not damage flange -2-  and door sill reinforcements -3 and 4-  .