Removing Outer Side Member (Rear Section)

Information 

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

1. Mark and make cut -D-  . > Distance 26 mm 

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   Cut D

   1. 1.1  Cut outer side member -1-  and flange -2-  . Do not damage door sill reinforcement -3 and 4-  .

   Information 

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

2. Mark and make cut -C-  . > Distance 30 mm 

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   Cut C

3. Disconnect connection points.

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   Punch rivets

   1. 3.1  Drill out spotwelds in the area -A-  .
   2. 3.2  Remove punch rivets in areas -B-  and -C-  using > VAS 852 001 - aluminium body dent removal system  and > VAS 6790 - Compact Booster  .

      > 5X00IN23 REPLACE PUNCH RIVETS AND CLINCHING POINTS

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

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   Edge in door aperture

   1. 4.1  Heat bonding area using > V.A.G 1416 - hot-air blower  .
   2. 4.2  Bend up edge -1-  in door apertures 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 (rear section).
7. Mark and make cut -E-  . > Distance approx. 20 mm 

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   Step cut (on body side)

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