Replacing center side member

Remove all accessories and interior components from the center body section as well as the front

Operation

Instructions

Cut through outer side member and separate spotwelds

Cut through outer side member ahead of rear side panel using a body saw; use a spotweld cutter to separate spotwelds between outer side member and center side member, inner side member, floorpan, fender mating panel and closing panel.

Cut through gusset plate and separate spotwelds

Cut through gusset plate ahead of rear side panel using a body saw. Separate spotwelds between gusset plate and center side member as well as side panel using a

Cut through center side member and separate spotwelds

Cut through center side member ahead of rear side panel using a body saw.

Separate spotwelds between center side member and floorpan, inner side member as well as front side panel using a spotweld cutter

Clean welding areas

Use a hot air gun or rotary wire brush to remove under-body sealant, paint etc. from welding areas of body. Remove factory primer from spare part welding areas with a rotary wire brush.

Trial-fit center side member into body and prepare for fitting

Trial-fit spare center side member to body center side member, making a butt joint. Drill center side member at joints to front side panel for plug welding.

Operation

Instructions

Weld in center side member

Use clamping tools to attach spare center side member and MIG-weld to body center side member running a butt full seam. Plug weld center side member to front side panel using MIG equipment. Spotweld center side member to floorpan and inner side member.

Trial-fit gusset plate, prepare for fitting and weld into place

Trial-fit spare gusset plate to body gusset plate, making a butt joint. Drill gusset plate at joints to center side member for plug welding. MIG-weld spare gusset plate to body gusset plate, running a butt full seam. Plug weld gusset plate to center side member, using

Trial-fit outer side member to body and prepare for fitting

Trial-fit spare outer side member to outer side member, making a butt joint. Drill outer side member at joints to fender mating panel and closing panel for plug welding.

Preparing the bonding cartridge for application of adhesive

Prepare bonding areas

Clean bonding areas of gusset plate and outer side member for bonding and apply primer.

Open nozzle fitting of cartridge containing component A

Use a screwdriver to pierce the diaphragm in the nozzle fitting of the cartridge containing component A (C1).

Open flanged cover of cartridge containing component A

Use the screwdriver handle to pierce the flanged cover at the end of the cartridge containing component A (C1).

Screw filling nozzle onto cartridge containing component A

Screw filling nozzle (C10) onto cartridge containing

10 Place cartridge containing component A into bonding gun

Place cartridge containing component A (C1) into Remove screw-on cap from mixing cartridge (C3).

Operation

Press component A into mixing cartridge

Open nozzle fitting of cartridge containing component B

Screw injector nozzle onto cartridge containing component B

Place cartridge containing component B into bonding gun

Press component B into mixing cartridge with component A

Close mixing cartridge

Screw mixing rod into mixing cartridge

Mix component A and component B

Instructions

Engage filling nozzle (C10) of cartridge containing component A (C1) into mixing cartridge (C3). Use bonding gun (A) to press component A into mixing cartridge (C3).

Use a knife to cut off the tip of the nozzle fitting of the cartridge containing component B (C2).

Screw injector nozzle (C7) onto cartridge containing component B (C2).

Place cartridge containing component B (C2) into

Insert injector nozzle (C7) of cartridge containing component B (C2) into mixing cartridge (C3). Use the bonding gun (A) to press component B (C2) into mixing cartridge (C3) with component A.

Pull injector nozzle (C7) out of mixing cartridge (C3) and close mixing cartridge with screw-on cap.

Screw mixing rod (B) manually into internal threads of mixing disc of mixing cartridge (C3). Clamp the other end of the mixing rod in a power drill chuck. Fit the power drill in a suitable clamping device.

Switch on drill (speed 900 - 1200 rpm) and move mixing cartridge 25 times from stop to stop. Perform all 25 double strokes fairly rapidly!

Operation

Instructions

Engage mixing disc into piston

Pull back mixing cartridge until a rattling sensation is Switch off drill and screw mixing rod out of mixing This causes the mixing disc to engage into the piston of

20 Place mixing cartridge into

Place mixing cartridge with mixed 2-pack window adhesive into bonding gun.

Screw application nozzle (C8) onto mixing cartridge.

Caution: Observe open time of 15 minutes!

Open time is the time available for application of the adhesive and for fitting the outer side

Apply adhesive to gusset plate

Apply 2-pack adhesive with bonding gun to entire gusset plate surface to a thickness of 4 mm. Do not apply any adhesive to the outer side member to side panel

22 Weld in outer side member Fit outer side member to body and adjust to contours of door.

MIG-weld spare outer side member to body outer side member running a butt full seam.

Plug-weld outer side member to fender mating panel and closing panel using MIG equipment.

Spotweld outer side member to inner side member and center side member (floorpan).

Grind down butt weld seam

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