Replacing outer side member

Remove all accessories and interior components from the outer side member section as well as the front fender!

Operation

Instructions

Cut through outer side member and separate spotwelds

Using a body saw, cut through outer side member

Separate spotwelds between outer side member and center side member, fender mating panel and closing

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

2 Trial-fit outer side member to Trial-fit spare outer side member to body side panel, body and prepare for fitting Drill out outer side member along joints with fender mating panel and closing panel for plug welding. Fit outer side member into body and adjust with door con tours.

3 Remove outer side member and Lift spare outer side member off the body. Clean bond-prepare bonding area ing areas on gusset plate and outer side member for bonding and apply primer.

Preparing the bonding cartridge for application of adhesive

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

5 Open flanged cover of cartridge Use the screwdriver handle to pierce the flanged cover containing component A 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

Place cartridge containing component A into bonding gun

Place cartridge containing component A (C1) into bonding gun (A).

Remove screw-on cap of mixing cartridge (C3).

Press component A into mixing

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

Open nozzle fitting of cartridge containing component B

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

10 Screw injector nozzle onto cart ridge containing component B

Screw injector nozzle (C7) onto cartridge containing

11 Place cartridge containing component B into bonding gun

Place cartridge containing component B (C2) into

Operation

Instructions

12 Press component B into mixing cartridge with component A

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) containing component A.

Close mixing cartridge

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

14 Screw mixing rod into mixing

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

15 Mix component A und component B

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

Engage mixing disc into piston

Pull back mixing cartridge until a rattling sensation is Switch off drill und unscrew mixing rod from mixing This will cause the mixing disc to engage into the piston

17 Place mixing cartridge into

Place mixing cartridge with mixed 2-pack adhesive into 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 member to the body.

Operation

Instructions

18 Apply adhesive to the gusset

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

19 Fit outer side member and weld

Fit outer side member into body and adjust according to

MIG-weld spare outer side member to body side panel, running a butt full seam. Plug-weld outer side member, fender mating panel and closing panel using MIG equip-

Spotweld outer side member to center side member

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