Frame: Service and Repair

41 21 ... Replacing Inside Left Side Frame With Side Member (B-Pillar Reinforcement)







Observe procedure for repair stage 3.
Read contents of Body, General.
Spot-weld bonding is used on this vehicle. Observe specific procedure.
Use only approved spot-welding apparatus for repairs.
For stripping and rigging operations, refer to texts on KSD CD (job number 41 21 930).
Additional setup work: Remove petrol tank.
Side panel removed
Place vehicle on straightening bench.







Following new body parts are required (refer to Electronic Parts Catalogue):
- (1) Inner side frame
- (2) Shaped part, B-pillar, bottom (not shown)
- (3) Shaped part, B-pillar, outer (not shown)

Following consumables are required:












Removal of side frame with side member (B-pillar reinforcement)







In addition to removal of side wall: (Severance cut in sill area offset forwards)
Mark severance cut in accordance with dimension and cut.

IMPORTANT: Cut outer metal panel only.

Dimension a = 220 mm from 25 mm diameter hole.
Open welded connections in areas (1).







In addition to removal of side wall:
Mark severance cut in radius along line (1) and cut.

IMPORTANT: Cut outer metal panel only.

Open welded connections in areas (2).







Cut reinforcement plate along line (1).
Open welded connections in areas (2).
Remove part section (3).

Installation note:
Part section (3) is used for installation.







Mark severance cut in accordance with dimension and cut.

IMPORTANT: Cut outer metal panel only.

Dimension a = 160 mm from 15 mm diameter hole.
Open welded connections in areas (1).
Loosen spot-welded adhesive joints in areas (2).
Detach B-pillar reinforcement from cavity sealings (3) and remove.







Undo metal active gas welded connections in areas (1) and remove support (2).







New part preparation







Open weld joint in area (1).
Mark severance cut (2) in accordance with severance cut on vehicle and cut.
Prepare reinforcement plate at severance cut.
Adjust new parts to fit with alignment bracket or universal mounting.







In addition to new part preparation of side wall:
In area (1), create two 4.2 mm dia. bore holes for blind rivetsN3.
(2) Severance cut for replacement of side wall.
(3) Severance cut of side wall offset forwards for replacement of side frame with side member.

NOTE: The reinforcement plate (bonding-riveting technology) must be slightly adapted due to the offset severance cut (3).







Installation of side frame with side member (B-pillar reinforcement)

Coat cavity sealings with sealant.
Install new parts and reinforcement plates with alignment bracket or universal mount and weld.







In area (1) the floor panel and side member are joined by spot-welding bonding technology.
Apply repair welding spots in area (1) to existing welding spots on vehicle.
This is necessary because the adhesive between the spot flanges acts as an insulator.







In addition to installation of side wall:
In areas (1) the side wall is additionally bonded and riveted with 6 punch rivets N4.
In area (2), the side panel is welded.

IMPORTANT:
- Risk of damage to adhesive.
- Avoid generating excessive heat when making the welded connection (2).







Additional installation of side wall:
In area (1) side wall is additionally bonded and riveted with 2 punch rivets N5.
(2) Severance cut for replacement of side wall.
(3) Severance cut of side wall offset forwards for replacement of side frame with side member.