rane The present document was valid at the time of print. A later version may be available online Replacing front side member (section) ‘WM 507955 Replacing front side member (section) Tools Designation ‘Type Number | Description Hot-air blower, Leister- Workshop WE 1119 Electron/V.A.G. 1416 equipment twist drill Commercially | Nr201 available tool osman/47@gmail.co} Dec 14, 2014 Technical values Location Description Type | Basic value | Tolerance | Tolerance 1 2 ‘Side member connection point Large cut Length 180 mm Connection point for longitudinal Dimension X | Length 125 mm member ‘Side member connection point Outer shell only | Length 100 mm Drill bit Diameter omm Drill bit Diameter 9mm Drill bit Diameter 6.5mm Applying adhesive ‘Spread out Application 05mm evenly depth Applying adhesive ‘Spread out Application 05mm evenly depth Bead of adhesive Application 5mm depth tps:techino2 persche.com PAGInfosystem/VFModuleManager 7 ype-Navigatlon§Prin=trueBlk=GVO a6rane Replacing front side member (section) Threaded joint on side member Tightening 15Nm torque (11 fib.) Preliminary work Preliminary work for body repairs (with straightening system) 1, Remove accessories in the repair area, 4.1. Remove accessories in the repair area according to the extent of damage on the vehicle. 2. Set up straightening bench with straightening system, 3. Set vehicle on straightening bench 4. Cover accessories adjacent to the repair area on the vehicle. 4.1. Cover all accessories remaining on the vehicle and adjacent areas with fire-proof protective covers. 5. _ Reshape connection area of the sheetmetal parts to be replaced. See Information on aluminium repairs. = SXO0INO5 Information on aluminium repairs - section on "Information" 6. Expose joint areas 6.1, Remove underbody protection, paint, etc. from the joint areas of the body using a hot-air gun or rotary brush Safety instructions and information on quality Safety instructions and information on quality Non-observance of safety instructions for body repairs + Risk of damage to the vehicle + Danger of injury — Read the relevant safety instructions as well as general information and quality instructions + SXOOINO1 Safety instructions. Protection of electrical components during body repairs —> 5X00iN02 Protection of electrical components during body repairs Corrosion protection measures during repairs — SXO0INO3 Corrosion protection measures during repairs Information on aluminium repairs —> 5XOOINOS Information on aluminium repairs Body parts of various sheet-steel strengths > SXOOIN04 Body parts of various sheet-steel strengths Replacing punch rivets and penetrated joints > 5X00IN23 Replacing punch rivets and penetrated joints Setting setf-tapping screws —> SXO0IN24 Setting seff-tapping screws Working with body structural adhesive — 5X00IN21 Working with body structural adhesive Removing front side member Removing front side member hps:techino2 persche.com PAGInfosystem/VFModuleManager ype=Navigatlon8Prin=trueBk=GVO 26vane Replacing frnt side memb (section) Front side member 1. Roughly cut out longitudinal member -1- and longitudinal member for wheel housing -2- 1.1. Cut longitudinal member to dimension -X- . > Length: 180 mm n oo , Roughly cutting longitudinal member Dimension -X- is measured from the bent edge to the reinforcement -3- ea] Information The final dimension is measured from the new front side member (section). Mark and make cut. —» Length: 125 mm Remove remaining piece -1- nipe:techinfo2.persche.com/PAGInosystonVF ModeManage’7T ypo=Navigation8Print= ue8iK= GVO 316rane Replacing ront side momber (section) Connection point for inner longitudinal member 1.2, Drill through punch rivets using a twist drill Nr.201. Removing side member tps:techino2 persche.com PAGInfosystem/VFModuleManager? ype=Navigatlon§Prin=trueBlk=GVO anerane Replacing ront side momber (section) Removing side member BB sernation Only make cuts in the top plate. Make sure not to damage the plate undemeath when doing this. 1.3. Cut outer shell to dimension -Y-. —+ Length: 100 mm Dill through punch rivets using twist drill Nr.201 Cut on outer shell of longitudinal member tps:techino2 persche.com PAGInfosystem/VFModuleManager? ype=Navigatlon§Prin=trueBlk=GVO 516yanaaoi Replaciog rant side member (setion) 1.3.1. Heat bonding areas —- Removing outer shel! . Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119 1.4. Remove remaining part of outer shell. 5 This page contains t error on line 285 at |coli error on line 285 at |coli Below is a rendering ‘ > Removing outer shell 1.5. Mark cut on inner shell in accordance with the new part with slight oversize. @ Information Only make cuts in the top plate. Make sure not to damage the plate undemeath when doing this. 1.6. Cut inner shell. Be careful of inner panels on the underside -arrow- I This page contains t error on line 54 at olur Below is a rendering hz > Inner shell cut This page contains t error on line 67 at ¢olur Below is a rendering niptochine2.persche.com/PAGIfosysten VF ModeManage’7T ypo=Navigtion8Print=ue8ik= GVO areranaao% Replacing frnt side memb (section) Lower inner shell cut 2. Remove remaining part of wheel housing 2.1. Heat bonding areas. Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119 a Bonding areas This page contains t error on line 66 at golur error on line 66 at ¢olur Below is a rendering 22. Remove remaining part of wheel housing. 3, Fit sub-part exactly using the straightening set. Shorten side member on the vehicle as required. Preparing connection areas of body for installing side member Replacing rivet nut 1, Unscrew threaded bolt 2, Drill out rivet nut, >» Diameter: 9 mm. nipe:techinfo2.persche.com/PAGInosystonVF ModeManage’7T ypo=Navigation8Print= ue8iK= GVO m6rane Replacing ront side momber (section) Removing rivet nut 3. Remove rivet nut 4. Fit sub-part and secure it to the body. Position sub-part using the straightening system. 4.1. Drill bores for rivet screw through the existing hole. + Diameter: 9 mm. 5, Remove subpart. 6. _De-burr bores on both sides. 7. _ Following final installation of the side member, fit a —» RIVET SCREW N107 608 01. Preparing connection areas of body for installing side member DBD snormation + The screws also serve as ground connections. + Remove dirt and primer from the threads of the spare part using a tap. + Remove dirt and primer from the body close to the screw heads. > 5X00IN25 Making ground connections 1. Fit sub-part and secure it to the body, Position sub-part using the straightening system. 1.1. Drill bores for the rivets through the existing holes. —- Diameter: 6.5 mm 2. Also drill a hole close to the overtap at the bottom ~arrow- 3. Drill another hole close to the angled panel -A-. tps:techino2 persche.com PAGInfosystem/VFModuleManager? ype=Navigatlon§Prin=trueBlk=GVO aneranaao% Replacing frnt side memb (section) This page contains t Below is a rendering 4. Apply markings to the side member. 4.1. Copy screw points to the outside of the side member and apply markings. 5. Drill holes for threaded connections. 5.1, Remove sub-part 5.2, Drill through bores on the side member using an 8,5-mm drill bit. 6, _ De-burr the bores. 7. _ Prepare bonding areas on the side member for bonding. — SX00IN21 Working with body structural adhesive Bonding areas nipe:techinfo2.persche.com/PAGInosystonVF ModeManage’7T ypo=Navigation8Print= ue8iK= GVO 6ronan Replacing front side memb (section) Preparing front side member for installation Preparing front side member for installation 1. Prepare bonding areas on the sub-part for bonding. — SX00IN21 Working with body structural adhesive ntpe:tochine2.persche com /PAGIosyston VF ModeManage’7T ypo=Navigtion8Print=ue8iK= GVO This page contains t error on line 54 at olur Below is a rendering =z > Bonding area This page contains t error on line 72 at folur error on line 72 at ¢olur Below is a rendering =a , Bonding areas wwi6ranaao% Replacing frnt side memb (section) This page contains t error on line 62 at ¢olur error on line 62 at dolut Below is a rendering Instal ig front side member Installing front side member 1. Apply adhesive to the body. Apply adhesive evenly over the entire bonding surface. + Application depth: 0.5 mm Working with body structural adhesive > 5X00IN21 Working with body structural adhesive Bonding areas nipe:techinfo2.persche.com/PAGInosystonVF ModeManage’7T ypo=Navigation8Print= ue8iK= GVO wi6ronan Replacing front side memb (section) Bonding areas 2. Apply adhesive to the side member. Apply adhesive evenly over the entire bonding surface. > Application depth: 0.5 mm This page contains t error on line 72 at ¢olur error on line 72 at 4olur Below is a rendering. ntpe:tochine2.persche com /PAGIosyston VF ModeManage’7T ypo=Navigtion8Print=ue8iK= GVO wi6yanaaoi Replaciog rant side member (setion) This page contains t error on line 62 at folur error on line 62 at dolur Below is a rendering, a 7 > Bonding areas 2.1. Also apply a bead of adhesive to the front edge of the screw flange. + Application depth: 5 mm 3. Position sub-part on the side member using the straightening ~ system. This page contains t error on line 68 at ¢olur error on line 68 at folur Below is a rendering Tightening torque: 15 Nm (11 ftlb.) This page contains t error on line 153 at |colt error on line 153 at |coli Below is a rendering =z > Installing front side member niptochine2.persche.com/PAGIfosysten VF ModeManage’7T ypo=Navigtion8Print=ue8ik= GVO 16vanaao% Replaciog rant side member (setion) This page contains t error on line 144 at |colt error on line 144 at |coli Below is a rendering = mi Installing front side member 5. Rivet in side member 5.1. Rivet in the area shown -arrow- using + BLIND RIVET - 999.190.227.01 I This page contains t error on line 1161 at co: error on line 1161 at co: Below is a rendering =a , Bottom bore 5.2. _ Rivet in the area shown -A- using > BLIND RIVET ~ 999.190.230.01 I This page contains t error on line 1161 at co: error on line 1161 at co: Below is a rendering =a > Bottom bore 5.3. Rivet in areas shown -A- using —> BLIND RIVET 999.190.230.01 ~ This page contains t error on line 158 at |coll error on line 158 at |coli Below is a rendering 7) > ntpe:techinea.pereche com /PAGIniosystom VF ModJeManager7Type=NevigalnPrint=tuekik= GVO wieranaao% Replacing frnt side memb (section) Installing side member 5.4. Rivet in areas shown -B- using > BLIND RIVET 999, 190.229.01 * This page contains t error on line 158 at |coll error on line 158 at |coli Below is a rendering 5.5. _ Rivet in areas shown using — BLIND RIVET 999.190.229.01 Removing side member 5.6. The blind rivet is inserted in the area shown -arrow: after fitting the wing joining plate.» 505355 Replacing wing joining plate Removing side member nipe:techinfo2.persche.com/PAGInosystonVF ModeManage’7T ypo=Navigation8Print= ue8iK= GVO wwi6rane Replacing front side member (section) Subsequent work Subsequent work for body repairs 1 Release and remove vehicle from the straightening system. Clean joint areas and sheetmetal flanges with a wire brush, Prime joint areas and sheetmetal flanges with 2K primer. Restore standard seal with body sealant + 5X00IN42 Seam sealing - section on “Information”. ‘iso seal the repair area carefully. Paint repair area and adjacent surfaces, if necessary. Restore standard underbody protection with underbody sealant — 5X00IN43 Underbody protection - section ‘on "Information". Apply standard cavity preservation > SXO0IN44 Cavity preservation - section on “Information”. Also carefully apply cavity preservation to the repair area. Install removed accessories in the repair area, 981110, 981111, 981120, 981121, 981130, 981131, 981310, 981311, 981320, 981321, 981330, 981331 Model year as of 2012 C00, C02, C05, CO, CO7, COB, CO9, C10, C11, C12, C13, C14, C15, C16, C17, C18, C19, C20, C21, C22, C23, C24, C25, C26, C27, C28, C32, C33, C34, C35, C36, C37, C38, C39, C41, C45, C46, C96, C97, C98, C99 tps:techino2 persche.com PAGInfosystem/VFModuleManager? ype=Navigatlon§Prin=trueBlk=GVO 1818