Cowl: Service and Repair
Remove/install waist rail panelingRemove
1. License plate
2. Phillips screws
3. Cap
4. Collar bolt
5. Cap
6. Spreading rivet
7. Bumper
8. Front section center assembly
9. Collar bolt
10. Hood lock
11. Radiator mount
12. Hood pull cable
13. Turn signal lamp
14. Hex. head bolt
15. Hex. head bolt
1. Remove engine hood
2. Remove wiper arms
3. Remove ventilation box
4. Remove wiper motor
5. Remove wiper linkage
6. Remove windshield
7. Remove instrument panel cover
8. Remove miscellaneous detachable body components in repair area
9. Cover all detachable body components remaining in area to be repaired Tarpaulin (fire-proof)
10. Separate waist rail paneling (1)
Install
11. Prepare connection points for waist rail paneling
12. Straighten connecting plates, grind off and coat with zinc dust paint Zinc dust paint for spot welding
13. Prepare waist rail paneling (1) for installation
14. Weld in waist rail paneling (1)
15. Grind down extending welding material
16. Vacuum out hollow cavities Metal filings or metallic grinding dust in cavities can lead to corrosive damage.
17. Clean areas repaired and prime with primer/filler
18. Supplement standard seals with body sealing compound Seam sealing after repairs
19. Add permanent underfloor protection as a supplement to underbody protection installed as standard
20. Paint repair area and adjacent surfaces
21. Supplement cavity preservation
22. Install windshield
23. Install instrument panel cover
24. Install wiper motor
25. Install wiper linkage
26. Install ventilation box
27. Install engine hood
28. Install wiper arms
29. Reinstall miscellaneous detachable body components
Separating waist rail paneling
1. Cut spot welds out of waist rail paneling (1) and A-pillar paneling (2).
The following steps apply for the right side of the vehicle and must be performed on the left side with locations reversed.
2. Grind welding seams off of A-pillar paneling (2) (arrows).
3. Bend A-pillar paneling (2) open and cut spot welds (3) out of waist rail paneling (1).
4. Separate waist rail paneling (1) along A-pillar inner section (4) (dotted line, A).
Prepare connection points for waist rail paneling
1. Carefully grind remaining sheet metal (5) off of A-pillar inner section (4).
Preparing waist rail paneling for installation
The following steps apply for the right side of the of waist rail paneling (1) and must be performed on the left side with locations reversed.
1. Mark holes with the following gaps:
a = 25 mm,
b = 15 mm,
c = 11 mm.
2. Drill all marked holes with 6 mm dia. bit.
3. Grind waist rail paneling (1) down to bare metal in marked area (6) and coat with zinc dust paint.
4. Fit waist rail paneling, align and clamp.
Welding in waist rail paneling
The following steps apply for the right side of the of waist rail paneling (1) and must be performed on the left side with locations reversed.
1. Weld waist rail paneling (1) to A-pillar inner section (4) (A).
2. Weld waist rail paneling (1) to waist rail brace (3).
3. Align A-pillar paneling (2) and weld to waist rail brace and waist rail paneling (1).
4. Spot weld waist rail paneling (1) to waist rail brace (arrows).