Firewall: Service and Repair
WM 501455 Replacing front panel
- General warning notes
- Tools and materials
- Preliminary work for body repairs with alignment bench
- Removing front panel
- Preparing connection areas of the body for installing the front panel
- Preparing front panel for installation
- Installing front panel
- Subsequent work
Tools
General warning notes
Safety instructions for body repairs
-> 5X00IN04 Safety instructions 5X00IN04 Safety instructions
Tools and materials
Tools and materials
Spotweld drill bit Nr.129
Spotweld cutter Nr.128-2
Star gauge Nr.127-1 Pos.1
Star gauge Nr.127-1 Pos.2
Star gauge Nr.127-1 Pos.3
Pneumatic body saw PS 1 WE 1138
Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119
Inverter welder ATL InvertaSpot WE WE1194
Special electric cutter - fine WE 1137
Pneumatic spot-weld remover, Vario drill WS 90 WE 1139
Vice-grip wrench WE 1269
Body straightening system, Celette WE 1121
Preliminary work for body repairs with alignment bench
Preliminary work for body repairs with straightening bench
1. Remove add-on parts in the repair area
1.1. Remove add-on parts in the repair area according to the extent of damage to the vehicle.
2. Equip straightening bench with straightening attachments
2.1. Equip straightening bench with the basic straightening attachments according to the plans included with the straightening attachments.
3. Place vehicle on the straightening bench
3.1. Position vehicle on straightening bench, align according to the reference holes and bolt firmly to the straightening attachments.
4. Cover add-on parts adjacent to the vehicle repair area
4.1. Cover all add-on parts remaining on the vehicle and the adjacent areas with fire-proof protective covers.
5. Reshape connection area of the sheetmetal parts to be replaced
6. Expose welding areas
6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.
Preliminary work for body repairs
Information
- If it can be ensured there has been no deformation of the vehicle structure, the following repair can be carried out without the need of a straightening bench. In this case, the vehicle must not be raised when welding the component; it must stand on its wheels on an even surface.
1. Remove accessories in the repair area
1.1. Remove accessories in the repair area according to the extent of damage to the vehicle.
2. Equip straightening bench with straightening attachments
2.1. Equip straightening bench with the straightening attachments according to the setup plans included with the straightening attachments.
3. Place vehicle on the straightening bench
3.1. Position vehicle on the straightening bench, align according to the reference holes and bolt firmly to the straightening attachments.
4. Cover accessories adjacent to the vehicle repair area
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
6. Expose welding areas
6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.
Removing front panel
Removing front panel
Installation position of front panel
1. Remove end plate. -> 501055 Replacing end plate - section on "Removing"
2. Remove floor front section. -> 502055 Replacing floor front section - section on "Removing"
3. Milling off spotwelds
3.1. Mill off spotwelds in areas -A, B, C- using a spotweld cutter.
Milling off spotwelds
4. Separating spotwelds
4.1. Separate spotwelds in areas -A- and -B- using a parting grinder.
Separating spotwelds
5. Milling off spotwelds
5.1. Mill off spotwelds in areas -A- and -B- using a spotweld cutter.
Milling off spotwelds
6. Separating inert-gas welded seams
6.1. Separate inert-gas welded seams in areas -A- and -B- using a parting grinder.
Separating spotwelds
Preparing connection areas of the body for installing the front panel
Safety instructions for dealing with flying sparks during grinding and welding work
WARNING
Grinding and welding work
- Danger of fire or explosion
-> Avoid working in an area with highly inflammable or explosive materials.
-> Cover highly inflammable or explosive areas.
-> Remove highly inflammable or explosive parts.
Preparing connection areas of the body for installing the front panel
1. Clean undersealing, adhesive residue and paint off the body connecting flanges in the marked area -A- using a hot-air gun or rotary brush. Grind the connecting flanges until bare.
Cleaning the welding areas
2. Clean undersealing, adhesive residue and paint off the body connecting flanges in the marked area -A- using a hot-air gun or rotary brush. Grind the connecting flanges until bare.
Cleaning the welding areas
3. Clean undersealing, adhesive residue and paint off the body connecting flanges in the marked area -A- using a hot-air gun or rotary brush. Grind the connecting flanges until bare.
Cleaning the welding areas
4. Clean undersealing, adhesive residue and paint off the body connecting flanges in the marked areas -A, B, C, D- using a hot-air gun or rotary brush. Grind the connecting flanges until bare.
Cleaning the welding areas
5. Coating spot-weld flange areas with zinc powder paint
5.1. Coat spot-weld flange areas with zinc powder paint.
Preparing front panel for installation
Safety instructions for sharp-edged body and unit parts
CAUTION
Pointed or sharp objects
- Risk of cracks, pricks or cuts
-> Wear personal protective gear.
Preparing front panel for installation
1. Punching holes for plug welding using inert gas
1.1. Punch holes (dia. = 7 mm) in areas -A- and -B- for plug welding using inert gas. Maintain spacing between the bores as on the old part.
Punching holes for plug welding using inert gas
2. Punching holes for plug welding using inert gas
2.1. Punch holes (dia. = 7 mm) in areas -A- and -B- for plug welding using inert gas. Maintain spacing between the bores as on the old part.
Punching holes for plug welding using inert gas
3. Cleaning the welding areas
3.1. Grind both sides of the connecting flanges of the front panel in the marked areas -A, B, C, D, E- until bare using a rotary brush.
Cleaning the welding areas
4. Cleaning the welding areas
4.1. Grind both sides of the connecting flanges of the front panel in the marked areas -A, B, C, D- until bare using a rotary brush.
Cleaning the welding areas
5. Coating spot-weld flange areas with zinc powder paint
5.1. Coat spot-weld flange areas with zinc powder paint.
Installing front panel
Danger of injury while welding
WARNING
Electric welding
- Risk of electric shock or burns
-> Wear personal protective gear.
-> Disconnect both battery terminals.
-> Do not weld in a damp area or when it is wet under foot.
-> Move highly inflammable materials out of the work area. Ventilate the work area well.
-> Remove smoke gases with an extraction system.
-> Read specific safety information for the welder.
-> Check that welder is working perfectly before use.
Installing front panel
1. Fitting the front panel to the body
1.1. Fit the front panel to the side member and right and left wheel housings and fix in place with tensioning clamps.
1.2. Fit floor front section and end plate to the body and fix in place with tensioning clamps.
1.3. Tack-weld the front panel.
1.4. Remove floor front section and end plate.
2. Welding in the front panel
2.1. Resistance spot-weld the front panel in areas -A, B, C-.
Welding in the front panel
3. Welding in the front panel
3.1. Plug-weld the front panel in areas -A- and -B- using inert gas.
Welding in the front panel
4. Welding in the front panel
4.1. Plug-weld the front panel in areas -A- and -B- using inert gas.
Welding in the front panel
5. Welding in the front panel
5.1. Apply a full weld to the front panel in the marked areas using inert gas.
Welding in the front panel
6. Install floor front section. -> 502055 Replacing floor front section - section on "Installing"
7. Install end plate. -> 501055 Replacing end plate - section on "Installing"
Subsequent work
Subsequent work for body repairs
1. Remove vehicle from the straightening bench.
2. Clean welded joints and sheetmetal flanges with a wire brush.
3. Prime flange areas with 2K primer.
4. Restore standard sealing with body sealant.
-> 5000IN Seam sealing
5. Restore standard undersealing with underbody sealant.
-> 5000IN Undersealing
6. Paint repair area and adjacent surfaces, if necessary.
7. Install removed add-on parts in the repair area.
8. Apply cavity preservation.