Firewall: Service and Repair

Replacing Front Panel

Tools
















General warning notes

Safety instructions for body repairs

Refer to Safety instructions.

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 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 body front section







1. Remove end plate. Refer to Replacing end plate.
2. Remove floor front section. Refer to Replacing floor front section.
3. Mill off spotwelds
3.1. Mill off spotwelds in areas -A, B, C, D- using a spotweld cutter.







4. Mill off spotwelds
4.1. Mill off spotwelds in areas -A- and -B- using a spotweld cutter.







5. Mill off spotwelds
5.1. Mill off spotwelds in areas -A- and -B- using a spotweld cutter.







6. Mill off spotwelds
6.1. Mill off spotwelds in areas -A- and -B- using a spotweld cutter.







7. Separate inert-gas welded seams
7.1. Separate inert-gas welded seams in areas -A- and -B- using a parting grinder.







Preparing connection areas of the body for installation of 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 installation of the front panel

1. Clean undersealing, adhesive residue and paint off the body connecting flanges in the marked areas -A, B, C, D, E, F- using a hot-air gun or rotary brush. Grind the connecting flanges until bare.







2. 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.







3. Coat spot-weld flange areas with zinc powder paint
3.1. Coat spot-weld flange areas with zinc powder paint.

Fitting front panel and preparing 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.

Fitting front panel and preparing for installation

1. Punch holes for plug welding using inert-gas welding
1.1. Punch holes (Dia. = 7 mm) in areas -A, B, C, D- for plug welding using inert gas. Maintain spacing between the bores as on the old part.







2. Clean the welding areas
2.1. Grind both sides of the connecting flanges of the front panel in the marked areas -A, B, C, D, E, F, G, H- until bare using a rotary brush.







3. Coat spot-weld flange areas with zinc powder paint
3.1. 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. Fit 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. Weld in front panel
2.1. Plug-weld the front panel in areas -A- and -D- using inert gas.
2.2. Resistance spot-weld the front panel in areas -B- and -C-.







3. Weld in the front panel
3.1. Plug-weld the front panel in areas -A- and -B- using inert gas.







4. Weld in the front panel
4.1. Plug-weld the front panel in areas -A- and -B- using inert gas.







5. Weld in the front panel
5.1. Plug-weld the front panel in areas -A- and -B- using inert gas.







6. Weld in the front pane
6.1. Apply a full weld to the front panel in areas -A- and -B- using inert gas.







7. Install floor front section. Refer to Replacing floor front section.
8. Install end plate. Refer to Replacing end plate.

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.
Refer to Seam sealing

5. Restore standard undersealing with underbody sealant.
Refer to Undersealing

6. Paint repair area and adjacent surfaces, if necessary.
7. Install removed add-on parts in the repair area.
8. Apply cavity preservation.