Replacing Body Front Section
Replacing Body Front Section
Tools
Technical values
Preliminary work
Preliminary work for body repairs (with straightening bench)
1. Removing accessories in the repair area.
1.1. Remove accessories in the repair area according to the extent of damage to the vehicle.
2. Set up straightening bench with straightening set.
2.1. Equip straightening bench with the straightening attachments according to the setup plans included with the straightening attachments.
3. Set vehicle on 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 the accessories adjacent to the repair area on the vehicle.
4.1. Cover all accessories 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 joint areas.
6.1. Remove undersealing, paint, etc. from the joint areas of the body with a hot-air gun or rotary brush.
Safety instructions and information on quality
CAUTION:
Non-observance of safety instructions for body repairs
- Risk of damage to the vehicle
- Danger of injury
- Observe the relevant safety instructions as well as general information and notes on quality
- Tools and metalworking tools
- Working with body structural adhesive
- Replacing punch rivets
- Setting self-tapping screws
Tools and materials
Tools and materials for body repairs
INFORMATION: The tools for working on steel and aluminium must always be kept separate from each other. We recommend that you colour-code the tools, just like in the aluminium tool set with trolley V.A.G 2010/2 WE 1350.
Straightening set 970 Panamera. Body Straightening System, Celette WE 1121 Body Straightening System, Car Bench WE 1122
Resistance spot welder
Metal inert gas (MIG) welder
Pneumatic spotweld remover Pneumatic Spotweld Remover, Vario Drill WS 90 WE 1139
Pneumatic body saw PS1 Pneumatic Body Saw PS 1 WE 1138
Oscillating body saw (special electric cutter) Special Electric Cutter - Fine WE 1137
Rotary brush
Leister Electron hot-air blower Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119
Cartridge gun Cartridge gun V.A.G. 1628 WE 1141
Spotweld drill Nr.129, Twist drill Nr.201
Countersink for rivets Countersink Nr.202
Blind riveting tool for high-strength rivets Blind riveting tool TAURUS 4 WE 1348
Safety vacuum cleaner for aluminium dust Safety vacuum cleaner for aluminium dust B1 WE 1344
Star gauges for body gap dimensions Nr.127-1
W�rth Sticks and Seals body sealant
Removing body front section
Removing front gusset plate on the left and right side
1. Remove front gusset plate.
1.1. Drill out spotwelds -A- using spotweld drill.
1.2. Grind down MIG seams -B- .
1.3. Remove front gusset plate.
Removing body front section
INFORMATION:
- The steps described here relate to the left side. The same steps must also be performed on the right side.
- Drill out spotwelds A through two plate thicknesses.
1. Drill out spotwelds using spotweld drill.
2. Mill off spotwelds using a spherical cutter.
3. Grind down MIG seams.
4. Heat up connection areas using a hot-air gun.
5. Remove body front section.
Preparing body front section for installation
1. Fit body front section and secure in installation position with the straightening bracket.
INFORMATION:
More rivets are set during installation than in the original setup.
To prevent the edges of the rivets from touching at a later stage, make sure to leave sufficient and equal space between the bores.
2. Drill 109 new holes for rivets using a 6.6-mm drill bit twist drill Nr.201.
3. Remove body front section.
4. Prepare connection areas on body front section for bonding.
Preparing front gusset plate at the left and right for installation
1. Make holes for plug-welding using inert gas with a body hole punch.
Preparing connection areas of body for installing body front section
1. Prepare connection areas for bonding.
Installing body front section
INFORMATION:
- Before final assembly, make sure you fully understand all the work steps involved and carry out a trial assembly without applying adhesive.
- The bonding process can only be carried out reliably when a smooth and swift sequence of operations is guaranteed.
- Do not begin bonding work until all materials and tools necessary for later repair work are available.
1. Apply adhesive. -> Application depth: 3.0 mm
Working with body structural adhesive
2. Fit body front section and secure in installation position with the straightening bracket.
3. Rivet in body front section.
-A- BLIND RIVET 000.043.207.57
-B- BLIND RIVET 000.043.207.58
4. Resistance spot-weld the body front section.
5. Spot-weld the body front section using inert gas.
6. Apply 2K acoustic body filler foam "AFS Vario" on the sealing element through the opening in the A-pillar.
Installing front gusset plate
1. Install front gusset plate.
1.1. Fit and secure the front gusset plate.
1.2. Plug-weld the gusset plate using inert gas -A- .
1.3. Spot-weld using inert gas -B-.
Subsequent work
Subsequent work for body repairs
1. Loosen and remove vehicle from the straightening bench.
2. Clean joint areas and sheetmetal flanges with a wire brush.
3. Prime joint areas and sheetmetal flanges with 2K primer.
4. Restore standard seal with body sealant
Also seal the repair area carefully.
5. Paint repair area and adjacent surfaces, if necessary.
6. Restore standard undersealing with underbody sealant
7. Apply standard cavity preservation. Also carefully apply cavity preservation to the repair area.
8. Install removed accessories in the repair area.