Operation CHARM: Car repair manuals for everyone.

501455 Replacing Front Panel



WM 501455 Replacing front panel

Tools









Technical values





Removing front panel

Removing front panel

Information

- Some of the repair illustrations show only one side of the vehicle.

- Naturally, some steps also have to be performed on the opposite side of the vehicle as well.

- These must be carried out as a mirror image of the steps shown.





Front panel
1. Remove wing joining plate. -> 505355 Replacing wing joining plate
2. Drill through punch rivets using a twist drill Nr.201.
Grind down welded seams.





Removing front panel





Removing front panel





Removing front panel





Removing front panel





Milling off welded seam





Removing front panel
3. Heat bonding areas. Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119





Loosening bonding areas





Loosening bonding areas





Loosening bonding areas





Loosening bonding areas
4. Remove front panel.

Preparing connection areas of body for installing front panel

Preparing connection areas of body for installing front panel

Information

- Some of the repair illustrations show only one side of the vehicle.

- Naturally, some steps also have to be performed on the opposite side of the vehicle as well.

- These must be carried out as a mirror image of the steps shown.

1. De-burr the bores.
2. Prepare connection areas for bonding. -> 5X00IN21 Working with body structural adhesive





Preparing connection areas for bonding





Preparing connection areas for bonding

Preparing front panel for installation

Preparing front panel for installation

Information

- Some of the repair illustrations show only one side of the vehicle.

- Naturally, some steps also have to be performed on the opposite side of the vehicle as well.

- These must be carried out as a mirror image of the steps shown.

1. Fit front panel and secure it to the body.
1.1. Drill bores for the rivets through the existing holes. -> Diameter: 6.5 mm
2. Drill new holes in the areas shown. -> Diameter: 6.5 mm





Drilling new holes





Drilling new holes





Drilling new holes





Drilling new holes





Drilling new holes
3. Countersink the bores shown for installing countersunk rivets. Countersink Nr.202





Counterbores





Counterbore
4. Remove front panel.
5. De-burr the bores.
6. Prepare connection areas for bonding. -> 5X00IN21 Working with body structural adhesive





Preparing connection areas for bonding





Preparing connection areas for bonding





Preparing connection areas for bonding

Installing front panel

Installing front panel

Information

- Some of the repair illustrations show only one side of the vehicle.

- Naturally, some steps also have to be performed on the opposite side of the vehicle as well.

- These must be carried out as a mirror image of the steps shown.

1. Apply adhesive to the front panel and 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





Applying adhesive





Applying adhesive
2. Also apply a bead of adhesive to the joint areas.-> Application depth: 5 mm
3. Position the front panel using the straightening system.
4. Rivet in front panel.
4.1. Rivet in areas shown using -> BLIND RIVET 999.190.228.01.





Riveting in front panel





Riveting in front panel
4.2. Rivet in areas shown using -> BLIND RIVET 999.190.230.01.





Riveting in front panel
4.3. Rivet in area -B- using -> BLIND RIVET 999.190.230.01.





Riveting in front panel
4.4. Rivet in areas shown using -> BLIND RIVET 999.190.227.01.





Riveting in front panel





Riveting in front panel
4.5. Rivet in area -A- using -> BLIND RIVET 999.190.227.01.





Riveting in front panel
4.6. Rivet in areas shown using -> BLIND RIVET 999.190.229.01.





Riveting in front panel
4.7. Rivet in area -C- using -> BLIND RIVET 999.190.229.01.





Riveting in front panel
5. Make ground connections.
5.1. Drill bores for ground connections. -> Diameter: 8.2 mm





Screw-on points for ground connection
5.2. Make ground connection using a screw and nut. -> 5X00IN25 Making ground connections-> COUNTERSUNK SCREW 999.073.549.01 -> HEXAGON NUT 900.377.003.01 -> Tightening torque: 15 Nm (11 ftlb.)





Ground connections
5.3. Carefully seal screw heads and nuts.
6. Install wing joining plate. -> 505355 Replacing wing joining plate

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991110, 991111, 991120, 991121, 991310, 991311, 991320, 991321, 991410, 991411, 991420, 991421, 991430, 991431, 991510, 991511, 991520, 991521, 991610, 991611, 991620, 991621

Model year as of 2012
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