Radiator Support: Service and Repair

Front section

Replacing the front section





Remove:
- the three screws in the fan shroud
- two screws on each side of the front fenders.

Remove:
- the three mounting screws on the radiator member
- the connector
- the washer hose.

Install (on the front section):
- the wiper motors
- the cable harness
- the bulbs
- the horn.
Screw the front section into place on the car.

Note! Check the height on both sides so that the front section does not rub against the side member.

Replacing the front fender




The front fender is secured using 9 screws and one nut.
The plastic fender liner is secured using 5 blind rivets.

Replacing the side member and outer wheel arch




Pull out the damaged section. Use a puller tool.
Measure out a 400 mm strip of tape.
Secure the tape to the side member.
Begin at the hole for the brake line bracket.
Mark the joint using the template.
Cut according to the marking.
Cut the replacement part correspondingly.
Grind clean.




Apply welding primer.
Align the replacement part.
Tack-weld. Check.
Weld into place.

Replacing the front inner side member




Mark the edge using a template.
Cut according to the marking.
Align the replacement part.
Cut the replacement part correspondingly.
Weld into place.




Weld the side member cover into place.

Replacing the radiator member




Grind off the spot welds.
Remove the member.
Grind clean.
Apply welding primer.
Secure the member.
Dimension D = 60 mm.
Weld into place.

Replacing the bumper mounting




The bumper mounting is secured to the front side member using two M10 screws.

Replacing the front wheel arch




Grind the welds.
Cut off the damaged section.
Grind clean.
Apply welding primer.
Align and secure the wheel arch.
Weld into place.




Weld the side member cover into place.

Replacing the upper side member




Grind the welds.
Cut off the damaged section.
Grind clean.
Apply welding primer.
Secure the upper side member.
Weld into place.








Alternative cutting points.