Observe procedure of REPAIR STAGE 3.
Read contents of BODY, GENERAL.
Steel-aluminium composite construction is used on the vehicle.
Observe specific procedure.
Use only approved SPOT-WELDING APPARATUS for repairs.
Place vehicle on straightening bench.
Following new body parts are required:
Fig. 126: Identifying Engine Support And Engine Support, Rear
Open welded connections in area (1).
Fig. 127: Identifying Welded Connections Area
Drill out riveted connections in areas (1) and (2).
Installation note: Use 19 N2 RIVETS in areas (1) and (2).
Glue new component with ADHESIVE K1.
Fig. 128: Identifying Rivet Holes Drill Areas
Mark severance cut (1) in accordance with dimension a and cut engine support.
Measurement a=140 mm
Installation note: Weld in REINFORCEMENT PLATES at severance cut.
Fig. 129: Identifying Reinforcement Plate Severance Cut
Roughly mark severance cuts (1) and cut.
IMPORTANT: Do not damage spring strut dome (2).
Fig. 130: Identifying Spring Strut Dome And Severance Cuts
Heat ADHESIVE AREAS with hot air blower and release sheet sections (1) from spring strut dome.
IMPORTANT: Do not damage spring strut dome (2).
Installation note: Remove adhesive residue from spring strut dome.
Then FLAME-COAT bonding surfaces of spring strut dome.
Grind bonding surfaces on engine support blank.
Clean bonding surfaces with CLEANING AGENT R1 !
Fig. 131: Identifying Sheet Sections And Spring Strut Dome
Open welded connections in area (1) and remove engine support section (2).
Fig. 132: Identifying Welded Connections Area And Engine Support Section
Installation note: MAG-weld new part in area (1).
To do so, apply 2 fillet welds at spacing of 15 mm.
Length of fillet welds approx. 10 mm.
Fig. 133: Identifying New Component MAG-Welding Area
Preparation of new part
Mark new parts in accordance with severance cuts on vehicle and cut.
Installation note: Adjust new parts to fit with alignment bracket or universal mounting.