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Inner, lower A-pillar with sill, 4D

Inner, lower A-pillar with sill, 4D

Replacement

Certain welded joints on the car may be MIG brazed with bronze as the filling material. A MIG brazed seam may be recognized from the gold colour of the joint. A MIG brazing must always be replaced by a new MIG brazing.

Warning

Repairs to MIG brazing using conventional welding methods and normal filler material are forbidden. Cracks can arise which can impair performance in a collision.



1. Remove Outer A-pillar with reinforcement, 4D .

2. Drill out the spot welds on the front transverse reinforcement.



3. Drill out the spot welds from the inside as illustrated. Drill straight through the panels. The drill holes are useful for fitting.


4. Tap loose the front transverse reinforcement.

5. Cut the centre sill as illustrated.


6. Drill out the spot welds.

7. Tap loose the centre sill.

8. Cut the inner sill as illustrated.


9. Cut the inner, lower A-pillar as illustrated.


10. Drill out the spot welds and grind down the MIG brazing.


If necessary, drill out the spot welds on the dashboard reinforcement.


11. Tap loose the inner, lower A-pillar.

12. Align any deformed plates.

13. Cut the front edge of the spare part inner, lower A-pillar to roughly the right size. Cut so that it overlaps the previous cut.


14. Position the inner, lower A-pillar roughly and secure with welding clamps.

15. Cut the inner sill (spare part) so that it measures 460 mm.


16. Position the inner sill and secure with welding clamps.

17. Position the inner, lower A-pillar. It must be 260 mm from the previous cut.


18. Now cut the front edge of the inner, lower A-pillar so it is edge-to-edge with the previous cut.


19. Grind the surfaces which are to be welded.

20. Apply welding primer to the surfaces to be spot and plug welded. Use Teroson Zink Spray.

Warning

Repairs to MIG brazing using conventional welding methods and normal filler material are forbidden. Cracks can arise which can impair performance in a collision.


21. Secure the spare part with spot and plug welds. Replace the MIG brazing.



22. Seam weld as illustrated. Weld the inside and outside of the inner sill.

23. Apply primer to the internal seam welds. Use Standox 1k.

24. Cut the centre sill so that it matches the previous cut.


25. Grind the surfaces which are to be welded.

26. Apply welding primer to the surfaces to be spot and plug welded. Use Teroson Zink Spray.

27. Position the centre sill and secure it with welding clamps.

28. Weld the centre sill in place.


29. Smooth off the welds.

30. Fit the front transverse reinforcement and support. Use the dill holes from the spot welds.




31. Grind the welds and apply rustproofing. Use Terotex HV 400.

32. Fit Outer A-pillar with reinforcement, 4D

33. Wash away surplus welding primer. Welding primer reduces the adhesion of paint, filler and sealant.

34. Apply primer to all bare metal surfaces. Use Standox 1K.

35. Use Terostat 1K-PUR to seal joints and metal folds.

36. Apply anti-corrosion agent to internal surfaces after painting. Use Terotex HV 400.