Section of front frame member
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Section of front frame member
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The description refers to frame member joints. For replacement of wheel housing and complete front frame member, see under the heading "Front wheel housing and complete frame member". The following description shows the left-hand side.
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1.
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Position the car in an aligning bench.
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2.
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Remove the front wing.
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3.
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Remove the bumper member.
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4.
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Cross-measure if necessary.
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5.
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Drill holes in the spot-welds on the radiator crossmember-frame member mounting.
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6.
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Drill holes in the spot-welds on the inner front frame member up to the location for the joint. Max. 330 mm from the front edge.
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7.
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Cut away the inner front frame member and knock it loose.
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8.
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Realign the centre member if it is deformed. Only minor deformations may be rectified.
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9.
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If the centre frame member is to be cut, the spot-welds in the outer wheel housing must be drilled out.
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10.
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The centre frame member must not be cut farther than 270 mm in from the front edge.
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1.
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Cut the spare part roughly to size.
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2.
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Put the spare part in place and adjust its position exactly with the aid of the alignment bench. Fix it with a few welding clamps.
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3.
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Cut the spare part exactly at the edge of the existing frame member.
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4.
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Remove the spare part and grind clean the surfaces on it and on the body that are to be welded.
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5.
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Apply welding primer to the surfaces that are to be plug welded or spot welded.
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6.
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Fit the spare part and fixate with a couple of welding clamps.
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7.
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Fit the spare part in the exact position using the aligning bench measuring system.
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8.
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Attach the spare part with a couple of spot-welds.
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9.
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All-weld the joint in the frame member and spot-weld the frame member.
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10.
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Spot-weld the radiator crossmember mounting bracket.
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11.
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Smooth off the welds.
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12.
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Fit the bumper member.
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13.
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Remove any remaining welding primer. Welding primer reduces adhesion of paint, filler and sealant.
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14.
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Apply primer to all bare metal surfaces.
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15.
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Seal joints and seams with sealant.
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16.
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Apply underseal to the underbody and in the wheel housing after painting. Use Terostat 9320.
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17.
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Apply anti-corrosion agent to the interior of the frame member after painting. Use Terotex HV 400 or Mercasol 1.
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