41 21... Replacing Left Side Frame Complete
Compliance with the following points is mandatory before beginning work:
- DISCONNECT HIGH-VOLTAGE SYSTEM FROM POWER .
- Observe SAFETY INFORMATION for handling electric vehicles.
Read contents of BODY, GENERAL .
Strip down vehicle.
Place vehicle on straightening bench.
The following body components are required:
- (1) Side frame, complete
- (2) Blind rivet nut M5 (quantity: 2, not shown)
- (3) Blind rivet nut M6 (quantity: 1, not shown)
- (4) Blind rivet nut M6 (quantity: 11, not shown)
- (5) Wheel arch holder (not shown)
- (6) Side sill holder, front (not shown)
Following CONSUMABLES are required:
| Material | Quantity |
|---|---|
| Adhesive K1 | 1 |
| Adhesive K2 | 2 |
| Betawipe 4800 | 1 |
| Cleaning agent R1 | 1 |
| Adhesive tape for spacer | 1 |
| Non-woven abrasivesS1 |
Necessary preliminary work:
- Remove A-PILLAR REINFORCEMENT
- Remove DEFORMATION ELEMENT, FRONT BOTTOM
- Remove roof outer skin. See REPLACE ROOF OUTER SKIN or REPLACE ROOF OUTER SKIN WITH SLIDE/TILT SUNROOF .
Removal
Release screws (1).
Mark position (3) of carrier support (1) to wheel arch (2).
Apply the hydraulic press (1) such that the carrier support (2) can be pressed outwards at the side.
Attention!
Risk of damage to the bulkhead!
When releasing the bonded connection (connecting flange), a low amount of pressure must be applied to the carrier support with even heat supply. If force is applied abruptly, this can lead to carbon fibres breaking off the bulkhead. The body must be replaced if this occurs!
Press the carrier support outwards by dimension a.
Dimension a = approx. 2 mm.
Attention!
Risk of damage!
The connecting flange will be released in the A-pillar area last. Ensure damage-free repair work in this area!
Heat connecting flange (1) with autogenous torch in front area for approx. 15-20 min. until carrier support detaches.
Attention!
Only direct the flame of the autogenous torch onto the surface of the carrier support.
The object temperature of carbon parts that are not replaced must not exceed 120 °C. Use an infrared thermometer for temperature measurement.
Draw off vapor and gases! Use personal protective clothing/equipment.
After detaching the carrier support in the front area of the connecting flange, slightly increase the pressure of the hydraulic press. At the same time, heat the connecting flange and release the carrier support further.
Removed completely detached carrier support.
Attention!
Observe procedure for RELEASING CARBON PARTS .
Only disconnect the outer component!
Grind off the adhesive flanges in areas (1).
Release the lock washer (1).
Remove crash foam (2).
In areas (1) heat up and remove METAL REINFORCEMENTS .
In areas (2), heat up and remove THERMOPLASTIC PARTS .
Attention!
Observe procedure for RELEASING CARBON PARTS .
Only disconnect the outer component!
The separating cuts (1) are marked on the vehicle at the works by two lines with 5 mm spacing. The lines show the position of the joint after carrying out the repair.
Cut the outer C-pillar.
Grind off the adhesive flanges in areas (2).
Remove outer C-pillar.
HEAT the adhesive flange of the reinforcement (1) on inner side frame with hot air blower.
Apply peeling load to bonded connection.
Roughly cut deformation element (1) along separating cut (2) with RECIPROCATING SAW .
Attention!
Risk of damage in area (3).
PEEL OFF deformation element, beginning in area (1).
Release the lock washer (1).
Remove crash foam (2).
In areas (1), heat up and remove REINFORCEMENTS MADE OF METAL and PLASTIC .
Support the convertible top bow.
Roughly disconnect A-pillar (1) at the separating lines (2) with SABRE SAW .
Front convertible top bow:
Support the convertible top bow.
Attention!
Risk of damage!
Do not damage the convertible top bow when sawing.
Roughly cut the side frame (1).
Grind off adhesive flange in area (2).
Remove the outer side frame section.
Front convertible top bow:
Support the convertible top bow.
Grind off the A-pillar reinforcement (1).
Front convertible top bow:
Support the convertible top bow.
Grind off adhesive flanges (1).
Remove the inner side frame section (2).
Front convertible top bow:
Support the convertible top bow.
Prepare the bonding surfaces (1) on the convertible top bow (2).
Grind off adhesive flanges in areas (1).
Remove inner frame (2).
Support the convertible top bow.
Roughly disconnect side frame at the separating lines (1).
Rear convertible top bow:
Support the convertible top bow.
Attention!
Risk of damage!
Do not damage the convertible top bow when sawing.
Roughly cut the side frame (1).
Grind off adhesive flange in area (2).
Remove the outer side frame section.
Rear convertible top bow:
Support the convertible top bow.
In areas (1), grind off adhesive flanges.
Remove the inner side frame section (2).
Rear convertible top bow:
Support the convertible top bow.
Prepare the bonding surfaces (1) on the convertible top bow (2).
REMOVE remnants of the C-pillar reinforcement (1).
Grind off adhesive flanges in the areas (2).
Central convertible top bow:
Support the convertible top bow.
Attention!
Risk of damage!
Do not damage the convertible top bow when sawing.
Roughly cut the side frame (1).
Grind off adhesive flange in area (2).
Remove the outer side frame section.
Central convertible top bow:
Support the convertible top bow.
Heat up and remove this area (1) on the reinforcement (2).
Central convertible top bow:
Support the convertible top bow.
Grind off adhesive flanges in areas (1).
Remove the inner side frame section (2).
Central convertible top bow:
Support the convertible top bow.
Prepare the bonding surfaces (1) on the convertible top bow (2).
Preparation of the A-pillar (outer side)
Release the lock washer.
Remove reinforcement ().
Grind off adhesive flanges in areas (1).
Remove inner frame (2).
Preparation of side frame (inside)
Fit in new part.
Prepare bonding surfaces on vehicle.
PREPARE bonding surfaces on the inside of side frame (1).
Installation of the side frame:
Apply K2 adhesive to all bonding surfaces on vehicle.
Position the side frame (1) and secure using collets.
Position the new part and fix with clamps.
Attention!
Exclusively position collets on the spacers to maintain the required adhesive gap.
Remove ADHESIVE that has emerged.
Installing carrier support
Screw the carrier support together with the spring strut dome. Tighten screws (1) hand-tight.
Tighten screws (1) after adhesive hardening.
Tightening torque 41 11 Az .
Required follow-up work:
Remove adhesive that has emerged. Never use cleaning agents containing solvent.
After adhesive has hardened, remove clamping pliers.
Set missing BLIND RIVET NUTS (1) to (3).
Position missing holders (4) in combination with the associated mounted parts.
Prepare bonding surfaces on the holder (4) and on the vehicle.
Bond the holders (4) with adhesive K2.
Insert missing BLIND RIVET NUTS (1).
Position missing holders (2) in combination with the associated mounted parts.
Prepare bonding surfaces on the holder (2) and on the vehicle.
Bond the holders (2) with adhesive K2.