Rocker Panel Reinforcement, Replacing
Pull out the damaged section.
Cut, grind or saw off the damaged sections.
Scheme 115
Align the new sill reinforcer.
Weld into place.
Scheme 116
Align the outer door sill.
Weld into place.
Scheme 117
Alternative cutting points.
Side Member Front, Replacing
Special tools
9995797
9995798
9995799
Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
The extent of the deformation varies depending on the type of damage. Therefore different joining points have been tested. These joining points are shown below.
Note. It is extremely important that there is an offset of 70 mm at the point of the joint on the inner and outer section.
Removing the front side member, common information
Remove components. See Front section, exposing (-2003) or Front section, exposing (2004) or Front section, exposing (2005-).
Secure the car in an alignment bench.
Pull out the damaged section using puller tools 9995797 , 9995798
and 9995799 .
Check that the dimensions of the car are correct. See Front section, alignment chart and Side members front, alignment chart .
Remove
- the bumper rail
- the light frame. See «Headlamp support frame, replacing»(ref-407141-S26329521642011070100000) .
Scheme 118
Cut the side member according to alternative (1) (see the illustration). Cut the side member 30 mm (M1) in front of the deformed kink.
Joining may be carried out as far as the deformation kink (3).
Drill or grind out the spot welds.
Pry off the component.
Grind the welding surfaces clean. Carry out the corresponding operation on the replacement part.
Note. Do not cut at the reinforcement (2)
Scheme 119
Scheme 120
Cut the replacement part.
Apply welding primer.
Align the replacement part. Use the measurement system on the alignment bench.
Secure and weld the replacement part into place.
Scheme 121
Start from the original joint (1). Position the new joint within the shaded area.
M1 = 150 mm
M2 = 350 mm
Carry out the corresponding join on the replacement part.
Drill or grind out the spot welds.
Pry off the component.
Grind the welding surfaces clean.
Note. It is extremely important to check that there is no deformation in the joining area.
Scheme 122
Apply welding primer.
Align the replacement part. Use the measurement system on the alignment bench.
Secure and weld the replacement part into place.
Scheme 123
Measure a suitable cutting point. Position the new joint behind the original joint (1).
Cut the section.
Carry out the corresponding join on the replacement part.
Drill or grind out the spot welds.
Pry off the component.
Grind the welding surfaces clean.
Scheme 124
Apply welding primer.
Align the replacement part. Use the measurement system on the alignment bench.
Secure and weld the replacement part into place.
Scheme 125
Position the joint through the hole (4).
Cut the section.
Drill or grind out the spot welds.
Pry off the component.
Grind the welding surfaces clean.
Scheme 126
Apply welding primer.
Align the replacement part. Use the measurement system on the alignment bench.
Secure and weld the replacement part into place.
Scheme 127
Measure a suitable cutting point.
Position the new joint (2) behind the original joint (1).
A = 50-230 mm
Carry out the corresponding join on the replacement part.
Drill or grind out the spot welds.
Pry off the component.
Grind the welding surfaces clean.
Scheme 128
Apply welding primer.
Align the replacement part. Use the measurement system on the alignment bench.
Secure and weld the replacement part into place.
Scheme 129
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 the section.
Carry out the corresponding join on the replacement part.
Drill or grind out the spot welds.
Pry off the component.
Scheme 130
Scheme 131
Apply welding primer.
Align the replacement part. Use the measurement system on the alignment bench.
Secure and weld the replacement part into place.
Installing The Front Side Member, Common Information
Install
- the bumper rail
- the light frame. See «Headlamp support frame, replacing»(ref-407141-S26329521642011070100000) .
Seal. See Body, sealant application chart .
Wheel Housing, Rear, Replacing
Replacing the wheel arch
Scheme 132
Secure the outer section of the wheel arch.
Weld into place.
Scheme 133
Secure the inner section of wheel arch.
Weld into place.
Modification when replacing
If the wheel arch is replaced on a car with gas power the wheel arch must be modified to allow for filling the tank.
Carry out operation Replacing the rear fender .
Use the rear fender holes to align when sawing.
Also see the safety precautions. See Safety precautions .
Scheme 134
Grind the welds.
Cut off the damaged section.
Grind clean.
Apply welding primer.
Secure the upper side member.
Weld into place.
Remove the light frame. See Headlamp support frame, replacing .
Scheme 135
Weld the cover to the side member.
Side member, joining
The side member need not be replaced whole but can be joined.
Scheme 136
Cut off the damaged section.
Cut so that the member is 100 mm longer than the cover.
(Dimension A).
Grind clean.
Cut the replacement part (upper side member)
Apply welding primer.
Secure the replacement part.
Weld into place.
Grind the welds.
Scheme 137
Cut the replacement part (cover).
Weld into place.
Spare Wheel Well, Replacing
Carry out operation Side member, rear, replace .
Scheme 138
Secure the rear, outer section of the floor.
Weld into place.
Scheme 139
Secure the end of spare wheel well against the side members and rear floor.
Weld into place.
Scheme 140
Spot-weld the battery shelf.
For dimensions, see Dimensions (G) .
Scheme 141
The battery shelf must be secured with 11 spot welds.
Scheme 142
Secure the inner rear section.
Weld into place.
Scheme 143
Secure the inner rear section.
Weld into place.
Scheme 144
Grind the welds.
Cut off the damaged section.
Grind clean.
Apply welding primer.
Align and secure the wheel arch.
Weld into place.
Scheme 145
Secure the outer section of the wheel arch.
Weld into place.
Scheme 146
Secure the inner, rear section of the wheel arch.
Weld into place.
See Side member front, replacing
Side Member, Upper, Replacing
See Side member, upper, replacing
See Spare wheel well, replacing
Wheel Housing, Front, Replacing
See Wheel housing, front, replacing
See Wheel housing, rear, replacing
See Side member front, replacing
See Side member, upper, replacing
See Spare wheel well, replacing
See Wheel housing, front, replacing
See Wheel housing, rear, replacing
See Side member front, replacing
See Side member, upper, replacing
See Spare wheel well, replacing
See Wheel housing, front, replacing
See Wheel housing, rear, replacing
See Side member front, replacing
See Side member, upper, replacing
See Spare wheel well, replacing
See Wheel housing, front, replacing
See Wheel housing, rear, replacing
See Side member front, replacing
See Side member, upper, replacing
See Spare wheel well, replacing
See Wheel housing, front, replacing
See Wheel housing, rear, replacing
See Side member front, replacing
See Side member, upper, replacing
See Spare wheel well, replacing
See Wheel housing, front, replacing
See Wheel housing, rear, replacing
Preparations
Remove
- the tail lamps. See «Tail lamp, replacing»(ref-406830-S06027055002011070100000) V70 see «Bumper rear, replacing»(ref-407128-S16677772402011070100000) and «Rear bumper guides»(ref-441162-S22841464122011121500000) (-2003) or «Bumper rear, replacing»(ref-407128-S32102617512011070100000) (-2004) or «Bumper rear, replacing»(ref-407128-S31630170222011070100000) (2005-) V70 XC see «Bumper rear, replacing»(ref-441161-S21122360502011121500000) and «Bracket for the rear bumper»(ref-441161-S27198883492011121500000) (-2004) or «Bumper rear, replacing»(ref-441161-S42695297272011121500000) (2005-).
- the rear bumper: V70 see «Bumper rear, replacing»(ref-407128-S16677772402011070100000) and «Rear bumper guides»(ref-441162-S22841464122011121500000) (-2003) or «Bumper rear, replacing»(ref-407128-S32102617512011070100000) (-2004) or «Bumper rear, replacing»(ref-407128-S31630170222011070100000) (2005-) V70 XC see «Bumper rear, replacing»(ref-441161-S21122360502011121500000) and «Bracket for the rear bumper»(ref-441161-S27198883492011121500000) (-2004) or «Bumper rear, replacing»(ref-441161-S42695297272011121500000) (2005-).
Note. The bumper rail is made of BORON steel. See HSS steel .
Scheme 147
Pull out the damaged section.
Use a puller tool. See Aligning the rear frame member .
Use an alignment bench and its units of measurement.
Ensure that the general dimensions of the car are correct.
Scheme 148
Cut the rear section off and replace as illustrated. This is to access the upper row of spot welds on the bumper rail.
Scheme 149
Grind off the spot welds to prevent damage to the inner rear section. Use a grinder.
Note. Cover the windows and interior trim to protect them from grinding chips, filings or shavings.
Scheme 150
Splice the bumper rail at the corner as illustrated.
Use a cutter or plasma torch.
Remove the damaged section.
Scheme 151
Alternative cutting points
If the damage is less serious on one side, the rail can be spliced as illustrated.
Note. Splicing is only permitted based on the alternative cutting points.
Cut the replacement part, align and weld into place.
Use welding primer P/N 116 1342 .
Scheme 152
Align the replacement part.
Apply bodywork adhesive P/N 116 1524 on the replacement part.
Weld into place.
Follow the sealant chart for the rear section. See Body, sealant application chart .
Note. Do not forget to rustproof after painting.
Install removed components in reverse order.
Rear Bumper Guides
Removing the slide mounting
Scheme 153
Scheme 154
Remove
- the rear bumper according to «Bumper rear, replacing»(ref-407128-S16677772402011070100000) .
- Five screws.
- Four blind rivets according to.
Installing the slide mounting
Install
In reverse order.
Bracket For The Rear Bumper
Removing the slide mounting
Scheme 155
Remove
- the rear bumper according to «Bumper rear, replacing»(ref-441161-S21122360502011121500000)
- The four blind rivets according to «Removing rivets»(ref-441129-S11847328642011121500000)
- Five screws.
Scheme 156
Installing the slide mounting
Install
In reverse order.
Scheme 157
Secure the rear roof member.
Check the measurements.
Test install and check the alignment of the outer rear section.
Weld several points.
Remove the outer rear section.
Weld into place.
Scheme 158
Secure the rear fender.
Check the alignment with the outer rear section.
Weld into place.
Scheme 159
Secure the subframe.
Weld several points.
Check the measurements.
Test install and check the alignment of the outer rear section.
Remove the outer rear section.
Weld into place.
Scheme 160
Cantrail
Cut off the damaged section.
Roughly cut replacement part.
Cut. See Joint and cutting points for work on roof .
Remove excess materials.
Weld into place.
Scheme 161
Align cantrail reinforcements.
Check the dimensions. See Roof arch, replacing .
Locate the sections which reinforce the inner cantrails in the car. Use holes as a guide.
Tack, spot and respectively seam weld to secure in place.
Scheme 162
Roof side
Roughly cut the replacement parts.
Align on car.
Saw through the two panels.
Remove excess materials.
Align the replacement part.
Weld into place.
Joint And Cutting Points For Work On Roof
Principles of joining
Note. When welding in the vicinity of the roof: Cover the interior components that have not been removed. This is to protect against welding drops and spray.
Scheme 163
Cut the A-post.
Dimension C = minimum 50 mm.
Scheme 164
Cut the B-post.
Dimension C = minimum 50 mm.
Scheme 165
Cut the C and D-posts.
Dimension C = minimum 50 mm.
Roof Arch, Front And Rear Windshield Frame, Replacing
Grind off the spot welds.
Remove the damaged components.
Check the distance between the roof arches. See Roof, alignment chart .
Scheme 166
Install a new front or rear windshield frame.
Install a new roof arch.
Weld into place.
Note. There is no roof member between the B-posts on cars with a sun roof.
Scheme 167
The upper section of the rear roof member is made up of the upper section of the outer rear section frame.
Roof Panel, Replacing
Grind off the spot welds on the front and rear windshield.
Grind off the laser weld along the sides.
If the car has a sun roof
Grind the off bead welds (three on each side) which retain the sun roof frame in the inner cantrail.
Remove the roof arch from the roof with a putty knife or with piano wire.
| WARNING | Do not use heat: There is a risk of dangerous gases. |
Remove the roof panel.
Lever carefully so as not to damage the cantrail.
Clean the roof arch. Replace if necessary.
Grind all mating surfaces to bare metal.
Scheme 168
Align the new roof panel.
Check the distance between the cantrails. See Roof arch, replacing .
Mark the roof arches with a pencil.
Lift off the roof panel.
Grind those areas to receive adhesive.
Scheme 169
Drill four 6 mm diameter holes in the roof panel on each side.
Drill as illustrated for plug welds. Use a 6 mm drill bit.
Dimension A = 300 mm.
Dimension B = 540 mm.
Apply welding primer to the windshield and rear windshield members.
Scheme 170
Apply adhesive to the sides of the roof.
Apply generously so that adhesive is pressed out when the roof is installed.
Note. Do not apply any adhesive within 30 mm of the hole that is to be plug welded.
(Dimension C = 30 mm.)
Scheme 171
Apply primer to the roof arch.
Apply PUR adhesive to the roof arch.
Dimension A = 100 mm.
Dimension B = 100 mm.
Dimension C = 15 mm.
Scheme 172
Align the roof.
Scheme 173
Spot weld the front and rear edges.
Plug-weld the four holes in the roof side.
Wipe off excess adhesive.
For optimal alignment: Use welding grips on the roof edges.
Scheme 174
Scheme 175
If the car has a sun roof
Weld the frame for the sun roof to the cantrail.
(3 seam welds on each side).