PRE-RELEASE
Outer sill
| Outer sill |
Both the sill and B-pillar are provided with reinforcements. These must not be damaged when the sill is cut.
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Body reinforcements must only be cut and joined if they are specifically covered in the description of the methods. Unless otherwise stated, it is mandatory to discard and replace the damaged reinforcement component. |
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| 1. |
Position the car in an aligning bench and cross-measure if necessary.
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| 2. |
Cut away the damaged portion of the sill. See
Permissible joints
. At the front edge, the sill may be cut max. 50 mm above the front wing fastening hole (A). Be careful so as not to damage the underlying reinforcement. The B-pillar should be cut under the weld pins.
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| 3. |
Drill out the spot-welds along the top edge of the sill.
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| 4. |
Drill out the spot-welds on the underside of the sill.
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| 5. |
Tap loose the sill and remove it.
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| 6. |
Align any deformed sheet metal or panels.
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| 7. |
Cut the spare part so that it overlaps the joints by approximately three centimetres.
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| 8. |
Fit the spare part and fixate using with a couple of welding clamps. Fit the doors and check the fit of the sill.
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| 9. |
Remove the doors. Cut through the spare part and the body at the same time so that the joints can be welded edge-to-edge.
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| 10. |
Remove the spare part and drill or punch holes for plug-welding on the underside of the sill.
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| 11. |
Grind the surfaces to be welded on the spare part and on the body.
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| 12. |
Apply welding primer on the surfaces to be plug and spot-welded. Use Teroson Zinkspray.
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| 13. |
Fit the spare part and fixate it using a few welding clamps. Fit the doors and check the fit of the sill. Fasten the sill with a couple of welds.
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| 14. |
Remove the doors and spot-weld the top edge of the sill.
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| 15. |
Spot-weld the lower edge of the sill.
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| 16. |
Plug-weld the underside of the sill to the reinforcements in the sill and B-pillar.
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| 17. |
All-weld the joints by the rear wheel housing, B-pillar and the front wheel housing.
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| 18. |
Grind the welds.
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| 19. |
Remove any remaining welding primer. Welding primer reduces adhesion of paint, filler and sealant.
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| 20. |
Apply primer on all ground surfaces. Use Teroson Zinkspray.
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| 21. |
Seal joints and sheet metal flanges with sealant. Use Terostat 1K-PUR.
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| 22. |
Apply anti-corrosion agent to the inside of the sill after painting. Use Terotex HV 400 or Mercasol 1.
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