TSB : Front Door Hinge: Service and Repair

Details

WM 575355 Replacing door hinge (on body side) Tools General warning notes Safety instructions for body repairs -> 5X00IN04 Safety instructions Tools and materials Spotweld drill bit Nr.129 Spotweld cutter Nr.128-2 Star gauge Nr.127-1 Pos.1 Star gauge Nr.127-1 Pos.2 Star gauge Nr.127-1 Pos.3 Pneumatic body saw PS 1 WE 1138 Hot-air blower, Leister-Electron/V.A.G. 1416 WE 1119 Inverter welder ATL InvertaSpot WE WE1194 Special electric cutter - fine WE 1137 Pneumatic spot-weld remover, Vario drill WS 90 WE 1139 Vice-grip wrench WE 1269 Body straightening system, Celette WE 1121 Preliminary work for body repairs with alignment bench Preliminary work for body repairs Information - If it can be ensured there has been no deformation of the vehicle structure, the following repair can be carried out without the need of a straightening bench. In this case, the vehicle must not be raised when welding the component; it must stand on its wheels on an even surface. 1. Remove accessories in the repair area 1.1. Remove accessories in the repair area according to the extent of damage to the vehicle. 2. Equip straightening bench with straightening attachments 2.1. Equip straightening bench with the straightening attachments according to the setup plans included with the straightening attachments. 3. Place vehicle on the straightening bench 3.1. Position vehicle on the straightening bench, align according to the reference holes and bolt firmly to the straightening attachments. 4. Cover accessories adjacent to the vehicle repair area 4.1. Cover all accessories remaining on the vehicle and adjacent areas with fire-proof protective covers. 5. Reshape connection area of the sheetmetal parts to be replaced 6. Expose welding areas 6.1. Remove undersealing, paint , etc. from the welding areas of the body with a hot-air gun or rotary brush. Removing door hinge (on body side) Installation position of door hinge 1. Remove the wing. -> 505519 Removing and installing wing - section on "Removing" 505519 Removing and installing Front Wing 2. Remove door. -> 575119 Removing and installing door - section on "Removing" 575119 Removing and Installing Front Door 3. Separating inert-gas welded seams 3.1. Separate inert-gas welded seams in areas -A- and -B- using a parting grinder or spherical cutter. Separating inert-gas welded seams 4. Separating inert-gas welded seams 4.1. Separate inert-gas welded seams in areas -A- and -B- using a parting grinder. Separating inert-gas welded seams Preparing connection areas of the body for installing the door hinge (on body side) Safety instructions for dealing with flying sparks during grinding and welding work WARNING Grinding and welding work - Danger of fire or explosion -> Avoid working in an area with highly inflammable or explosive materials. -> Cover highly inflammable or explosive areas. -> Remove highly inflammable or explosive parts. Preparing connection areas of the body for installing the door hinge (on body side) 1. Clean undersealing, adhesive residue and paint off the body connecting flanges from inside in the marked areas -A- and -B- using a hot-air gun or rotary brush. Grind the connecting flanges until bare. Preparing connecting flanges 2. Clean undersealing, adhesive residue and paint off the body connecting flanges in the marked areas -A- and -B- using a hot-air gun or rotary brush. Grind the connecting flanges until bare. Preparing connecting flanges Preparing door hinge (on body side) for installation Safety instructions for sharp-edged body and unit parts CAUTION Pointed or sharp objects - Risk of cracks, pricks or cuts -> Wear personal protective gear. Preparing door hinge (on body side) for installation 1. Cleaning the welding areas 1.1. Grind both sides of the connecting flanges of the door hinge in the marked areas -A, B, C, D- until bare using a rotary brush. Cleaning the welding areas Installing door hinge (on body side) Danger of injury while welding WARNING Electric welding - Risk of electric shock or burns -> Wear personal protective gear. -> Disconnect both battery terminals. -> Do not weld in a damp area or when it is wet under foot. -> Move highly inflammable materials out of the work area. Ventilate the work area well. -> Remove smoke gases with an extraction system. -> Read specific safety information for the welder. -> Check that welder is working perfectly before use. Installing door hinge (on body side) 1. Fitting door hinge to the body 1.1. Position door hinge on the body, align it and screw down securely. Installing door hinge 1.2. Install wing, door lock and striker pin before fitting. 1.2.1. -> 505520 Removing and installing front wing - section on "Installing" 505519 Removing and installing Front Wing 1.2.2. -> 571719 Removing and installing door lock - section on "Installing" 1.2.3. -> 572619 Removing and installing striker pin - section on "Installing" Information Two persons are needed to install the door hinges! 2. Fitting door to the body 2.1. Fit the door to the body and adjust gaps between the door, wing and outer side member according to the adjustment values. -> 501000 Diagram - body gap dimensions - section on "Information" Adjusting the door hinge 2.2. Fix the door in place. 3. Welding in the door hinge 3.1. Apply a full weld to door hinge in areas -A- and -B- from the inside using inert gas. Welding in the door hinge 4. Welding in the door hinge 4.1. Secure the door hinge in area -A- by tack welding it using inert gas. Welding in the door hinge 4.2. Check position and gap dimensions of door and adjust them if necessary. Adjusting the door hinge 4.3. Lift the door and remove it. 5. Welding in the door hinge 5.1. Apply a full weld to the door hinge in areas -A- and -B- using inert gas. Welding in the door hinge Information After the required hardening time has elapsed, cut off excess expanded sealant to a height of more than 25 mm using a knife. 6. Applying expanded sealant 6.1. Seal inside of A-pillar in area -A- with => AFS Vario. See: -> 5000IN Working with acoustic body foam 2K AFS Vario 6.2. Apply expanded sealant using a spatula. Applying expanded sealant Subsequent work Subsequent work for body repairs 1. Remove vehicle from the straightening bench. 2. Clean welded joints and sheetmetal flanges with a wire brush. 3. Prime flange areas with 2K primer. 4. Restore standard sealing with body sealant. -> 5000IN Seam sealing 5. Restore standard undersealing with underbody sealant. -> 5000IN Undersealing 6. Paint repair area and adjacent surfaces, if necessary. 7. Install removed add-on parts in the repair area. 8. Apply cavity preservation.