41 11 420 Left Sills Replacement
Compliance with the following points is mandatory before beginning work:
- DISCONNECT HIGH-VOLTAGE SYSTEM FROM POWER .
- Observe SAFETY INSTRUCTIONS for handling electric vehicles.
Read contents of BODY, GENERAL .
For stripping and rigging operations, refer to texts on KSD CD (FRU number 41 11 420).
The following body parts are required (see Electronic Parts Catalog EPC):
- Side frame, outer
- Blind rivet nuts (quantity: 4, not shown)
- Door sill holder (quantity: 2, not shown)
- Front door sill reinforcing plates (quantity: 2, not shown)
- Rear sill reinforcing plates (quantity: 2, not shown)
Following CONSUMABLES are required:
| Material | Quantity |
|---|---|
| Adhesive K2 | 1 |
| Cleaning agent R1 | 1 |
| Betawipe 4800 | 1 |
| Adhesive tape for spacer | 1 |
| Non-woven abrasives S1 |
Remove the door sill
The separating cuts (1) are marked on the spare part at the works by two lines with 5 mm spacing. The lines show the position of the joint after carrying out the repair.
Only disconnect the outer component!
Cut the door sill at the separating lines (1).
Grind off the adhesive flanges (2).
Grind off the adhesive flange (1).
Remove the door sill.
HEAT the adhesive flange of the reinforcement (1) on inner side frame with hot air blower.
Apply peeling load to bonded connection.
Preparation
The separating cuts (1) are marked on the spare part at the works by two lines with 5 mm spacing. The lines show the position of the joint after carrying out the repair.
Carry out the separating cuts (1) on the new part.
Fit in new part.
Insert BLIND RIVET NUTS (1).
PREPARE bonding surfaces (1) and (2) on the vehicle and new part.
Sand in area (1) from inside.
Bond a spacer approximately every 20 cm in this area (1).
Installing the door sill
Apply adhesive K2 to bonding surfaces (1).
Apply adhesive K2 to the reinforcement plates (1) and (2).
Bond the REINFORCEMENT PLATES (1) and (2).
Position reinforcement plate (1) first. Then position reinforcement plate (2).
Fix reinforcement plates (1) and (2) with MAGNETS .
Repeat procedure on second separating cut.
Position the new part and fix with clamps.
Ensure uniform gap.
Remove excess ADHESIVE AND ADHESIVE TAPES at the joint.