When replacing body panels, observe the following measures:
Check number and position of present spot welds, complete missing spot welds.
Compare spot welds on new part with old part.
Use resistance spot welding method to create multiple-layer sheet metal connections, if the spot welder has the appropriate welding capacity (weldable sheet metal thickness and number of layers).
If this it not the case, pre-drill corresponding spot welds, countersink and plug weld.
Before performing planishing, welding and tinning work remove foam parts installed in some body hollow cavities for noise insulation. Heat can cause high smoke and fire development.
Improper body work can influence the strength and endanger the safety. For this reason perform replacement of body parts precisely and carefully and then preserve permanently.
When using welded body parts always deburr welding points, grinding down to bare metal, coat with zinc dust paint before welding and preserve. The welding method to be performed is given in the corresponding repair instructions.
When performing section repairs refer to the appropriate repair instructions for the separation points in question and always observe.
Never weaken nor strengthen separation points.
Replacing a body part includes cutting out a part, preparation of new parts (unpacking, cutting to size, cleaning of contact surfaces), fitting and welding in or screwing in as well as smoothing and cleaning welding areas, moreover, removing uneven surfaces and remachining contours with recommended materials (with angular grinder up to a grain size of 90 or vibration grinder up to a grain size of 100).
When performing straightening work never stand in a direct line in front of the pulling chains when introducing straightening forces to the frame or body.
Secure pull chains with catch cables or chains to prevent it from snapping away.
Since the body consists in part of high tensile strength steels, considerable forces may be required to bend the parts back into the original shape. Observe that high tensile strength steels have a higher tendency to spring back than conventional steels.
We recommend fastening the body to the straightening bench with additional universal anchors in order to better distribute the straightening forces, some of which are quite high.
Before welding in body parts always ensure that the battery (ground lead) and control units are disconnected (negative pole of battery must be covered). If welding should be done in close proximity to the SeDrive unit and alternator, these component parts must also be disconnected.
Before performing any type of welding work or other work causing sparks in the area of the vehicle battery, always remove the battery and store in a protected location.
Before disconnecting the battery ensure that any codes for anti-theft security (radio, etc.) are known. Moreover, read out fault memory before disconnecting the battery in order to prevent erasing any error present.
Perform welding work on carriers (e.g. longitudinal member, crossmember) only with straightening bench. Welding in the carriers precisely according to dimensions is not possible without straightening bench. Possible deviations and tolerances can no longer be eliminated by adjusting the axle geometry.
The firewall is glued to the body with PUR adhesive. The firewall can be removed with commercially available tools (wire or cutting blade).
Gas welding (autogenous welding) is not permissible on the entire body. Generally perform only resistance spot welding and MIG welding.
When planishing or replacing body parts, minor uneven surfaces or dents can remain on the body. They can be repaired with filler or by tinning. We recommend the solder filling process, because the properties of the tin are similar to that of steel or sheet steel. Tin also prevents corrosion.
Following welding work or a fire we recommend replacing seam sealant with paintable sealant, because the adhesive may be damaged by the heat.
After painting, treat areas affected by repair with appropriate corrosion protection measures (e.g. wax, hollow cavity sealing agent, underbody protection, etc.)