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Front Side Member Section > < Fender Apron Panel Reinforcement

S-MAX.Galaxy 2006.5 (03.2006-)

Front End Sheet Metal Repairs - Front Side Member and Fender Apron Panel LH S-MAX/Galaxy 2006.5 (03/2006-)
Removal and Installation

General Equipment
Measurement and alignment angle system
  1. Replacement parts
    • Inner side member
    • Outer side member with apron panel
    • Strut tower reinforcement
    • Longitudinal member flange plate
    • NVH element

Removal

  1. General information
    • The apron panel reinforcement needs to be removed before the repairs can be started.
    • Necessary removal work: Radiator, engine/transmission unit, crash padding and A-pillar trim.
    • Reposition the carpeting and the wiring harness away from the working area.

  1. Apron panel
    1. Mill out the spot welds.
    1. Mill out the spot welds (two panel thicknesses).

  1. Strut tower reinforcement
    1. Mill out the spot welds (two panel thicknesses).
    1. Mill out the spot welds.

  1. Strut tower reinforcement
    • Heat the area (approx. 170° C) and release the NVH element.

  1. Side member, bottom
    1. Mill out the spot welds.
    1. Mill out the spot weld (two panel thicknesses).

  1. Bulkhead crossmember
    • Mill out the spot welds.

  1. Bulkhead, inner
    • Mill out the spot welds.

  1. Bulkhead, inner
    • Mill out the spot welds (two panel thicknesses).

  1. NOTE:
    NOTE:In order to enable removal of the complete side member with apron panel, a partial section needs to be cut out at the apron panel.
    Bulkhead, inner
    • Cut points.

  1. Bulkhead, inner
    • Heat the area (approx. 170° C) and release the NVH element.

Installation

NOTE:
NOTE:
  • Fit the outer side member with the apron panel and the inner side member and secure them with the alignment angle.
  • Accurate positioning of the suspension strut turret is necessary for subsequent alignment of the axle geometry.
  • Before resistance spot welding of body panels with a total panel thickness of 3 mm and greater, the welding equipment instructions contained in sub-section 501-25 must be followed.
  1. Outer side member with apron panel
    • Drill holes for puddle welding.

  1. Inner side member
    • Drill holes for puddle welding.

  1. NOTE:
    NOTE:In order to enable installation of the inner side member, a partial section needs to be cut out at the apron panel.
    Side member with fender apron panel
    • Cut points.

  1. NOTE:
    NOTE:Use a measuring and alignment system to ensure accurate positioning of the suspension strut turret.
    Mounting points for the suspension strut

  1. Bulkhead, inner
    • Apply PU glass adhesive to the NVH element.

  1. NOTE:
    NOTE:By drilling out the holes it is possible to weld all three layers of metal together.
    Bulkhead, inner
    • Drill out by one panel thickness.

  1. Bulkhead, inner
    • Puddle weld.

  1. NOTE:
    NOTE:In order to ensure that complete sealing is achieved, the remaining openings on the mounting tube for the instrument panel bracket need to be sealed with body sealant.
    Bulkhead, inner
    • Continuous MIG weld seam.

  1. Bulkhead crossmember
    • Puddle weld.

  1. Side member, bottom
    • Puddle weld.

  1. NOTE:
    NOTE:By drilling out the holes it is possible to weld all three layers of metal together.
    Apron panel
    • Drill out by one panel thickness.

  1. Apron panel
    • Puddle weld.

  1. Inner side member
    • Resistance spot weld.

  1. Suspension strut turret
    • Puddle weld.

  1. Suspension strut turret
    • Surface grind the MIG spot welds.

  1. Strut tower reinforcement
    • Drill holes for puddle welding (10 mm diameter).

  1. NOTE:
    NOTE:Working from the inside, insert the NVH element at the suspension strut turret reinforcement using PU window adhesive and secure it with the plastic clip.
    Strut tower reinforcement
    • Apply PU glass adhesive to the NVH element.

  1. Strut tower reinforcement
    1. Puddle weld.
    1. Resistance spot weld.

  1. NOTE:
    NOTE:Fit the longitudinal member flange plate using the straightening angle.
    Longitudinal member flange plate
    • Resistance spot weld.

  1. Longitudinal member flange plate
    • Resistance spot weld.

Front Side Member Section > < Fender Apron Panel Reinforcement