Illustrations mostly show a bare bodyshell. All flammable components and
those easly damaged by heat must be removed or covered over.
Take off the engine compartment lid 41 61 000.
Take off both front side panels 41 35 040.
Drill away the spot welds.


41 61 000

Using a pneumatic chisel, separate the spot weld seams between the front
panel and the wheel arches.

Separate the spot welds between the front panel and the engine mountings
with the pneumatic chisel.
Take off the front panel.

Split the weld seam at the battery tray and front panel joint.

Remove traces of old metal.
Align the joint areas and grind to a bright finish on either side.

Grind all contact areas on the new front panel to a bright finish.

Offer up the front panel to the body.
Insert the metal tongues on the front panel below the wheel arch, and the metal
tongues on the wheel arch between the sheet metal sections of the front panel.

Use a jack to press the front panel carefully against both engine mountings.
Center the front panel until the front bumper mountings pass freely through the
cutouts.
Tack weld the front panel to the engine mountings with inert gas welding
equipment.

Hold the front panel and the wheel arches together with screw clamps, and
tack weld with the inert gas welding equipment.

Check position by measuring both diagonals between the upper spring /
damper strut mountings and the front corners of the front panel.

Spot weld the front panel to the wheel arches.

Weld the wheel arches to the front panel using the inert gas method.

Weld the engine mountings to the front panel with inert gas equipment.

Weld the front panel to the battery tray.