Weld in inner section and console - AR63.20-P-1100-04P

Fig 1: Identifying Side Portal Frame (210 589 17 23 00)

Fig 2: Identifying Check And Welding Device (203 589 00 23 00)

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1003-01A	Electrode miller
WH58.30-Z-1003-02A	Clamping pliers
WH58.30-Z-1031-02A	C-clamp
WH58.30-Z-1001-03A	Round wire brush, braided, dia. 70 mm
WH58.30-Z-1021-04A	Cutting disk, dia. 65 mm, 80 m/s (max. 23,500 rpm)
WH58.30-Z-1024-04A	Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)

WORKSHOP EQUIPMENT

WE58.40-Z-1001-02A	Inert gas welder
WE58.40-Z-1002-02A	Spot welder
WE58.40-Z-1001-03A	Drill (electric/pneumatic)
WE58.40-Z-1002-03A	Straight grinder (electric/pneumatic)
WE58.40-Z-1003-03A	Angle grinder (electric/pneumatic)
WE58.40-Z-1004-03A	Body saw (electric/pneumatic)
WE58.40-Z-1005-03A	Wet/dry vacuum cleaner

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1003-01A	Sealant	A 001 989 63 20
BR00.45-Z-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42

Fig 3: Identifying Inner A-Pillar Spot Welds Area

1. Fit inner A-pillar, fasten with check and welding device and clamping pliers.
2. inner A-pillar (area N).
   Fig 4: Identifying Inner A-Pillar And Wheelhouse Spot Welds Area (1 Of 2)

   
3. inner A-pillar and wheelhouse (areas L and O)
4. inner A-pillar and wheelhouse (areas J, K, T and X).
5. inner A-pillar and upper A-pillar inner section (area V).
6. inner A-pillar and main floor (area I).
   Fig 5: Identifying Inner A-Pillar And Wheelhouse Spot Welds Area (2 Of 2)

   
7. inner A-pillar and wheelhouse (areas H and M).
8. Fit bottom front reinforcement and fasten with clamping pliers and C-clamps.
9. bottom front reinforcement (area W).
10. bottom front reinforcement (area W).
    Fig 6: Identifying Bottom Front Reinforcement Spot Welds Area

    
11. Clean welds with wire brush and apply zinc dust paint.
12. Fit upper front reinforcement and fasten with clamping pliers.
13. upper front reinforcement (areas R)
14. upper front reinforcement (area A).
    Fig 7: Identifying Upper Front Reinforcement Spot Welds Area

    
15. Clean connection surfaces in shaded areas with wire brush and coat with zinc dust paint.
    Fig 8: Identifying Connection Surfaces

    
    Fig 9: Identifying Spacer Plate

    
16. Fit A-pillar reinforcement, fasten with check and welding device and tighten.

    Use spacer plate.

    Fig 10: Identifying A-Pillar Reinforcement Spot Welds Area (1 Of 4)

    
17. A-pillar reinforcement (areas E and I).
18. A-pillar reinforcement (areas Y).
19. A-pillar reinforcement (area C).
20. A-pillar reinforcement (area S).
21. A-pillar reinforcement (area D).
    Fig 11: Identifying A-Pillar Reinforcement Spot Welds Area (2 Of 4)

    
22. A-pillar reinforcement (area G).
23. A-pillar reinforcement (area F).
    Fig 12: Identifying A-Pillar Reinforcement Spot Welds Area (3 Of 4)

    
24. A-pillar reinforcement (area M).
    Fig 13: Identifying A-Pillar Reinforcement Spot Welds Area (4 Of 4)

    
25. Clean connection surfaces in shaded areas with wire brush.
26. Coat connection surfaces with zinc dust paint (area S).
    Fig 14: Identifying Connection Surfaces (1 Of 2)

    
    Fig 15: Identifying Connection Surfaces (2 Of 2)

    
27. Clean connection surfaces in shaded areas with wire brush.
28. Coat connection surfaces with zinc dust paint (area C).