Separating outer side wall - AR63.10-P-0805-01PB

Fig 1: Identifying Spot Weld Cutter (201 589 00 51 00)

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1002-01A	Ball cutter, dia. 12 mm
WH58.30-Z-1006-01A	Vario Drill WS 91 spot weld removing tool
WH58.30-Z-1001-03A	Round wire brush, braided, dia. 70 mm
WH58.30-Z-1024-04A	Abrasive disk, dia. 115 mm, 80 m/s (max. 13,250 rpm)
WH58.30-Z-1004-20A	Hot-air gun

WORKSHOP EQUIPMENT

WE58.40-Z-1001-03A	Drill (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-1001-07A	Zinc dust paint suitable for spot welding	A 000 986 34 42

Fig 2: Identifying Separation Points On Outer Side Wall

Mark separation points and cut with body saw (areas A and B).
Do not damage outer side roof frame and longitudinal member below.

Fig 3: Identifying Outer Side Wall Spot Welds Area (1 Of 3)
Expose spot welds and cut out with spot weld cutter (areas F, G, J, K and O).

Fig 4: Identifying Outer Side Wall Spot Welds Area (2 Of 3)
Expose spot welds and cut out with spot weld cutter (areas C - E, I, L, M, N and H).
Expose spot welds and cut out with spot weld cutter (areas P and T).
Expose spot welds and cut out from inside of vehicle (area Q).
Expose spot welds and drill out with 7 mm dia. bit (area S).
Heat outer side wall in shaded areas with hot air blower.
Shaded areas are filled with foam.

Fig 5: Identifying Outer Side Wall Spot Welds Area (3 Of 3)
Remove outer side wall.
Grind connection surfaces down to bare metal in shaded areas. Grind spot welding flanges down to bare metal on both sides
Remove grinding and drilling chips using wet/dry vacuum cleaner.
Coat insides of spot welding flanges with zinc dust paint.

Fig 6: Identifying Outer Side Wall Spot Welding Flange Grinding Area