Replace complete A-pillar together with side longitudinal member - AR63.20-P-1150SX
MODEL 221 except CODE (Z07) Top protection
| Removing | |||
| Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding splatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes. | Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. | AS00.00-Z-0007-01A | |
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Risk of poisoning caused by inhaling vapors or swallowing adhesive. Risk of injury caused by adhesive coming into contact with skin and eyes | Wear respiratory protection, protective gloves and safety glasses. Pour adhesive into suitable and appropriately marked containers only. | AS00.00-Z-0016-01A | |
| Risk of injury caused by scraping or cutting body parts on sharp vehicle parts | Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels. |
AS00.00-Z-0017-01A | |
| General information on repair of vehicles with ultra-strength steels. | Failure to observe instructions when straightening/repairing, separating, preparing adhesive points, joining/connecting, resistance spot welding, MIG welding, MIG brazing can lead to considerable damage to ultra-strength steels and their joints. | AH60.00-P-0024-01N | |
| Measures for preventing damage to vehicles or components when performing electric welding work | AH00.00-N-0005-01A | ||
| General information on body repair | AH60.00-N-0001-01A | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| Notes on various body materials | AH60.00-P-0011-01SX | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 1 | Remove A-pillar outer section | AR63.20-P-1102SX | |
| 2 | Cover all detachable parts remaining in vehicle | Tarp (fire-resistant) | |
| 3 | Equip straightening bench with module members or crossmembers and straightening bracket set | Passenger car straightening system (Celette) Straightening system accessories (Celette) Straightening systems for passenger cars (Car Bench) Straightening system accessory (Car Bench) |
|
| 4 | Lift vehicle with two-post lift | Two-post lifting platform 3.0-3.5 t, electromechanical | |
| 5 | Remove stop plugs from jack support points | ||
| 6 | Set vehicle onto straightening bench | ||
| 7 | Fasten vehicle to straightening bench | ||
| 8 | Separate upper inner A-pillar (1), inner outer longitudinal member (2) and outer longitudinal member (3) | AR63.20-P-1150-01SX | |
Ball cutter, dia. 12 mm Vario Drill WS 91 spot weld removing tool BTR Usibor milling cutter, dia. 8X44 mm BTR Usibor drill bit, dia. 6.7 mm BTR Usibor milling cutter, dia. 8 mm BTR Usibor center punch, dia. 8X80 mm Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Cutting disk, Ø 65 mm, 80 m/s (max. 23, 500 rpm) Hot air gun - 3000 W Drill Straight grinder Angle grinder Body jig saw Wet/dry vacuum cleaner |
Fig 2 | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 9.1 | Separate upper firewall support (5), lower firewall support (6), A-pillar closing panel (7) and A-pillar support (8) | AR63.20-P-1100-12SX | |
Ball cutter, dia. 12 mm Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Hot air gun - 3000 W Drill Angle grinder Wet/dry vacuum cleaner |
Fig 2 | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 10 | Prepare upper inner A-pillar (1), inner outer longitudinal member (2) and outer longitudinal member (3) for installation | AR63.20-P-1150-06SX | |
Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Cutting disk, Ø 65 mm, 80 m/s (max. 23, 500 rpm) Drill Straight grinder Angle grinder Body jig saw |
Fig 2 | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 11.1 | Prepare upper firewall support (5), lower firewall support (6), A-pillar closing panel (7) and A-pillar support (8) for installation | Round wire brush, braided, dia. 70 mm Drill |
AR63.20-P-1100-13SX |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Install | |||
| 12.1 | Install welding device | ||
| With suspension strut installed | AR62.20-P-1286-05SX | ||
| With suspension strut removed | AR62.20-P-1286-05SY | ||
| Fig 5 | |||
| 13.1 | Install upper firewall support (5), lower firewall support (6), A-pillar closing panel (7) and A-pillar support (8) | Electrode miller Clamping pliers Round wire brush, braided, dia. 70 mm Inverter spot welder Drill Wet/dry vacuum cleaner |
AR63.20-P-1100-14SX |
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Adhesive | *BR00.45-Z-1092-02A | ||
| 14.1 | Remove welding device | ||
| 15 | Set up side portal frame with inspection and welding device | ||
| Fig 2 | |||
| Figure | |||
| 16 | Install upper inner A-pillar (1), inner outer longitudinal member (2), doubler panel (4) and outer longitudinal member (3) | AR63.20-P-1100-10SX | |
| Figure | |||
Electrode miller BTR Usibor drill bit, dia. 6.7 mm BTR Usibor center punch, dia. 8X80 mm C-clamps Clamping pliers Manual temporary fastener, Ø 6.4 mm, clamping area 0 to 15 mm, identification color silver Round wire brush, braided, dia. 70 mm Abrasive disk, dia. 115 mm, 80 m/s (max. 13, 250 rpm) Blind rivet/punch riveting method MIG MAG gas welder (steel, brazing, aluminum) Inverter spot welder Drill Angle grinder Wet/dry vacuum cleaner |
Figure | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Adhesive | *BR00.45-Z-1092-02A | ||
| Rivet | *BR00.45-Z-1001-13A | ||
| Rivet | *BR00.45-Z-1012-13A | ||
| 17 | Install A-pillar outer section | AR63.20-P-1102SX | |
| 18 | Remove side portal frame with inspection and welding device | ||
| 19 | Unfasten vehicle from straightening bench | ||
| 20 | Install stop plugs in jack support points | ||
| 21 | Lift vehicle with two-post lift | Two-post lifting platform 3.0-3.5 t, electromechanical | |
| 22 | Remove straightening bench. | ||
| 23 | Clean repair areas | ||
| 24 | Prime repair area using primer filler | ||
| 25 | Paint repair areas and adjacent surfaces | ||
| 26 | Carry out seam sealing after repairs | AR97.10-P-4000SX | |
| Sealant | *BR00.45-Z-1003-01A | ||
| Seam sealant, sprayable 310 ml | *BR00.45-Z-1041-01A | ||
| 27 | Apply additional cavity preservation | AR97.20-P-1500SX | |
| Notes on cavity preservation Combination pressure spray gun (corrosion protection) |
AH97.20-P-0001-01B | ||
| MB cavity wax preservation, 1 l | *BR00.45-Z-1003-05A | ||
| 28 | Remove tarp |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1003-01A | White sealing compound, 310 ml, DBL 6069.20 | A 001 989 63 20 |
| BR00.45-Z-1041-01A | Seam sealant, sprayable 310 ml | A 002 989 84 20 |
| BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |
| BR00.45-Z-1003-05A | Cavity sealant, solvent-free (1 l container) | A 000 986 72 70 05 |
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
| BR00.45-Z-1001-13A | Blind rivet 6.4X14 | A 003 990 35 97 |
| BR00.45-Z-1012-13A | Blind rivet 6.5X12.5 | A 004 990 16 97 |