Replace B-pillar with side longitudinal member - AR63.20-P-0550SC
MODEL 216
| 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 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 | |
| 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 | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| 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 | |
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| Notes on various body materials | AH60.00-P-0011-01SX | ||
| General information on body connection techniques | AH60.00-P-0015-01SX | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 1 | Remove detachable parts in repair area and cover all remaining detachable parts remaining in the vehicle using a tarp (fire-resistant) | Tarpaulin (fire-proof) | |
| 2 | Remove rear fender | AR63.50-P-1400SC | |
| 3 | Set up straightening bench with straightening bracket set and attach vehicle | For set-up plans. |
|
| 4 | Separate B-pillar with side longitudinal member | Metal needle template. For BTR Usibor milling cutter. |
AR63.20-P-0550-01SC |
| 5 | Prepare B-pillar with side longitudinal member for installation | Metal needle template. |
AR63.20-P-0550-04SC |
| Install | |||
| 6 | Install side portal frame | ||
| *210589172300 | |||
| *216589002300 | |||
For set-up plans. |
*221589002300 | ||
| 7 | Install and weld in B-pillar with side longitudinal member | Observe setup plans. For set-up plans. |
AR63.20-P-0550-03SC |
| Adjust gap dimensions on hoods, doors and lids | AR60.00-P-0700-01SC | ||
| Front door to rear fender | *BE60.00-P-1002-01T | ||
| Trunk lid to upper rear fender, trunk lid to taillamp, rear fender to taillamp | *BE60.00-P-1003-01T | ||
| Fuel filler flap | *BE60.00-P-1004-01T | ||
| *129589032100 | |||
Metal needle template. For BTR-Usibor drill bit, dia. 6.7 mm. For MIG-MAG inert gas welder. For blind rivet tool 571110. Notes on brazing material. |
*221589002300 | ||
| Rivet | *BR00.45-Z-1001-13A | ||
| Adhesive | *BR00.45-Z-1092-02A | ||
| Rivet | *BR00.45-Z-1012-13A | ||
| Rivet | *BR00.45-Z-1016-13A | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| 8 | Remove side portal frame with check and welding devices | *210589172300 | |
| *216589002300 | |||
| *221589002300 | |||
| 9 | Install rear fender | AR63.50-P-1400SC | |
| 10 | Loosen vehicle and remove from straightening bench | ||
| 11 | Clean repair areas and prime using primer filler | ||
| 12 | Carry out seam sealing after repairs | AR97.10-P-4000SX | |
| 13 | Paint repair areas and adjacent surfaces | AR98.00-P-0150SX | |
| 14 | Apply additional cavity preservation | AR97.20-P-1500SC | |
| 15 | Remove tarp (fire-resistant) and install all detachable parts in the area of repair point |
CHECK VALUES FOR GAPS
| Number | Designation | Model 216 up to model year 2011 | Model 216 as of model year 2011 | |||
|---|---|---|---|---|---|---|
| BE60.00-P-1002-01T | Gap dimension | Front door to fender | Dimension "E" | mm | 4.0 (±0.5) | 4.0 (±0.5) |
| Front door to rear fender | Dimension "F" | mm | 4.0 (±0.5) | 4.0 (±0.5) | ||
| Front fender to A-pillar | Dimension "G" | mm | 3.5 (±0.5) | 3.5 (±0.5) | ||
| Front fender to headlamp | Dimension "H" | mm | 3.5 (±0.5) | 3.5 (±0.5) | ||
| See picture | AR60.00-P-0700-01SC | AR60.00-P-0700-01SC | ||||
| BE60.00-P-1003-01T | Gap dimension | Trunk lid to rear fender, top | Dimension "J" | mm | 3.5 (±0.8) | 3.5 (±0.8) |
| Trunk lid to rear lamp unit | Dimension "K" | mm | 3.5 (±0.8) | 3.5 (±0.8) | ||
| Trunk lid to bumper | Dimension "L" | mm | 5, 5 (±1.5) | 5, 5 (±1.5) | ||
| Rear fender to rear lamp unit | Dimension "M" | mm | 2.5 (±0.5) | 2.5 (±0.5) | ||
| See picture | AR60.00-P-0700-01SC | AR60.00-P-0700-01SC | ||||
| BE60.00-P-1004-01T | Gap dimension | Fuel filler flap | Dimension "O" | mm | 3.0 (±0.5) | 3.0 (±0.5) |
| See picture | AR60.00-P-0700-01SC | AR60.00-P-0700-01SC | ||||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1001-13A | Blind rivet 6.4 X14 | A 003 990 35 97 |
| BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |
| BR00.45-Z-1012-13A | Blind rivet 6.5 X12.5 | A 004 990 16 97 |
| BR00.45-Z-1016-13A | Blind rivet, 6.5 x 14.5 | A 004 990 17 97 |