Completely replace A and B-pillar with longitudinal member - AR63.20-P-1120LF
MODEL 222
except code Z07 (Top protection)
Shown on MODEL 222.0
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| 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 | |
| Risk of death when touching components on vehicles with high-voltage on-board electrical system | Do not touch components and open lines of the high-voltage on-board electrical system. Persons who wear electronic implants (e.g. cardiac pacemakers), must not carry out any work on high-voltage on-board electrical systems. | AS54.00-Z-0001-01A | |
| Risk of explosion from aluminum grinding dust, risk of injury to respiratory system from inhaling dust | Wear dust filter mask, safety glasses and protective gloves. Use a suitable, grounded dust extraction system. |
AS60.00-Z-0007-01N | |
| Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | ||
| Note on high-voltage on-board electrical system | AH54.00-P-0010-01A | ||
| Note on high-voltage battery | AH54.10-P-0006-01MEV | ||
| Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | ||
| General information on repair of vehicles with ultra-strength steels. | AH60.00-P-0024-01N | ||
| Evaluation of high-voltage components | AH54.00-P-6500-01SXH | ||
| General information on body repair | AH60.00-P-0001-01A | ||
| Notes on acoustic foam and structural foam in the vehicle | AH60.00-P-0039-01A | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| Remove | |||
| 1 | Remove detachable parts in area to be repaired | ||
| 2 | Cover all detachable parts remaining in vehicle with spark protection blanket | ||
| 3 | Remove center roof paneling | Model 222 except code 413 (Automatic panoramic sliding sunroof) except code Z07 (Top protection) |
AR65.10-P-1000LF |
| 4 | Remove reinforcement for panoramic sliding roof | Model 222 with code 413 (Automatic panoramic sliding sunroof) except code Z07 (Top protection) |
|
| 5 | Remove upper front longitudinal member (4) and strut (5) | AR62.20-P-1286-01LF | |
| 000 588 02 39 00 Rivet press tool | WS60.00-P-0010B | ||
Torx EPL 12 Round wire brush Spot weld milling machine Body power jigsaw Drill bits and milling cutters for high-strength steels Aluminum tools Specific tools for working on aluminum bodies Heat gun Wet/dry vacuum cleaner |
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| 6 | Set up straightening bench with module members, crossmembers and straightening bracket set | ||
| 000 588 01 23 00 Body straightening system | WS60.00-P-0023K | ||
| 7 | Place vehicle on straightening bench and fasten | ||
| 8 | Remove A and B-pillar paneling (1.1), roof frame paneling (1.2), side longitudinal member paneling (1.3), A and B-pillar reinforcement (2), A-pillar inner panel (3.1), roof frame inner panel (3.2) and B-pillar inner panel (3.3) | AR63.20-P-1120-01LF | |
| 000 588 02 39 00 Rivet press tool | WS60.00-P-0010B | ||
Round wire brush Body power jigsaw Spot weld milling machine Metal needle template Heat gun Drill bits and milling cutters for high-strength steels Glass removal Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding |
*BR00.45-Z-1001-07A | ||
| Primer stick | *BR00.45-Z-1012-07A | ||
| 9 | Prepare A and B-pillar paneling (1.1), roof frame paneling (1.2), side longitudinal member paneling (1.3), A and B-pillar reinforcement (2), A-pillar inner panel (3.1), roof frame inner panel (3.2) and B-pillar inner panel (3.3) | AR63.20-P-1120-02LF | |
Round wire brush Body power jigsaw Zinc dust paint suitable for spot welding |
*BR00.45-Z-1001-07A | ||
| 10 | Prepare upper front longitudinal member (4) and strut (5) | AR62.20-P-1286-02LF | |
Round wire brush |
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| Install | |||
| The high voltage used for electric welding presents a lethal hazard. Risk of explosion from welding in areas close to highly inflammable materials. Risk of injury from weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases | Use insulating mats. Wear protective clothing, safety glasses and a protective mask. Remove highly flammable materials from the hazard area. Use air extraction 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 | |
| Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | ||
| Notes on processing of 2-K structural foam adhesive during body repairs | AH60.00-P-0040-01A | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| 11 | Install A and B-pillar paneling (1.1), roof frame paneling (1.2), side longitudinal member paneling (1.3), A and B-pillar reinforcement (2), A-pillar inner panel (3.1), roof frame inner panel (3.2) and B-pillar inner panel (3.3) | AR63.20-P-1120-03LF | |
| 000 588 02 39 00 Rivet press tool | WS60.00-P-0010B | ||
| 000 588 01 84 00 Welder | WS60.00-P-0021K | ||
| 000 588 02 84 00 Welder | WS60.00-P-0022K | ||
| 000 588 01 23 00 Body straightening system | WS60.00-P-0023K | ||
Round wire brush Drill bit for high-strength steels Manual temporary fastener, 6.35 mm Specific tools for working on aluminum bodies Wet/dry vacuum cleaner White sealing compound, 310 ml, DBL 6069.20 |
*BR00.45-Z-1003-01A | ||
| Adhesive kit, body, 2-component adhesive | *BR00.45-Z-1092-02A | ||
| Cleaner | *BR00.45-Z-1025-04A | ||
| 2-component adhesive for reinforcements | *BR00.45-Z-1152-02A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Polygrip countersunk-head rivet, 6.4x14 | *BR00.45-Z-1002-13A | ||
| Blind rivet 6.5x12.5 | *BR00.45-Z-1012-13A | ||
| Blind rivet, 6.5 x 14.5 | *BR00.45-Z-1016-13A | ||
| Flow-form rivet structure up to 3.5 mm clamping range (S1) | *BR00.45-Z-1026-13A | ||
| Blind rivet 6.4x12 (clamping range 1 mm to 3.5 mm) | *BR00.45-Z-1035-13A | ||
| Figure | |||
| 12 | Release vehicle from straightening bench, lift vehicle and remove straightening bench | ||
| 13 | Clean welds and sheet metal flange | Round wire brush |
|
| 14 | Install reinforcement for panoramic sliding roof | Model 222 with code 413 (Automatic panoramic sliding sunroof) except code Z07 (Top protection) |
|
| 15 | Remove spark protection blankets | Model 222 with code 413 (Automatic panoramic sliding sunroof) except code Z07 (Top protection) |
|
| 16 | Clean repair area | Model 222 with code 413 (Automatic panoramic sliding sunroof) except code Z07 (Top protection) Wet/dry vacuum cleaner |
|
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 17 | Prime repair area using primer filler | Model 222 with code 413 (Automatic panoramic sliding sunroof) except code Z07 (Top protection) |
|
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 18 | Carry out seam sealing after repairs | Model 222 with code 413 (Automatic panoramic sliding sunroof) except code Z07 (Top protection) |
AR97.10-P-4000LF |
| Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. | No smoking! No open fire! Use respiratory protection, protective clothing, gloves, safety glasses and protective skin cream. Ensure that the area is well ventilated. | AS98.00-Z-0002-01A | |
| 19 | Paint repair areas and adjacent surfaces | Model 222 with code 413 (Automatic panoramic sliding sunroof) except code Z07 (Top protection) |
|
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 20 | Apply additional cavity preservation | Model 222 with code 413 (Automatic panoramic sliding sunroof) except code Z07 (Top protection) |
AR97.20-P-1500LF |
| 21 | Install detachable parts in area to be repaired | Model 222 with code 413 (Automatic panoramic sliding sunroof) except code Z07 (Top protection) |
|
| 22 | Install center roof paneling | Model 222 except code 413 (Automatic panoramic sliding sunroof) except code Z07 (Top protection) |
AR65.10-P-1000LF |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
| BR00.45-Z-1002-13A | Polygrip countersunk-head rivet, 6.4x14 | A 003 990 86 97 05 |
| BR00.45-Z-1003-01A | White sealing compound, 310 ml, DBL 6069.20 | A 001 989 63 20 |
| BR00.45-Z-1012-07A | Primer stick | A 000 986 27 50 |
| BR00.45-Z-1012-13A | Blind rivet 6.5x12.5 | A 004 990 16 97 |
| BR00.45-Z-1016-13A | Blind rivet, 6.5 x 14.5 | A 004 990 17 97 |
| BR00.45-Z-1025-04A | Cleaner | A 005 989 19 71 |
| BR00.45-Z-1026-13A | Flow-form rivet structure up to 3.5 mm clamping range (S1) | A 000 991 11 33 |
| BR00.45-Z-1035-13A | Blind rivet 6.4x12 (clamping range 1 mm to 3.5 mm) | A 000 991 76 32 |
| BR00.45-Z-1092-02A | Adhesive kit, body, 2-component adhesive | A 009 989 36 71 |
| BR00.45-Z-1152-02A | 2-component adhesive for reinforcements | A 011 989 99 71 |