Outer A-Pillar Section Installation - Ar63.20-S-1102-03E

Model 447, 448

MODIFICATION NOTES

28.10.2021

Method extended.

Operation steps 24 up to 27

ADJUST GAP DIMENSIONS

Number	Designation				Model 447, 448 except code W64, W65, W68	Model 447, 448 with code W64, W65, W68
BE60.00-Z-1004-01KOJ	Adjust gap dimensions	Front door to longitudinal member	Dimension "DA"	mm	6 (+2/-1)	6 (+2/-1)
		Front door to sidewall	Dimension "DB"	mm	4 (±1)	4 (±1)
		Front door to sliding door	Dimension "DC"	mm	4 (+1, 2/-0, 8)	4 (+1, 2/-0, 8)
		Front door to A-pillar	Dimension "DD"	mm	4, 5 (+1, 5/-1)	4, 5 (+1, 5/-1)
		Front door to fuel filler door	Dimension "DE"	mm	4 (±1)	4 (±1)
		Front door to fuel filler door	For picture, see		AR60.00-S-0700-01E	AR60.00-S-0700-01E

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

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Fig 2: Identifying Feeler Gauge (129 589 03 21 00)

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Apply sealant to body (area A).

Model 447, 448 except code CN1 (Exterior rocker panel)
Install A-pillar outer section (1), fit and fix in place with welding devices and side portal frame.

Model 447, 448.8 with code CN1 (Exterior rocker panel)

Install A-pillar outer section (1) together with mounting rail (2) on longitudinal member panel, fit and fix A-pillar outer section (1) with welding device and side portal frame.

Fasten mounting rail (2) on longitudinal member panel with bolts (3).

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Model 447, 448.8 with code CN1 (Exterior rocker panel)
Tack weld A-pillar outer section (1) (area S).
Model 447, 448.8 with code CN1 (Exterior rocker panel)
Remove mounting rail (2) on longitudinal member panel.

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A-pillar outer section (1) (areas B to D).
A-pillar outer section (1) (area E).
Grind MIG spot welds down flat (area E).

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A-pillar outer section (1) (area F).
A-pillar outer section (1) (areas G to J).
A-pillar outer section (1) (area K).
Grind inert gas welds and inert gas spot welds down flat (areas G to K).

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A-pillar outer section (1) (area N).
A-pillar outer section (1) (areas L and M).
Inert gas weld in intervals and allow to cool down in between. Reduces heat distortion.
Grind inert gas welds and inert gas spot welds down flat (areas L to N).
Remove side portal frame and welding device.
Install door hinge straps (4) with front door, fit and fix in place.
Check gaps using feeler gauge and adjust.
Door hinge strap (4) (areas O and P).
Remove front door.
Door hinge strap (4) (areas Q and R).
Inert gas weld in intervals and allow to cool down in between. Reduces heat distortion.

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Clean all weld joints.
Restore surfaces on A-pillar outer section (1) and smooth.
Remove shavings and drill chips.

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Shown on MODEL 447.811
Model 447, 448.8 with code CN1 (Exterior rocker panel)
Position mounting rail (2) and align.
Model 447, 448.8 with code CN1 (Exterior rocker panel)
Transfer holes of mounting rail (2) to body.

Then remove mounting rail (2).
Model 447, 448.8 with code CN1 (Exterior rocker panel)
Drill and center punch holes (arrows).
Model 447, 448.8 with code CN1 (Exterior rocker panel)
Deburr holes and remove drill chips.