Partially replace side longitudinal member paneling - AR63.30-P-1040LF
MODEL 205
MODEL 222
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 | |
| 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 | ||
| Notes on processing of 2-K structural foam adhesive during body repairs | AH60.00-P-0040-01A | ||
| Evaluation of high-voltage components | AH54.00-P-6500-01SXH | ||
| Notes on acoustic foam and structural foam in the vehicle | AH60.00-P-0039-01A | ||
| Notes on foam-protected insulation in body | AH60.00-P-0041-01A | ||
| General information on body repair | AH60.00-P-0001-01A | ||
| 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 | Partially remove side longitudinal member paneling (1) | AR63.30-P-1040-01LF | |
Round wire brush Body power jigsaw Spot weld milling machine Heat gun Wet/dry vacuum cleaner |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 4 | Prepare side longitudinal member (1) | AR63.30-P-1040-02LF | |
Round wire brush Body power jigsaw |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| 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 | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| 5 | Install side longitudinal member paneling (1) | ||
| WS60.00-P-0022K | |||
| WS60.00-P-0021K | |||
| AR63.30-P-1040-03LF | |||
| WS60.00-P-0010B | |||
| 000 588 01 84 00 Welder | WS60.00-P-0021K | ||
Round wire brush Manual temporary fastener, 6.35 mm Wet/dry vacuum cleaner |
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| 2-component adhesive for reinforcements | *BR00.45-Z-1152-02A | ||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A | ||
| Blind rivet 6.4 X 12 (clamping range 1 mm to 3.5 mm) | *BR00.45-Z-1035-13A | ||
| 6 | Clean welds and sheet metal flange | Round wire brush |
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| 7 | Remove spark protection blankets | ||
| 8 | Clean repair area | Wet/dry vacuum cleaner |
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| 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 | |
| 9 | Prime repair area using primer filler | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 10 | Carry out seam sealing after repairs | Model 205 | AR97.10-P-4000LW |
| Model 222 | 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 | |
| 11 | Paint repair areas and adjacent surfaces | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A | ||
| 12 | Apply additional cavity preservation | Model 205 | AR97.20-P-1500LW |
| Model 222 | AR97.20-P-1500LF | ||
| 13 | Install all detachable body components in area to be repaired |
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-1035-13A | Blind rivet 6.4 X 12 (clamping range 1 mm to 3.5 mm) | A 000 991 76 32 |
| BR00.45-Z-1152-02A | 2-component adhesive for reinforcements | A 011 989 99 71 |
| BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |