Side Longitudinal Member Removal And Installation - Ar63.30-P-0800RG
Model 190
Shown on model 190.3
| 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 | |
| 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 | |
| Notice | General information on body repair | AH60.00-P-0001-01S | |
| Notice | General information on crack diagnosis of aluminum parts | AH60.00-P-0014-01N | |
| Notice | Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | |
| Note on working on aluminum components and vehicles | AH60.00-P-0034-01RG | ||
| Remove | |||
| 1 | Prepare all workshop equipment and commercially available devices/tools required for the repair. | ||
| 2 | Remove detachable parts in area of repair points. | ||
| 3 | Cover all detachable parts that remain in the vehicle with fire-resistant welding protection blankets. | ||
| 4 | Set up straightening bench with module members, crossmembers, and straightening set. | ||
| 5 | Place vehicle on straightening bench and fasten. | ||
| 6 | Remove A-pillar outer section. | AR63.20-P-1102RG | |
| 7 | Remove entire B-pillar. | AR63.20-P-1350RG | |
| 8.1 | Remove complete side roof paneling. | Model 190.3 | AR65.10-P-1020RG |
| 8.2 | Remove outer paneling of upper A-pillar. | Model 190.4 | AR63.20-P-1105RGR |
| 9 | Remove main floor. | AR63.40-P-1180-09RG | |
| 000 588 15 84 00 Heat gun | Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner |
WS54.00-P-0125B | |
| 10 | Remove A-pillar reinforcement. | AR63.20-P-1110-01RG | |
| 000 588 15 84 00 Heat gun | WS54.00-P-0125B | ||
| 000 588 04 39 00 Rivet press tool | Vacuum unit suitable for aluminum dusts Round wire brush Spot weld milling machine Drill bit and milling cutter for ultra-high-strength steels Hand drill Body saw Wet/dry vacuum cleaner |
WS60.00-P-0440B | |
| 11 | Remove side longitudinal member (1). | AR63.30-P-0800-01RG | |
| 000 588 15 84 00 Heat gun | WS54.00-P-0125B | ||
| 000 588 04 39 00 Rivet press tool | Vacuum unit suitable for aluminum dusts Round wire brush Spot weld milling machine Drill bit and milling cutter for ultra-high-strength steels Hand drill Body saw Wet/dry vacuum cleaner |
WS60.00-P-0440B | |
| Preparation | |||
| 12 | Prepare new side longitudinal member part (1) for installation. | Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Body saw Wet/dry vacuum cleaner |
AR63.30-P-0800-02RG |
| 13 | Prepare new A-pillar reinforcement part for installation. | Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner |
AR63.20-P-1110-03RG |
| 14 | Prepare new main floor part for installation. | Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner |
AR63.40-P-1180-10RG |
| 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 inflammable 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 | |
| Notice | Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | |
| General notes on welding | AH60.00-P-0005-01N | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| 15 | Install new side longitudinal member part (1). | AR63.30-P-0800-03RG | |
| 000 588 04 39 00 Rivet press tool | WS60.00-P-0440B | ||
| 000 588 12 84 00 Welder | Vacuum unit suitable for aluminum dusts Round wire brush Drill bit for ultra-high-strength steels Hand drill Manual temporary fastener 6.35 mm Wet/dry vacuum cleaner |
WS00.00-P-0318K | |
| *BE60.00-P-1007-01EA | |||
| *BE60.00-P-1008-01EA | |||
| *BE60.00-P-1009-01EA | |||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| Blind rivet Y7 6.4x14 (clamping range 2.6 mm to 6 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1045-13A | ||
| Blind rivet Y8 6.4x17 (clamping range 4.5 mm to 7 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1046-13A | ||
| Flow-form rivet structure 7.1 mm up to 8.3 mm clamping range (S68) | *BR00.45-Z-1054-13A | ||
| Fig 2 | |||
| 16 | Install new A-pillar reinforcement part. | AR63.20-P-1110-04RG | |
| 000 588 04 39 00 Rivet press tool | WS60.00-P-0440B | ||
| 000 588 12 84 00 Welder | Vacuum unit suitable for aluminum dusts Round wire brush Drill bit for ultra-high-strength steels Hand drill Manual temporary fastener 6.35 mm Wet/dry vacuum cleaner |
WS00.00-P-0318K | |
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| Blind rivet Y7 6.4x14 (clamping range 2.6 mm to 6 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1045-13A | ||
| Flow-form rivet structure 5.0 mm up to 6.1 mm clamping range (S48) | *BR00.45-Z-1052-13A | ||
| Flow-form rivet structure 7.1 mm up to 8.3 mm clamping range (S68) | *BR00.45-Z-1054-13A | ||
| 17 | Install main floor. | AR63.40-P-1180-11RG | |
| 000 588 04 39 00 Rivet press tool | Vacuum unit suitable for aluminum dusts Round wire brush Drill bit for ultra-high-strength steels Hand drill Manual temporary fastener 6.35 mm Wet/dry vacuum cleaner |
WS60.00-P-0440B | |
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| Blind rivet Y2 6.5x12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A | ||
| Blind rivet Y3 6.5x14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1016-13A | ||
| 18.1 | Install complete side roof paneling. | Model 190.3 | AR65.10-P-1020RG |
| 18.2 | Install upper A-pillar outer paneling. | Model 190.4 | AR63.20-P-1105RGR |
| 19 | Install entire B-pillar. | AR63.20-P-1350RG | |
| 20 | Install A-pillar outer section. | AR63.20-P-1102RG | |
| 21 | Release vehicle from straightening bench, lift and remove straightening bench. | ||
| Clean | |||
| 22 | Clean weld joints and sheet metal flange. | Vacuum unit suitable for aluminum dusts Round wire brush Hand drill Wet/dry vacuum cleaner |
|
| 23 | Remove fire-resistant welding protection blankets. | ||
| 24 | Clean repair area. | Wet/dry vacuum cleaner |
|
| Paint | |||
| 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 | |
| Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents | Never spray corrosion protection on flames or hot, glowing objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection. | AS97.00-Z-0001-01A | |
| Notice | Notes on cavity preservation | AH97.20-P-0001-01B | |
| Notice | Notes on sprayable joint sealant | AH97.10-P-0002-01A | |
| Notice | Notes on paintwork repairs | AH98.00-P-9408-02A | |
| General information on operation items and work procedures for painting | AH98.00-P-0003-01A | ||
| Notes on seam seal | AH97.10-P-0002-02A | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| 25 | Prime repair areas with a primer filler. | ||
| 26 | Perform seam sealing after repair. | AR97.10-P-4000RG | |
| 27 | Paint repair areas and adjacent surfaces. | ||
| 28 | Supplement cavity preservation. | AR97.20-P-1500RG | |
| Assemble | |||
| 29 | Install detachable parts in the area of the repair point. |
GAP DIMENSIONS
| Number | Designation | Model 190.3 | Model 190.4 | ||
|---|---|---|---|---|---|
| BE60.00-P-1007-01EA | Gap dimension, fender to door paneling | Dimension "G" | mm | 4 (±0, 5) | 4 (±0, 5) |
| See | AR60.00-P-0700-01RG | AR60.00-P-0700-01RG | |||
GAP DIMENSIONS
| Number | Designation | Model 190.3 | Model 190.4 | ||
|---|---|---|---|---|---|
| BE60.00-P-1008-01EA | Gap dimension, sidewall panel to door paneling | Dimension "H" | mm | 3, 5 (±0, 5) | 3, 5 (±0, 5) |
| See | AR60.00-P-0700-01RG | AR60.00-P-0700-01RG | |||
GAP DIMENSIONS
| Number | Designation | Model 190.3 | Model 190.4 | ||
|---|---|---|---|---|---|
| BE60.00-P-1009-01EA | Gap dimension, longitudinal member panel to fender/sidewall panel | Dimension "I" | mm | 0 (+0, 5) | 0, 5 (±0, 5) |
| See | AR60.00-P-0700-01RG | AR60.00-P-0700-01RG | |||
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| BR00.45-Z-1012-13A | Blind rivet Y2 6.5x12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | A 004 990 16 97 |
| BR00.45-Z-1016-13A | Blind rivet Y3 6.5x14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | A 004 990 17 97 |
| BR00.45-Z-1045-13A | Blind rivet Y7 6.4x14 (clamping range 2.6 mm to 6 mm, draw-off strength min. 15.5 kN) | A 000 991 55 32 |
| BR00.45-Z-1046-13A | Blind rivet Y8 6.4x17 (clamping range 4.5 mm to 7 mm, draw-off strength min. 15.5 kN) | A 000 991 53 32 |
| BR00.45-Z-1052-13A | Flow-form rivet structure 5.0 mm up to 6.1 mm clamping range (S48) | A 000 991 27 33 |
| BR00.45-Z-1054-13A | Flow-form rivet structure 7.1 mm up to 8.3 mm clamping range (S68) | A 000 991 29 33 |
| BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |