Remove/Install B-Pillar Outer Section - Ar63.20-P-1121GQX
Model 166.8, 292
Shown on model 166.8
| 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 . | |
| Topical note | General information on body repair | AH60.00-N-0001-01A | |
| General information on MB materials | AH98.00-P-9409-03A . | ||
| Remove | |||
| 1 | Remove all detachable parts in area to be repaired | ||
| 2 | Cover all detachable parts remaining in vehicle with fire-resistant welding protection blanket | ||
| 3 | Equip straightening bench with module members, cross members and straightening tool set | ||
| 000 588 01 23 00 Body straightening system | WS60.00-P-0023K . | ||
| 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 . | |
| 4 | Place vehicle on straightening bench and fasten | ||
| 5 | Remove side wall paneling (1) and outer B-pillar (2) | AR63.20-P-1121-01GQX . | |
Wet/dry vacuum cleaner |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A . | ||
| 6 | Prepare side wall paneling (1) and outer B-pillar (2) for installation | AR63.20-P-1121-02GQX . | |
Round wire brush |
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| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A . | ||
| Install | |||
| 7 | Set up side portal frame with portal straightening set | ||
| 000 588 01 23 00 Body straightening system | WS60.00-P-0023K . | ||
| 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 | |
| 8 | Install side wall paneling (1) and outer B-pillar (2) and weld in | AR63.20-P-1121-03GQX . | |
| Topical note | 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 . | ||
| WS60.00-P-0010B . | |||
| WS60.00-P-0021K . | |||
| WS60.00-P-0022K . | |||
Wet/dry vacuum cleaner |
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| Gap dimension | *BE60.00-P-1001-01Z . | ||
| Zinc dust paint suitable for spot welding | *BR00.45-Z-1001-07A . | ||
| Blind rivet with polygrip countersunk head 6.4 X14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN) | *BR00.45-Z-1002-13A . | ||
| Blind rivet 6.5X12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A . | ||
| Blind rivet 6.5X14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1016-13A . | ||
| Flow-form rivet structure 4 mm up to 5.15 mm clamping range (S3) | *BR00.45-Z-1028-13A . | ||
| Flow-form rivet structure 3.35 mm up to 4.1 mm clamping range (S2) | *BR00.45-Z-1027-13A . | ||
| White sealing compound, 310 ml, DBL 6069.20 | *BR00.45-Z-1003-01A . | ||
| 9 | Remove side portal frame with portal straightening set | ||
| 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 . | |
| 10 | Release vehicle from straightening bench and remove straightening bench | ||
| 11 | Clean welds and sheet metal flanges | ||
| 12 | Remove fire-resistant welding blankets | ||
| 13 | Clean repair area | ||
| 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 . | |
| 14 | Prime repair area using primer filler | ||
| Topical note | Notes on paintwork repairs | AH98.00-P-9408-02A . | |
| 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 . | |
| 15 | Seal seam following repairs | AR97.10-P-4000GQ . | |
| Notes on sprayable joint sealant | AH97.10-P-0002-01A . | ||
| Notes on seam seal | AH97.10-P-0002-02A . | ||
| 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 . | |
| 16 | Paint repair areas and adjacent surfaces | ||
| Topical note | Notes on paintwork repairs | AH98.00-P-9408-02A . | |
| 17 | Add cavity preserving agent | AR97.20-P-1500GQ . | |
| 18 | Install detachable parts in area to be repaired |
TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS
| Number | Designation | Model 166 | Model 292 | |||
|---|---|---|---|---|---|---|
| BE60.00-P-1001-01Z | Gap dimension | Engine hood to fender | Dimension "A" | mm | 3, 8 (±1) | 3, 0 (±0, 5) |
| Engine hood to headlamp | Dimension "B" | mm | 3, 9 (±1) | 3, 5 (±1) | ||
| Engine hood to bumper | Dimension "C" | mm | 5, 4 (±1, 5) | 4, 5 (±1, 5) | ||
| Fender to A-pillar | Dimension "D" | mm | 3, 5 (±1) | 3, 0 (±0, 5) | ||
| Front door to fender | Dimension "E" | mm | 4, 3 (±0, 7) | 4, 0 (+1/-0, 5) | ||
| Front door to rear door | Dimension "F" | mm | 4, 8 (±0, 7) | 4, 5 (+1/-0, 5) | ||
| Rear door to rear fender | Dimension "I" | mm | 4, 3 (±0, 7) | 3, 5 (+1/-0, 5) | ||
| For picture, see | AR60.00-P-0700-01GQ . | AR60.00-P-0700-01GQ . | ||||
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 | Blind rivet with polygrip countersunk head 6.4X14 (clamping range 2 mm to 8.5 mm, draw-off strength min. 10.8 kN) | 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-1012-13A | Blind rivet 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 6.5X14.5 (clamping range 4 mm to 7 mm, draw-off strength min. 19 kN) | A 004 990 17 97 |
| BR00.45-Z-1027-13A | Flow-form rivet structure 3.35 mm up to 4.1 mm clamping range (S2) | A 000 991 10 33 |
| BR00.45-Z-1028-13A | Flow-form rivet structure 4 mm up to 5.15 mm clamping range (S3) | A 000 991 12 33 |