Install Longitudinal Member Outer Shell On Entrance - Ar63.30-P-1102-03LF

Model 222.0 

Model 222.1/9 

except code Z07 (B7 armoring on special protection version) 

The following steps are shown on the left side of the vehicle and must be accomplished analogously on the right side in the event of damage.

When using Celette straightening system, also use anchoring set 9212.013.

Install adjustable fastening brackets with following dimensions:

• front: x = 45 mm, y = 44 mm, z = 77 mm (on upper alignment hole), z = 62 mm (on lower alignment hole)
• rear: x = 100 mm, y = 44 mm, z = 77 mm (on upper alignment hole), z = 62 mm (on lower alignment hole)

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Shown on model 222.0 

1. Install longitudinal member outer shell (1) with straightening tool, fit and fix in place.
2. Drill Ø 6.7 mm rivet holes in longitudinal member outer shell (1).
3. Remove straightening tool and longitudinal member outer shell (1).
4. Deburr rivet holes on longitudinal member outer shell (1) and body on both sides.
5. Remove drilling chips.

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   Shown on model 222.0 

6. Apply 2-component adhesive to body in crosshatched areas (areas A₁ ).

   Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

7. Apply sealant to foam parts in crosshatched areas (areas A₂ ).

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   Shown on model 222.0 

8. Install longitudinal member outer shell (1) with straightening tool, fit and fix in place.
9. Rivet longitudinal member outer shell (1) with Ø 6.5x12.5 (area B₂ ).
10. Longitudinal member outer shell (1) (areas B1).

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    Shown on model 222.0 

11. Longitudinal member outer shell (1) (areas C).
12. Longitudinal member outer shell (1) (area D).
13. Install outer A-pillar bottom section (2), fit and fix in place.
14. Drill Ø 6.7 mm rivet holes in outer A-pillar bottom section (2).
15. Remove outer A-pillar bottom section (2).
16. Deburr rivet holes on outer A-pillar bottom section (2) and body on both sides.
17. Remove drilling chips.
18. Coat insides of riveted joints with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (area D₂ ).

    Otherwise adhesion problems may occur.

    Shown on model 222.0 

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19. Apply sealant to contact surface on foam part (7) on longitudinal member outer shell (1).
20. Insert foam part (7) and apply sealant to foam part (7).
21. Clean contact surface on structured foam part (3) on longitudinal member outer shell (1), apply 2-component adhesive for reinforcements to longitudinal member outer shell (1) and insert structured foam part (3).

    Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive for reinforcements.

    Shown on model 222.0 

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22. Apply 2-component adhesive for reinforcements on structured foam part (3).

    Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive for reinforcements.

23. Apply 2-component adhesive to longitudinal member outer shell (1) in crosshatched area (area E).

    Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

24. Install outer A-pillar bottom section (2) and fix in place.
25. Rivet outer A-pillar bottom section (2) with Ø 6.5x14.5 rivets (area F₁ ).
26. Rivet outer A-pillar bottom section (2) with Ø 6.5x12.5 rivets (areas F₂ ).
27. Outer A-pillar bottom section (2) (area G).

    Shown on model 222.0 

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28. Outer A-pillar bottom section (2) (area H).

    Inert gas weld in intervals and allow to cool down in between. Reduces heat distortion.

29. Grind inert gas weld down flat (area H).

    Grind down flat only on beaded areas and contact areas of longitudinal member paneling.

30. Clean inert gas welds no longer accessible after installing longitudinal member paneling and coat with zinc dust paint (area H).

    Shown on model 222.0 

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31. Install B-pillar support (3), fit and fix in place.
32. Mark rivet holes on B-pillar support (3).

    Dimensions: 

    a₁ = 12 mm

    a₂ = 19 mm

    b₁ =12 mm

    b₂ =32 mm

    c₁ = 16 mm

    c₂ = 51 mm

    d₁ = 21 mm

    d₂ = 81 mm

    Shown on model 222.0 

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33. Model 222.0

    Model 222.1

    except code Z07 (B7 armoring on special protection version) Drill Ø 6.7 mm rivet holes in B-pillar support (3) (areas I₁ , I₂ and I₃ ).

34. Model 222.0

    Model 222.1

    except code Z07 (B7 armoring on special protection version) Remove B-pillar support (3).

35. Model 222.0

    Model 222.1

    except code Z07 (B7 armoring on special protection version) Deburr rivet holes on B-pillar support (3) and body on both sides.

36. Model 222.0

    Model 222.1

    except code Z07 (B7 armoring on special protection version) Remove drilling chips.

    Shown on model 222.0 

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37. Model 222.0

    Model 222.1

    except code Z07 (B7 armoring on special protection version) Apply sealant to contact surfaces on foam parts (8) to longitudinal member outer shell (1).

38. Model 222.0

    Model 222.1

    except code Z07 (B7 armoring on special protection version) Insert foam parts (8) and apply sealant to foam parts (8).

39. Model 222.0 Model 222.1

    except code Z07 (B7 armoring on special protection version) Apply 2-component adhesive to outer longitudinal member (1) in cross-hatched areas.

    Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

    Shown on model 222.0 

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40. Model 222.0

    Model 222.1

    except code Z07 (B7 armoring on special protection version) Install B-pillar support (3) and fix in place.

41. Model 222.0

    Model 222.1

    except code Z07 (B7 armoring on special protection version) Rivet B-pillar support (3) with Ø 6.5x12.5 rivets (areas K₁ and K₂ ).

42. Model 222.0

    Model 222.1

    except code Z07 (B7 armoring on special protection version) Rivet B-pillar support (3) with Ø 6.5x14.5 rivets (areas K3).

    Shown on model 222.0 

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    Shown on model 222.9 

43. Model 222.9

    except code Z07 (B7 armoring on special protection version)

    Install B-pillar reinforcement (4) and fix in place.

44. Model 222.9

    except code Z07 (B7 armoring on special protection version)

    Drill Ø 6.7 mm rivet holes in B-pillar reinforcement (3) (areas M).

45. Model 222.9

    except code Z07 (B7 armoring on special protection version)

    Deburr rivet holes on B-pillar inner panel (3) and body on both sides.

46. Model 222.9

    except code Z07 (B7 armoring on special protection version)

    Remove drilling chips.

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    Shown on model 222.9 

47. Model 222.9

    except code Z07 (B7 armoring on special protection version)

    Apply sealant to contact surfaces on foam parts (8) to longitudinal member outer shell (1).

48. Model 222.9

    except code Z07 (B7 armoring on special protection version)

    Insert foam parts (8) and apply sealant to foam parts (8).

49. Model 222.9

    except code Z07 (B7 armoring on special protection version)

    Apply 2-component adhesive to outer longitudinal member (1) in cross-hatched areas.

    Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive.

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    Shown on model 222.9 

50. Model 222.9

    except code Z07 (B7 armoring on special protection version)

    Install B-pillar reinforcement (4) and fix in place.

51. Model 222.9

    except code Z07 (B7 armoring on special protection version)

    Rivet B-pillar reinforcement (4) with Ø 6.5x12.5 rivet (areas N₁ and N₂ ).

52. Model 222.9

    except code Z07 (B7 armoring on special protection version)

    Rivet B-pillar reinforcement (4) with Ø 6.5x14.5 rivet (areas N₃ ).

53. Clean contact surface of structured foam parts (5 and 6) on body and apply 2-component adhesive for reinforcements on body.

    Observe pretreatment of bonding surfaces and manufacturer's specifications for drying and processing time of 2-component adhesive for reinforcements.

54. Insert structured foam parts (5 and 6).

    Shown on model 222.0 

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