Cut Off Complete Corner Pillar Paneling Outer Upper Section - Ar64.30-D-5731-01TS

Model 907.6/7

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1056-07A	1K-zinc dust paint	A 000 986 28 00

Additional information can be found in the superordinate service document.

The safety information in the superordinate KD document must be observed.

The following operation steps are shown on model 907.633 with code D03 (Roof and rear-end doors, high version) on the right side of vehicle and must be performed analogously on the left side of vehicle if damaged.

Mark separating points on outer corner pillar paneling upper section (1) (areas A, B and C).
Observe dimension (A).

Mark separating point along edge (area B).
Disconnect separating points on outer corner pillar paneling upper section (1) (areas A, B and C).
Do not make the cuts too deep.

Otherwise the components below can be damaged and weakened.

Commercially available devices/tools

Body power jigsaw
Expose spot welds at outer corner pillar paneling upper section (1) (areas D and E).
Commercially available devices/tools

Rotary wire brush
Cut off spot welds at outer corner pillar paneling upper section (1) (areas D and E).
Commercially available devices/tools

Spot weld milling machine
Remove damaged upper section of outer corner pillar paneling (1).
Mark separating point at remaining piece (1.2) (area G).
Mark separating point as shown (area G).
Disconnect separating point at remaining piece (1.2) (area G).
Do not make the cuts too deep.

Otherwise the components below can be damaged and weakened.

Commercially available devices/tools

Body power jigsaw
Expose spot welds on remaining piece (1.2) (area F).
Commercially available devices/tools

Rotary wire brush
Cut off spot welds at remaining piece (1.2) (area F).
Commercially available devices/tools

Spot weld milling machine
Expose spot welds on remaining piece (1.2) (area I).
Commercially available devices/tools

Rotary wire brush
Cut off spot welds at remaining piece (1.2) (area I).
Commercially available devices/tools

Spot weld milling machine
Remove remaining piece (1.2).
Bend remaining piece with chisel (area H).
Commercially available devices/tools

Chisel
Mark separating points at remaining piece (1.3) (areas J₁ and J₂ ).
Mark separating points as shown (areas J₁ and J₂ ).
Disconnect separating points at remaining piece (1.3) (areas J₁ and J₂ ).
Do not make the cuts too deep.

Otherwise the components below can be damaged and weakened.

Commercially available devices/tools

Body power jigsaw
Bead remaining piece in cross-hatched area (area K) approx. 10 mm.
Commercially available devices/tools

Sheet metal crimping pliers
Grind mating surface in cross-hatched area (area K) down to bare metal.
Commercially available devices/tools

Rotary wire brush
Grind down mating surfaces to bare metal in cross-hatched areas.
Sand down spot weld flanges to bare metal on both sides.

Commercially available devices/tools

Rotary wire brush
Remove shavings and milling chips.
Commercially available devices/tools

Wet and dry vacuum cleaner
Zinc dust paint to insides of spot weld flanges.