Remove/Install A-Pillar Outer Section - Ar63.20-P-1102LWA
Model 238.4
| 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 | |
| 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 injury . Skin or eye injuries may result when handling hot or glowing objects. | Wear protective gloves, protective clothing and safety glasses, if necessary. | AS00.00-Z-0002-01A | |
| 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 | |
| Notice | General information on body repair | AH60.00-P-0001-01KOA | |
| Notice | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | |
| Notice | Measures for preventing damage to components when performing electric welding and soldering work | AH60.00-P-0001-02A | |
| Notice | Pretreatment of bonding surfaces | AH60.00-P-0008-01SX | |
| 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 | ||
| General information on riveting | AH60.00-P-0003-01N | ||
| General information on repair of vehicles with ultra-strength steels. | AH60.00-P-0024-01N | ||
| Notes on acoustic foam and structural foam in the vehicle | AH60.00-P-0039-01LWO | ||
| General information on MB materials | AH98.00-P-9409-03A | ||
| Remove | |||
| 1 | Remove detachable parts in area of repair point. | ||
| 2 | Cover detachable parts that remain in vehicle with spark protection blankets. | ||
| 3 | Set up straightening bench with straightening bench support members and straightening set. | ||
| 4 | Place vehicle on straightening bench and secure. | ||
| 5 | Remove A-pillar paneling (1). | Round wire brush Spot weld milling machine Wet/dry vacuum cleaner |
AR63.20-P-1102-01LWA |
| 1K-zinc dust paint | *BR00.45-Z-1056-07A | ||
| Preparation | |||
| 6 | Prepare A-pillar paneling (1). | Round wire brush |
AR63.20-P-1102-02LWA |
| 1K-zinc dust paint | *BR00.45-Z-1056-07A | ||
| Install | |||
| 7 | Install A-pillar paneling (1). | Round wire brush Manual temporary fastener 6.35 mm Blind rivet gun (minimum pull-off force 19 kN) Wet/dry vacuum cleaner |
AR63.20-P-1102-03LWA |
| 1K-zinc dust paint | *BR00.45-Z-1056-07A | ||
| White sealing compound, 310 ml, DBL 6069.20 | *BR00.45-Z-1003-01A | ||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| Blind rivet Y2 6.5 x 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | *BR00.45-Z-1012-13A | ||
| Blind rivet Y1 6.4 x 12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1035-13A | ||
| Countersunk-head blind rivet Z1 6.4 x 14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) | *BR00.45-Z-1043-13A | ||
| Countersunk-head blind rivet Z2 6.4 x 15.5 (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN) As an alternative to restoring surfaces with body solder. ↓ Apply basic body filler. |
*BR00.45-Z-1044-13A | ||
| Process filler on body | AR60.00-P-0031-01LWG | ||
| Basic body filler | *BR00.45-Z-1057-07A | ||
| Parts kit for 2-component adhesive for body | *BR00.45-Z-1162-02A | ||
| 8 | Release vehicle from straightening bench, lift and remove straightening bench. | ||
| Clean | |||
| 9 | Clean weld joints and sheet metal flanges. | Round wire brush |
|
| 10 | Remove spark protection blankets. | ||
| 11 | Clean repair area. | Wet/dry vacuum cleaner |
|
| Paint | |||
| 12 | Prime repair areas with a primer filler. | ||
| 13 | Realize seam seal after repair work. | AR97.10-P-4000LWO | |
| 14 | Paint repair areas and adjacent surfaces. | ||
| 15 | Supplement cavity preservation. | AR97.20-P-1500LWO | |
| Assemble | |||
| 16 | Install detachable parts in area of repair point. |
REPAIR MATERIALS
| Number | Designation | Order number |
|---|---|---|
| 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 Y2 6.5 x 12.5 (clamping range 2 mm to 5 mm, draw-off strength min. 19 kN) | A 004 990 16 97 |
| BR00.45-Z-1035-13A | Blind rivet Y1 6.4 x 12 (clamping range 1 mm to 3.5 mm, draw-off strength min. 15.5 kN) | A 000 991 76 32 |
| BR00.45-Z-1043-13A | Countersunk-head blind rivet Z1 6.4 x 14.0 (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) | A 000 991 82 32 |
| BR00.45-Z-1044-13A | Countersunk-head blind rivet Z2 6.4 x 15.5 (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN) | A 000 991 83 32 |
| BR00.45-Z-1056-07A | 1K-zinc dust paint | A 000 986 28 00 |
| BR00.45-Z-1057-07A | Basic body filler | A 012 989 29 71 |
| BR00.45-Z-1162-02A | Parts kit for 2-component adhesive for body | A 012 989 17 71 |