Prepare Rear Portal For Installation - Ar64.20-P-1001-05A
| 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 inflammable materials from the hazard area. Use air extraction system. | AS00.00-Z-0007-01A | |
| 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 | |
| Measures for preventing damage to vehicles or components when performing electric welding work | AH00.00-N-0005-01A | ||
| General information on body repair | AH60.00-N-0001-01A | ||
| Notes on paintwork repairs | AH98.00-P-9408-02A |
Model 461
Model 463 up to model year 2019
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-1031-07A | Passenger car primer filler 283-150 VOC | Glasurit GmbH Glasuritstrasse 1 48165 Munster Germany Tel. +49 2501 14-0 Fax +49 2501 14 3373 www.glasurit.de |
- Grind the spot weld flange on the outside of the rear panel down to bare metal on both sides in the cross-hatched area.
- Coat the inside of the spot weld flange in the cross-hatched areas with zinc dust paint.
- Grind the spot weld flanges on the inside of the rear panel down to bare metal on both sides in the cross-hatched areas.
- Coat the insides of the spot weld flanges in the crosshatched areas with zinc dust paint. 5 Grind the mating surface down to bare metal on one side in area A.
- Coat the top holder for splinter protection (1) on the inside with passenger car primer filler 283-150 VOC.
Only for model 461, 463 with code (ZS4) special protection versionFB4, code (ZS6) special protection versionFB6 and code (ZS7) special protection version FB7.
- Grind the spot weld flanges down to bare metal on both sides in the cross-hatched areas.
- Coat the insides of the spot weld flanges in the crosshatched areas with zinc dust paint.
- Separate the roof frame on the new rear portal (2) according to the removed old part with a body jig saw.
- Grind the mating surfaces in the area of the top holder for splinter protection (1) down to bare metal on one side.
- Fit the top holder for splinter protection (1) together with the rear pillars to be installed vertically on the rear portal (2).
- Tack weld the top holder for splinter protection (1).
- Top holder for splinter protection (1) in area H and in the area of the arrows
.
- Punch holes in areas F and K with hole punching pliers.
- Grind the mating surfaces in areas F and K down to metal on both sides.
- Grind the spot weld flanges down to bare metal on both sides in the cross-hatched areas.
- Coat the insides of the spot weld flanges in the crossbare hatched areas with zinc dust paint.
- Grind the rear portal (2) down to bare metal on one side in areas B, C, D, E, L, M, N and O.
- Punch holes in areas P and Q with hole punching pliers.
- Grind the mating surfaces in areas P and Q down to bare metal on both sides.
- Grind spot weld flange down to bare metal on both sides in the cross-hatched area.
- Coat the inside of the spot weld flange with zinc dust paint.
- Grind the bottom reinforcement (4) for the rear portal (2) down to bare metal in areas R to Z.
- Grind spot weld flange down to bare metal on both sides in the cross-hatched area.
- Coat spot weld flange on both sides in the cross-hatched area with zinc dust paint.
- Punch holes in areas AA, AC and AD with hole punching pliers.
- Grind the mating surfaces in areas AA, AC and AD down to bare metal on both sides.
- Grind the mating surface down to bare metal on one side in area AB.
- Grind the mating surfaces in areas AF and AG down to bare metal on one side.
- Punch holes in areas AH, AJ, AK and AL with hole punching pliers.
- Grind mating surfaces in areas AH, AJ, AK and AL down to bare metal on both sides.
- Divide the roof frame profiles (5) for making the reinforcement shoes (6).
- Reform the reinforcement shoes (6).
- Grind the connecting points on the reinforcement shoes (6) down to bare metal on one side.