Outer Longitudinal Member Shell On Entrance Removal - Ar63.30-P-1102-01ME

Model 167 

The next steps are shown on the left side of the vehicle in model 167.1. In case of damage on the right side of the vehicle, these steps must be performed analogously.

The higher-level service document as well as the safety information in the service document must be observed.

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1. Mark separating points on longitudinal member outer shell (1) and A-pillar reinforcement (2) and, depending on the damage, cut ((area A), (area B), (area C), (areas A, B), (areas A, C) or (areas B, C)).

   Do not make the cuts too deep.

   Otherwise the components below can be damaged and weakened.

   Dimensions: 

   a= approx. 20 mm

   b = approx. 130 mm

   c = approx. 90 mm

   The next steps are shown on the most comprehensive repair.

2. Expose weld seam on longitudinal member outer shell (1) and cut (area D).

   Only when repairing the front area.

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3. Expose spot welds on longitudinal member outer shell (1) and cut off (areas E).

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4. Expose spot welds on longitudinal member outer shell (1) and A-pillar reinforcement (2) and cut off (areas F).

   Joint spot welds on panels that are one behind the other must be cut off through two panel thicknesses.

5. Expose spot welds on longitudinal member outer shell (1) and drill out with a diameter of 6.5 mm (area G).
6. Expose spot welds on longitudinal member outer shell (1) and cut off (area H).
7. Expose weld seams on longitudinal member outer shell (1) and cut (area J).

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8. Heat A-pillar reinforcement (2) in cross-hatched areas.

   Cross-hatched area is bonded.

9. Remove section of A-pillar reinforcement (2).

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10. Heat longitudinal member outer shell (1) in cross-hatched areas.

    Cross-hatched areas are bonded with adhesive.

11. Remove outer longitudinal member shell (1).

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12. Grind mating surfaces down to bare metal in cross-hatched areas.

    Grind spot weld flanges down to bare metal on both sides.

13. Remove grinding dust and drill chips.
14. Coat insides of spot weld flanges with zinc dust paint.

    Do not coat bonding surfaces with zinc dust paint (areas K).

    Otherwise adhesion problems may occur.

15. Grind mating surface down to bare metal in cross hatched area.
16. Remove grinding dust and drill chips.

    Observe pre-treatment of bonding surface.

    Observe pretreatment of bonding surfaces.

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